A Borg company

Vision Decisions at 200 Frames Per Second

Project Completion Date: 2014

Project Highlights

  • Integrating Beckhoff and Siemens Programmable Logic Controllers
  • Basler High Speed Cameras
  • Human Machine Interface delivered for Configuration and Control
  • Ultra High speed performance for 100% Inspection and defect rejection
  • Complete user control of product specific vision algorithms
  • Product-invariant algorithm design (i.e. algorithms can handle any new products introduced).
Vision Decisions at 200 Frames Per Second


Crossmuller was tasked with developing a quality control vision solution to detect numerous defects on a high-speed manufacturing process. The challenge was to provide 100% inspection and rejection for 10 defect types at speeds of up to 10,000 units per minute in order to eliminate complaints.

The architecture utilised a Beckhoff PLC to get the 150micro second scan speed required. This integrated with a Siemens PLC to manage interfacing with the machine controller, and the tracking and reporting functionality.
Vision Decisions at 200 Frames Per Second
Project #50

The Solution

Crossmuller used one of the first implementations of Adept Turnkey’s high-speed Dalsa FPGA frame-grabber cards, coupled with industrial spec Basler cameras via active CameraLink cables and Beckhoff high-speed PLCs to deliver the solution.

An image is acquired for each unit in the production line and 10 algorithms are run on the image in real-time via a three-camera system. If the item is defective, it is tracked to a reject point and rejected off the line with a high-speed air valve.

HMI software was custom developed to provide an intuitive user interface with a secure login for multi-level access to operators, supervisors and administrators, situational awareness for defects, alarm module for active and historical alarm review with machine stop control, and historical image and metric data for on-the-fly decision making.