TITLE: Medical IVs
BY:
John Lewis
Cognex Machine Vision Systems
(508) 650-3140
Touch Panel Computers Team with Vision Sensors for Valve Inspection
“Checking each valve individually was a waste of man-power and time,” said Pawel Biegunski, President of Vision Controls, Inc. “When we offered them a way to make sure their items were perfect, every time, all while improving the manufacturing process automatically, they knew the old way had to go.”
Vision Controls, Inc., a machine vision integrator from Naperville, IL, recently combined vision hardware from Cognex Corp. with a touch panel computer from Advantech Automation Corp. to create a vision inspection system tailored to the specific needs of a medical supply manufacturer.
“They manufacture valves for medical I.V. assemblies—it’s something that has to be precise and reliable,” said Biegunski. Before Vision Controls came along, the end-user inspected samples from the assembly line and measured for uniformity under a microscope. With the new setup, vision sensors from Cognex scrutinizeand a touch-panel from Advantech examine every valve,and confirming their uniformity and communicating the results to an Advantech touch-panel computer. To sweeten the deal, the vision sensors use provide process feedback to automatically improve the assembly process.
To perform the automated inspection, the system combines Cognex In-Sight 1000 vision sensors with illumination, optics and machine control hardware from other suppliers. In a compact, self-contained unit, In-Sight 1000 vision sensors combine a high-speed digital camera with vision processor, a full library of vision software tools, built-in network communications, and a vision spreadsheet interface for application set up.
In order to meet throughput requirements, the automated inspection system uses six separate vision sensors to perform three individual inspections. The vision sensors are paired so each inspection is performed on two parts simultaneously.
To set up the inspections, Vision Controls used the vision sensor’s spreadsheet interface designed by Cognex. The process involved selecting vision tools and parameters from simple drop-down menus. The spreadsheet then automatically generates tool results into worksheet cells, which are then linked together to set up the inspections.
During operation, a rotary table indexes the parts so that each of the six cameras is presented a single part for inspection. Once the parts are in position, each camera independently captures an image and transfers it to its on-board vision processor for analysis. Simultaneously, the inspection system makes three different checks on six valves, with each pair of cameras running a common inspection on two valve assemblies.
The first pair of cameras checks to make sure that the right components are present and properly assembled. Another pair of cameras performs a gauging operation measuring the area of an important valve feature. The last pair of cameras scrutinizes lubricant application, providing feedback to maintain process consistency, and ensuring the right amount is applied to each valve.
Vision Controls designed a software package to collect and analyze the raw data from the assembly line. A touch-panel computer from Advantech Automation was integrated to act as the operator interface for the system.
The Insight vision system is connected to the Advantech operator interface through an Ethernet switch. This allows images of the inspected parts to be easily viewed on the screen along side vision tool graphics and inspection results. Measurement results and tolerances are displayed in engineering units. Operators may adjust tolerances via the touch-screen display.
In addition to the visual information provided to the operator, each Insight vision system sends pass/fail information to the machine controller (PLC) through the I/O lines instructing defective parts to be discarded. Images of failed parts can be saved to the hard drive for later review.
According to Biegunski, Advantech’s TPC-1260 touch panel computer was a perfect fit for this customer. Featuring a 12.1” high luminance display and a low-power Crusoe 5400 processor, the TPC-1260T provided the unique feature of fanless operation in a slim compact design. Weighing less than 5 pounds, and only 2” thick, the TPC-1260 was easily mounted from the swing arm on the inspection machine.
Speed is an additional advantage to the system, he said. “The vision system can, in most cases, yield the result in less than a second. In some applications the vision system deals with more than ten partsper second. Humans can't work that fast.”
The benefits of machine vision in various areas of industry are becoming evident as the range of applications broadens from medical devices to machine builders in the automotive and packaging industries.
Working as a certified vision integrator with Cognex, Vision Controls has experienced great success locating companies who can benefit from machine vision. This rapid growth is driven by manufacturers around the world that are implementing machine vision to improve productivity, lower manufacturing costs, and assureThese rapid growths is driven by manufacturers around the world that are implementing machine vision to improve productivity, lower manufacturing costs, and assures product quality.
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Cognex Corporation designs, develops, manufactures, and markets machine vision systems and machine vision sensors, or computers that can "see." Cognex is the world's leader in the machine vision industry, having shipped more than 200,000 vision systems, representing over $1.5 billion in cumulative revenue, since the company's founding in 1981. Cognex's Modular Vision Systems Division, headquartered in Natick, Massachusetts, specializes in machine vision systems which are used for automating the manufacture of a wide range of discrete items and for assuring their quality. Cognex's Surface Inspection Systems Division, headquartered in Alameda, California, specializes in machine vision systems which are used for inspecting the surfaces of products manufactured in a continuous fashion, such as metals, paper, and plastics. In addition to its corporate headquarters in Natick, Massachusetts, Cognex also has regional offices located throughout North America, Japan, Europe, and Southeast Asia. Visit Cognex on-line at
Advantech Corporation, Industrial Automation Group - Founded in 1983, the Industrial Automation Group of Advantech Corporation is the only complete PC-based Industrial Automation Solution Manufacturer offering products such as Industrial PCs, Workstations, Panel PCs, Flat Panel Monitors, Heavy Environmental PCs, Customized PCs, Single Board Computers, Data Acquisition & Control Devices and Web-enabled products for a wide array of industries. Drawing on the talents of more than 1,800 people, Advantech operates an extensive sales and marketing network in 16 countries and 35 major cities to deliver fast time-to-market services to our worldwide customers. Today Advantech offers over 700 products and solutions, adding 30 new products each year. US operations for the Industrial Automation Group are based in Cincinnati, OH (877-294-8989). Web: Email:
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