Operators had been employed to manually detect up to 9 defects per can at a speed of 100 cans/min for finished goods due to the high speed nature of the task, operators had to be rotated hourly to avoid fatigue and struggled to provide the required level of accuracy.
The requirements of the vision solution included the flexibility to handle 23 different packaging labels, and to detect more than 10 defect types at speeds up to 240 cans/min.
The system needed to provide complete coverage of the can surface, to have automated reject mechanisms, be robust, low maintenance, have the ability to handle a dusty environment, be simple to calibrate, provide a comprehensive user interface, and have both visual and auditory alarming capability.
Crossmuller utilized Australia’s first Omron High-speed FH Series Controller to implement a 6-camera solution. This robust, embedded PC-based controller provided a multi-core platform that when coupled with Omron’s high-speed, high-resolution, Gigabit Ethernet cameras, was able to process can images for all defect types at speeds capable of handling current and future line speeds.
The multi-camera controller was configured to handle cameras independently in two separate booths in order to provide the necessary coverage.
The system allowed for asynchronous image triggering, processing and the feedback of result outputs to the line control system.
A Rockwell CompactLogix L23 PLC with standard digital I/O and high-speed analog inputs was used for line control and interfacing with both upstream and downstream line control systems.
Multiple Omron ZX1 laser distance sensors in Booth 2 provided high accuracy and high speed analog measurements of the can’s surface to detect 3D dent defects.
Custom-built calibration cans and a simple and intuitive interface allowed for quick setup of camera and laser trigger positions.
- Adaptability to various product label types
- Accurate and reliable inspection results (Barcode, date code, missing / torn labels, seam defects, crooked / out of position label, dent / delamination of rim, ovality, fallen can)
- Simple integration with multiple upstream and downstream control systems
- Transparent and low maintenance operation
- Comprehensive system documentation and staff training
- Quality Control challenge solved