Using Cameras to Automate Lineside Processes

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Simple USB cameras can be used at manufacturing lines and pack /re-pack stations for error-proofing the processes of identifying, counting, packing and labeling containers of finished parts. 

SPEDE Can Use USB Cameras for: 

1. Part validation - compares image of part to master part image; with conveyor interface can shunt incorrect part downstream
2. Color detection - compares colors presented to master image; shunts incorrect part downstream
3. Counting parts - increments part count if the part is correct
4. OCR - reading 1D, 2D barcodes and characters on parts and labels 
5. Controlling the packing sequence of dunnage layers
6. Verifying all dunnage layers are filled correctly, with video proof 
7. Verifying pack count is correct before triggering a container label

Benefits of Inexpensive, Off-the-shelf Cameras:

• OCR function can read label data on parts arriving from overseas to prevent mis-identifying parts at re-pack 
• Prevents putting the wrong part in a container
• Prevents container short-ships
• Controls packing to ensure each dunnage layer is packed correctly before the next layer can begin

The SPEDE Vision logic is "trained" to recognize a part, and then stores the Part Master Image in an SQL database on a PC workstation which all lines can access. No need to use multiple PCs and maintain multiple image databases.

USB Cameras are Inexpensive:

• Cost as little as $75
• Cameras have no intelligence; no need to program or configure the cameras
• Cameras simply capture an image which the SPEDE Vision logic analyzes for accuracy and error-proofing
• No PLC is needed. SPEDE uses image capture and pixel analysis on a video frame-by-frame basis
• USB Cameras can integrate with Mitsubishi and Koyo PLCs  
• All image processing is performed on a PC workstation connected to the camera(s)
• All Part Number targeting data (e.g. master image, size, shape, etc.) is stored in a common SQL database
• All lines can access this common database
• No local master image files; any SPEDE line can use the same
  master images
• No need to maintain local master image files on multiple PC workstations
• Camera can be “trained” to recognize a part at your office desktop PC – No need to perform this task at the line
• Multiple cameras can be used to capture multiple angles without excessive incremental costs
• 1080p cameras at 16:9 aspect provide much greater field of view
• Cameras can be easily swapped out by maintenance