Automation for industry - how to efficiently integrate a vision system into a production line?

Estimated reading time: approx. 10 minutes

TL;DR

• Vision systems are the 'eyes' of modern factories, indispensable for quality control and workpiece positioning.
• Camera integration with PLCs and robots provides instant, real-time data exchange.
• Appropriate lighting is crucial for precise image analysis.
• Implementation planning includes needs analysis, equipment selection and pre-testing.
• Effective integration vision system significantly reduces rejects and claim costs.

Table of contents

• Introduction
• Why is the vision system key in automation for industry?
• Vision systems integration - basics and key elements
• How to plan implementation in practice?
• Key benefits and key lessons from the implementations
• Example of implementation at Michale Automatyka
• External support and comprehensive services - why is it worth it?
• Vision integration versus other systems - a step towards Industry 4.0
• Summary of benefits and practical tips
• What next?

Introduction

Automation for industry is becoming one of the most important pillars for the development of manufacturing companies in Poland today. Increasing market demands, the need to improve product quality and the drive to minimise costs are challenges that are already difficult to overcome without solid support from robotisation and modern control solutions. One of the key technologies in such support are vision systems. They allow for precise process monitoring, rapid error identification and, most importantly, better quality control.

In this article you will learn:

• How vision systems work and why their integration with industrial automation is so important.
• How the implementation process works - from hardware selection to the creation of a consistent control environment.
• What to look for to ensure that the whole system is effective and delivers a quick return on investment.

As you read on, you will gain practical advice on selecting vision system components, synchronisation with industrial robots or ERP and MES systems. You will also learn about implementation examples that perfectly demonstrate how integrating a vision system into an existing line can measurably increase production efficiency.

Main content

Why is the vision system key in automation for industry?

We can regard vision systems as the 'eyes' of modern factories. Without them, it is difficult to imagine many tasks today, such as:

• In-flight quality control - for example, the detection of surface defects or errors in product labelling.
• Precise positioning - robots or cobots (collaborative robots) receive data on exactly where the workpiece is located.
• Reading codes, serial numbers or text - verification of labels, particularly in the food or pharmaceutical industries.

The aforementioned points emphatically demonstrate that the proper integration of a vision system increases production efficiency and reduces costs associated with complaints. Michale Automatyka (also often referred to as Michale Automation) implements such systems, creating complete robotic workstations, production lines and unique turnkey solutions. As an official distributor of SIASUN robots, we also ensure that robotisation is compatible with technologically advanced vision systems.

Vision systems integration - basics and key elements

Sensor and software layout

The primary task of a vision camera is to capture images, which are then processed by software. It is common to find 'smart camera' cameras or so-called vision sensors. For more complex processes, a separate processing unit (e.g. in the form of a PC) is sometimes necessary, but all-in-one solutions - combining a camera, a computing system and built-in analysis tools - are increasingly available. Capabilities:

• Contour and edge detection (checking product shape).
• Control of colour tones, saturation or even micro-scratches on surfaces.
• Reading of codes (1D and 2D), text and character interpretation.

For example, in the food industry, vision sensors make it easier to check whether a package is filled with enough product. In the metal industry - they help identify cracks or deformations at a very early stage.

Lighting and optimum contrast

The most expensive, top-of-the-range camera - without the right light - will not provide proper inspection. In automated production lines, it is particularly important to eliminate all noise and shadows in order to extract as much information as possible from the image. Typical types of lighting solutions include:

• Ring illuminators - mounted around the lens, they illuminate the subject well from all sides.
• Spotlights - focused on one area, used to highlight a specific element (e.g. an edge).
• Rear LED panel (so-called backlight) - allows a clear contour, which is ideal for shape measurements.

Communication with PLC and robots

In most cases, the integration of vision systems with other components takes place via industrial networks, such as industrial Ethernet (in a POWERLINK-type standard) or Profinet. A fully integrated approach, where the camera is treated in the same way as an input/output module, greatly facilitates the synchronisation of data and cycle times. Instead of long, multi-step data exchanges over different protocols - key information about the detection of a component arrives at the controller in real time.

This solution has a significant impact on the repeatability of the entire system. For example, if a robot has to pick up a workpiece from a moving belt, the vision system finds and recognises the position and the robot bypasses the risk of empty intercepts. This makes production more stable and prevents costly downtime.

How to plan implementation in practice?

Needs analysis and equipment selection

The first step is always to find out exactly what you need the vision system for. Is it for barcode recognition, geometry control or perhaps print verification? It is worth determining:

• The minimum and maximum size of the subject - this determines the choice of lens, sensor and lighting.
• The speed at which the product moves - this is important, for example, when setting exposure times, lighting and synchronisation.
• Level of precision and acceptable error tolerances.

If you know in advance that one sensor is not enough - plan an architecture in which several cameras will work together. Such a system should include a suitable data network and sufficient computing power.

Integration with a robot or cobot

For robotic workstations (e.g. welding, packaging or palletising), it is crucial that there is consistent feedback between the camera and the robot. The camera reads the position of the objects and transmits this data to the arm-grip controller (or other actuator) in fractions of a second.

Example: When we at Michale Automatyka are preparing the implementation of a new cobot with a vision system to operate a packaging line, we first check whether sufficient memory resources and suitable communication ports are available in the existing controller. If not, we propose to expand the control and, if necessary, add additional I/O modules or an operator panel.

Key benefits and key lessons from the implementations

Minimising rejects and complaints

Precise checking of details eliminates the risk of shipping defective products. In regulated industries (e.g. food or pharmaceuticals), this additionally avoids costly penalties. In the event of any shortcomings - the system sends an error signal by transmitting it to the PLC. This applies to defective packaging as well as incorrect filling levels.

