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Machine Vision Systems

Global Vision System Rollouts

global-rollouts-of-vision-systemsEPIC takes turnkey responsibility for your global rollout by standardizing systems, guaranteeing ship-dates, and adhering to all domestic and international guidelines for your global rollouts. We develop repeatable solutions, tested in one facility and rolled out nation or world-wide.

Designing vision systems that fit varying set-ups, local standards and staff without redesign is our specialty. Standardization means consistent inspection programs, mechanical setup, electrical components, and system controls. No matter how many systems you ship or where they end up in the world, EPIC Vision Systems perform to the highest standards.

Contact one of our machine vision experts today, or read about some of our recent global rollouts below.

Optical Character Verification (OCV) Systems for Snack Foods

snack food vision inspection systemThis vision system is designed to be an on-line vision inspection system. It uses customized PC software, with Optical Character Verification (OCV) technology, to inspect and verify the correct code and the quality and legibility of the can date code characters. The OVC vision system uses PLC logic, an encoder and a high speed pneumatic rejector to track and reject cans that fail inspection.

CLIENT: Fortune 500 Food & Beverage Company

INDUSTRY: Food Processing

MANUFACTURING PLANT LOCATIONS:

America (multiple locations), Belgium, Poland, Malaysia

KEY FEATURES:

  • PC with FlexOCV Vision Software
  • HMI for product selection, defect monitoring and real time image display
  • PLC and Encoder to track cans that fail inspection
  • High speed Pneumatic rejection system

CHALLENGES:

  • Achieve a .03 false failure rate on a line running 1000 cans/minute
  • Design a vision system for easy installation and maintenance
  • Provide method for maintenance technician to add new Date Code Formats

Global Integration of Automated Process Inspection Systems

EPIC was challenged to standardize the product inspection protocol globally to achieve strict quality control criteria, with repeatability in every plant. Customer criteria included product inspection  for numerous defect possibilities, including unwanted beds, cracks, incorrect assembly, mission components, and more.

CLIENT: Fortune 500 Consumer Products Company

INDUSTRY: Consumer Products

MANUFACTURING PLANT LOCATIONS:

USA (many locations), Mexico, South America (many countries), Europe (many countries), Africa (Egypt and South Africa), Middle East (several countries), India, Asia (several countries)

KEY MACHINE VISION FEATURES:

  • Cognex line scan camera
  • Vision tools programmed using Cognex InSight camera software
  • Customized LED line light chosen for this particular application
  • Machined aluminum frames with tight tolerances & calibration fixtures for accurate duplication

Core Challenges of Global Project

  • Project management of evolving delivery schedule for hundreds of units shipping worldwide, constant vendor communication to guarantee ship dates, and foreign documentation standards
  • Calibrating all units to adhere to a strenuous set of guidelines to ensure global quality standards
  • Streamlining build, calibration, and packing processes to ensure efficiency and quality were not lost in the large volume rollout
  • Troubleshooting installation problems or out-of-spec scenarios in destination countries

High Speed Production Line Inspection Systems Integration

Machine Vision systems were developed to inspect product at various stages of the manufacturing process. Integration by an experienced machine vision integrator ensured customer’s specifications were met. Systems were designed to improve product quality, provide tools to aid in preventative maintenance measures, and display live data and images for operators.

CLIENT: Fortune 500 Company manufacturing consumer goods

INDUSTRY: Consumer Goods

MANUFACTURING PLANT LOCATIONS:

USA (multiple locations), China, Europe

KEY FEATURES:

  • Multiple camera technologies were integrated, including systems for 2D, 3D and high-speed applications
  • Traceability to manufacturing process allows for preventative maintenance and a guarantee of product quality and performance
  • Integrated to customer’s historical database as well as line HMIs, giving access to images and data instantaneously and allowing for tracking over large periods of time
  • 100% inspection with all technologies at 900+/minute rate

CORE CHALLENGES:

  • Achieve a 0.03% false identification rate for each system at a line running 900 parts/minute
  • Integration to varying production lines, from 30+ years old to current controls technology
  • Perform 100% part inspection at full line speed, while maintaining traceability and saving images and data to customer’s databases

Automated Continuous Web Inspection Systems:

A linescan inspection was designed to perform on a continuous web production line. The machine vision system was engineered to identify rejects at 1,000+ parts per minute. The inspections are periodically updated to handle new materials and design features. Over 100 systems installed worldwide.

CLIENT:  Fortune 500 Consumer Products Company

INDUSTRY: Homecare products

MANUFACTURING PLANT LOCATIONS:

America (multiple plants), Europe (several countries), Asia (several countries), Northern Africa

KEY FEATURES:

  • Cognex linescan vision system with Ethernet/IP and OPC Communications
  • Continuous improvements to reduce scrap rates and further increase product reliability
  • High inspection rate (1,000+ parts per minute)
  • Reliable reject identification and rejection
  • Multiple camera inspection locations along web
  • 100+ installations

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