Smart camera helps stop stacks toppling

Edited by the Engineeringtalk editorial team Jul 18, 2005

A powerful, flexible and intelligent vision system is within the grasp of any company wishing to automate inspection operations.

Within food manufacturing and distribution environments, standardised transportation trays are a common sight.

To allow these trays to be both carried and stacked they have moveable handles that can double up as stacking supports - but only if they are in the correct position.

The consequence of misaligned supports is that a uniform stack cannot form and the potential for the trays to topple - leading to product waste and even employee injury - greatly increases.

An automated system was the obvious answer for one particular user of these stacking trays; but with varying ambient light conditions, differing tray colours and a variety of tray sizes all playing their part to complicate the issue, an intelligent, robust and accurate system became a prerequisite.

In this particular case and, indeed, many others like it, the ideal solution took the form of an IVC-2D smart camera system - available from Sick (UK) .

The obvious benefits for the customer on offer from this intelligent solution include high-speed operation, no false calls and robustness against stray light - all in combination with a 99.9% correct inspection level.

Prior to entering the stacking and sorting area, the trays, which in this case transport chickens, traverse an IVC-2D-equipped verification station.

This station automatically determines the tray type and then, using this information, ascertains the position the handles are in compared to where they should be.

It does this by measuring the handle position relative to the tray's outer edges.

A right/wrong signal is generated and sent to a PLC.

The PLC then ensures that the faulty box is diverted onto a special conveyor for manual remedial action.

The measurement is performed using some 50 programming steps, which were created using Sick's user-friendly IVC Studio programming software.

Not only does this give users quick and easy access to a huge set of powerful image-processing tools, but also, once configured, the camera can work in standalone mode, without the need for a PC.

To address the ambient light issue, laser light lines are used in combination with optical filters.

This lighting strategy also allows for an increased resilience against false calls due to "handle-like" content within the crate.

Easy to integrate with external devices such as light and trigger sources, the IVC 2D will satisfy a vast range of application demands.

This ease of integration is thanks to its plug-and-play I/O - compatible with the entirety of Sick's impressive range of sensors and camera accessories.

For more complex applications, the camera can also send data, such as object coordinates or imagery over RS485 or Ethernet.

Key features include a 640 x 480 b/w sensor, which can operate at 30frame/s; 10/100Mbit/s Fast Ethernet capabilities; two program control inputs; three program control outputs; and M12 industrial connectors.

There is also the option for a stainless steel enclosure for more hostile environments.

The IVC-2D's features and capabilities demonstrate that a powerful, flexible and intelligent vision system is within the grasp of any company wishing to automate inspection operations.

Indeed, its integration with other equipment in the Sick range will enable users to build a vast array of powerful vision and sensor-based systems.