Increasing the efficiency of the production line

The use of an advanced camera, synchronised with the drives, allows the belt speed to be increased while maintaining a high accuracy rate. When the production situation changes (e.g. introducing a new type of product), simply modify the camera settings - without the downtime of a full cycle.

Speeding up changeovers

By opting for a fully integrated system (e.g. using a PLC on one network together with the robot and camera), the manufacturer achieves a significant reduction in line conversion times. All it takes is a change of a few parameters in the software and the camera begins to recognise a new type of workpiece. Such functionality is particularly appreciated by companies that need to introduce new product variants frequently.

Example of implementation at Michale Automatyka

Initial diagnosis and goal setting

In one of our projects, the aim was to increase the efficiency of the production line, where faster detection of errors in the positioning of parts for assembly was key. The customer was having problems with quality deviations; one in ten products needed to be corrected. So we carried out an analysis to use a vision system.

Equipment selection and pre-testing

We proposed integrating a 'smart' camera with dedicated side lighting so as to enhance the visibility of the detail. After initial tests, it became apparent that at the same time it was worthwhile to use a rear LED panel to improve contrast with certain types of parts. This enabled faster recognition of surface defects.

Final implementation and effects

After connecting the camera to the PLC and synchronising its operation with the line drives (via Industrial Ethernet), we achieved almost 100% efficiency in detecting the position of misaligned workpieces already in the first phase of assembly. This reduced product rejection to less than 1% and the downtime associated with complaints was ultimately reduced by 30%.

External support and comprehensive services - why is it worth it?

Implementing vision systems yourself requires knowledge of both mechanics, lighting, electronics and programming. However, many companies that opt for automation prefer to trust the experts. In this case:

• A well-planned implementation schedule safeguards production continuity.
• Experienced specialists can arrive at optimum settings more quickly than if the project was carried out without expert support.
• It is also worthwhile to take advantage of the service and maintenance stands - regular maintenance prevents unforeseen breakdowns.

If you would like to find out more about similar implementations and comprehensive services, please see our tab Services. For many years, we have been active in the field of industrial automation and robotics, including the following automation of repetitive production processes. This enables us to offer not only vision integration, but also support in the most difficult challenges of line development.

Vision integration versus other systems - a step towards Industry 4.0

Connection to ERP and MES systems

When the vision system is integrated with key software, such as ERP (Enterprise Resource Planning) or MES (Manufacturing Execution System), real-time quality monitoring is possible. The automatic recording of defects (or the reading of codes at each stage of production) makes it possible to see from which batch the problems originated and at which point in the line something went wrong. This is a huge convenience for human resources and logistics departments and a clear reduction in reaction times to errors.

Expansion and service

A properly implemented vision system must be scalable. Imagine the scenario that a company expands its product range in the following years. Instead of investing in brand new cameras, it will simply add more types of detail to the application in the controller. In addition, the system must have service support to quickly replace a camera, check its settings or carry out maintenance on the entire station. In this context, it is worth taking a look at our an offer for the maintenance of postsas regular maintenance extends the life of the equipment and prevents costly downtime.

Summary of benefits and practical tips

- More effective quality control - The automatic vision system catches errors even at very high production speeds.
- Reduction of claim costs - damaged or defective products are eliminated even before they are packed.
- Saving time - integration with robots (e.g. SIASUN robots) allows automatic correction of gripper or arm movements.
- Scalability of the solution - in the future, all you have to do is change the settings to adapt to the new tasks.
- Increased security - By monitoring processes precisely, emergencies can be avoided.

Practical advice: before you start the implementation process, try to gather accurate information about your production line. This includes the dimensions and shapes of the parts, the position of the robots, the data exchange protocols used and the expected clocking speed. The more details you provide at the start, the faster the specialists will adapt the optimal solution.

What next?

Vision system technologies are developing at a dizzying pace. There is increasing talk of combining them with advanced artificial intelligence and the use of 3D or hyperspectral cameras. With these, automation for industry will be able to detect defects at an almost microscopic level and support robots even more precisely in handling processes.

If you are considering implementing vision solutions in your facility, remember that it is not only the choice of camera and lighting that matters, but also the right fit with the overall automation concept. On offer robotisation services our engineers support companies at every stage - from initial analysis to the installation and commissioning of equipment. Our many years of experience in the construction of machines and production lines enable us to combine our expertise in the areas of mechanics, robotics and industrial automation into a comprehensive, coherent service.

Need more information or looking for a specific solution for your facility? Contact us today or visit our page on automation for industry and find out how we can help you implement vision systems at the highest level.

FAQ

How long does it take to implement a vision system?
The time depends on the complexity of the process and the number of elements that need to be integrated. For simple applications it can take several weeks, for more complex projects even several months.

Is it difficult to integrate a vision system into an existing production line?
With the right approach and analysis of the production line, the process need not be difficult. The key is to plan the communication with the PLC and consider the lighting requirements. Specialists will help select the right solutions and optimise the implementation schedule.

Do such solutions only pay off for large companies?
No. Advances in technology are driving down the cost of purchasing and using a video system. Even small and medium-sized businesses can achieve a rapid return on investment if the choice of equipment and its configuration are right.

Does the implementation of a video system entail replacing the entire infrastructure?
Not necessarily. Very often it is sufficient to add dedicated cameras and lighting, to integrate them with an existing PLC or robot. If necessary, the controller can be expanded or I/O modules can be added, but a complete line replacement is usually not required.