CASE STUDY
High-Speed Web Inspection System for Defect Detection in Adhesive Vents
Medical Device
Client Challenge:
A medical device manufacturer producing adhesive vents on a carrier web sought to automate their quality control process to improve defect detection accuracy, efficiency, and throughput. The existing manual inspection process was labor-intensive, time-consuming, and prone to human error. The manufacturer needed a solution that could inspect vents on both sides of the web at high speeds, identify and mark defects, and facilitate manual removal of defective sections.
Our Solution:
We designed and deployed a high-speed web inspection system tailored to the manufacturer's specific requirements. The system utilized two Dalsa Piranha3 16k CMOS line scan cameras to capture high-resolution images of the adhesive vents as they passed by on the web at 800 feet per minute. A Cognex VisionPro PC-based vision system processed the images, identifying defects based on UV illumination of a brightener in the adhesive. The system included a defect marking system to guide operators in removing defective sections and splice tables for efficient web handling.
Web Inspection System Features
01.
Cameras
Two Dalsa Piranha3 16k CMOS line scan cameras for high-speed, high-resolution image capture.
02.
Lenses
Two Opto Engineering TC4MHR032-x 12k/16k 0.320x telecentric lenses for accurate imaging.
03.
Frame Grabbers
Dalsa Xcelera-HS PX8 for high-speed image acquisition.
04.
Lighting
Metaphase line lights with UV filters for defect illumination.
05.
Software
Cognex VisionPro 8.4 machine vision software for defect detection and analysis.
The Results:
The web inspection system significantly enhanced the manufacturer's quality control process. The automated inspection was faster, more accurate, and more consistent than manual inspection, reducing the risk of defective products reaching customers. The system's ability to inspect both sides of the web simultaneously increased throughput and efficiency. The defect marking system facilitated the removal of defective sections, minimizing waste and improving yield. The system's data logging capabilities provided valuable insights into production quality trends.