Cognex introduces first modular surface inspection system for detection of defects on web-based products

Citation

(1999), "Cognex introduces first modular surface inspection system for detection of defects on web-based products", Sensor Review, Vol. 19 No. 2. https://doi.org/10.1108/sr.1999.08719baf.003

Cognex introduces first modular surface inspection system for detection of defects on web-based products

Cognex introduces first modular surface inspection system for detection of defects on web-based products

Keywords Machine, Vision

Cognex, the world's leading supplier of machine vision systems, recently introduced the SmartView Modular Camera Network (MCN), the world's first modular, automated surface inspection system for detecting, measuring, and classifying defects on products made in a continuous process (see Plate 3).

Plate 3 SmartView MCN shown here, is an "intelligent" CCD Camera with camera-based inspection algorithms

"Early detection of surface defects is in the manufacturing of web-based products such as paper, plastics, metals and, nonwovens," said Colin Graves, sales manager of Cognex UK. "Our customers want to identify defects in order to minimise waste, achieve a zero defect standard of quality, and improve their manufacturing process. SmartView MCN, which leverages the success of its predecessor Fine-Line, provides a more powerful and flexible solution."

A SmartView MCN surface inspection solution consists of one or more "intelligent" CCD cameras with camera-based inspection algorithms, a drag-and-drop Windows NT-based interface for easy set-up, a PC, a mounting frame, and lighting components. Unlike some stand-alone systems, in which the cameras are connected to a central CPU, each SmartView MCN camera contains its own CPU and image processing electronics. The feature enables manufactures to add additional cameras to the system as their needs change without having to modify the hardware. In addition, the SmartView MCN system can be assembled in to a plant-wide inspection network supporting multi-view or multi-line configurations, providing customers with on-site or remote access to any node on the network.

"Cognex has designed the SmartView MCN as a set of building blocks because our customers have immediate needs and limited budgets", said Graves. "Customers can purchase our system in increments, so that as their requirements change, either through the addition of new product lines or new inspection specifications, additional camera unit can be easily installed and configured".

Surface inspection

Management of common surface defects such as foreign matter, stains, coating voids, pinholes another extraneous imperfections is mission critical in optimising the manufacturing process of continuous web products such as paper, plastics, metals, and nonwovens.

Under pressure to reduce costs of manufacturing while meeting increased global quality standards, manufacturers have shifted from manual to automated surface inspection systems.

Surface inspection or machine vision technology provides the ability to detect, analyse and react to user-definable substrate defects to a very high degree of accuracy. This removes the chance of human error, minimises waste and costly down time, and increases yield and overall product quality in manufacturing.

The limitations of stand alone inspection systems

Typical automated surface inspection systems consist of several camera inspection units driven by a single central processing unit (CPU). These systems are usually delivered as self-contained black box or stand-alone systems and are designed for a single application. Limitations in flexibility and expandability are critical issues: the ability to modify the system design, add new camera inspection units, or alter camera views requires significant hardware re-configurations.

For factories with multiple manufacturing lines, requiring multiple inspection systems, stand-alone systems are cumbersome to integrate, and have limited the ability to centralise quality control and trouble shooting. Additionally, the entry price of a basic stand-alone system can be cost prohibitive as an entire hardware infrastructure is required to support as little as one camera.

Network inspection system

The SmartView Modular Camera Network (MCN) surface inspection system provides an enterprise-wide solution through intelligent CDD cameras that contain their own CPUs and real-time image processing electronics.

The MCN technology allows manufacturers to easily position, move, add or delete camera units at user-definable locations in single or multiple manufacturing lines. And, unlike a stand-alone system that requires an application-specific hardware configuration, the intelligent plug-in cameras are configured through the SmartView MCN graphical user interface (GUI) software mapping function. Cameras can be added at will on a manufacturing line and can provide multiple surface views ­ top, bottom, and transmitted or side views.

Single and multiple manufacturing lines can be networked through Windows NT to achieve an enterprise-wide information network. Plan personnel can have on-site or remote access to any node on the network.

The SmartView MCN system can be purchased in increments. As end-user requirements change either through the addition of new product lines or new quality control specifications requiring increased defect resolution, additional intelligent camera inspection units can be quickly installed and re-configured through the SmartView MCN software.

For further information contact Colin Graves, Cognex UK, Chancery House, 199 Silbury Boulevard, Milton Keynes MK91JL, UK. Tel: +44 (0)1908 206000; Fax: +44 (0)1908 392463; E-mail: salesuk@cognex.com