Safe Stack Turners and Logistics Systems in the Printing Industry

Modular safety system exploits rationalization potential

Due to increased printing capacity, automation of logistics processes is critical. Printed sheets must arrive at the feeder and be delivered without process delays. With every unnecessary machine stop, the printing and ink parameters must be reset and optimized, adding time, waste, and cost to the process.

Application Solution:
All operator-accessible points on the machine are monitored with light barriers and light grids. Pepperl Fuchs SLA29 sensors are permanently active safety light barriers. Their detection range is extended by means of adjustable mirrors as far as this is useful. Depending on the risk potential, SLC30 safety light curtains may be required as an option for hand protection.

Benefit:
Previously, Krifft & Zipsner had used four different switching devices by two manufacturers for every machine, for example, the SLVA-4K evaluation device for the permanent light barriers and the SLVA-8K for the muted light barriers. All of these functions are now performed by the Safebox in an easier and more rational way.

Tri-Phase Automation is a distributor of Pepperl+Fuchs in Wisconsin.
Contact Tri-Phase Sales or Get a Quote

Sensors for Agricultural Machinery

Sensors have a wide range of uses in the agricultural industry

The MP 2000 compactor baling press from the Norwegian company Orkel has many applications for Pepperl Fuchs’ industrial sensors:

  • Filling level measurement in a container
  • Position control of flaps, shutters and casings
  • Counting the number of axle revolutions

Tri-Phase Automation is a distributor of Pepperl +Fuchs in Wisconsin. Contact Tri-Phase Sales or Get a Quote

Optical inspection of pharmaceutical labels

A customer success story from Cognex.

A medical device manufacturer needed to inspect for the presence of two dowel pins and a plastic cover on a product. Traditionally, this inspection was done manually, but was prone to operator error and resulted in rework costs. Traditional photoelectric sensors could not adequately identify the missing components due to their small size and position.

A Cognex vision system was installed in an inspection station. An operator would place the component into the station and would manually trigger the sensor to perform the inspection. It uses two contrast sensors to inspect for the missing dowel pins and a pattern sensor to inspect for the missing plastic cover.

Manual inspection errors were eliminated and product quality was increased. Rework costs declined dramatically and production line speed was increased.

Tri-Phase Automation is a Cognex distributor in Wisconsin. We offer evaluations and technical support to help our customers solve their applications.

Medical Device Assembly Check

A Medical Products Application From Cognex.

The Challenge

A medical device manufacturer needed to inspect for the presence of two dowel pins and a plastic cover on a product.

Traditionally, this inspection was done manually, but was prone to operator error and resulted in rework costs. Traditional photoelectric sensors could not adequately identify the missing components due to their small size and position.

Application Solution

A Cognex vision sensor was installed in an inspection station. An operator would place the component into the station and would manually trigger it to perform the inspection. The system uses two contrast sensors to inspect for the missing dowel pins and a pattern sensor to inspect for the missing plastic cover.

Manual inspection errors were eliminated and product quality was increased. Rework costs declined dramatically and production line speed was increased.

Product Recommendation: Cognex In-Sight 2000

Tri-Phase Automation is a Cognex distributor in Wisconsin. We offer evaluations and technical support to help our customers solve their applications.

Device Product Number Match

Medical Products Application by Cognex.

Device Product Number Match

The Problem

A Medical Device manufacturer required a Product Number inspection during their production process. Traditionally, this was done manually, but was prone to operator error and resulted in rework costs. Traditional sensors could not easily read the product numbers, and expensive Vision Systems were not practical.

The Solution

A Cognex vision system was installed. The manufacturer required a solution where a part would be manually inserted into a precision fixture and when an operator hits a start switch (external trigger) it would perform the Product Number inspection. The system met this goal using two pattern sensors to inspect for the matching Product Numbers based on an internally stored template. As a bonus feature, its ability to store settings for up to 16 jobs allowed the manufacturer an added benefit to quickly enable line changeovers.

The Benefit

Quality was improved with the manual inspection replaced with the Cognex’s system. Rework costs declined dramatically and the manufacturer was able to leverage the changeover capabilities to decrease errors during line changeovers.

Product Recommendation: Cognex In-Sight 2000

Tri-Phase Automation is a Cognex distributor in Wisconsin. We offer evaluations and technical support to help our customers solve their applications.

Cognex sensor checking bottle quality

A  customer application success story from Cognex.

When Meridian Beverage Co.’s new high-tech bottling line needed fill-and-cap verification, services provider Hamilton/ITS specified a reliable inspection sensor from Cognex that uses patterns to detect and inspect bottles and caps at speeds of 375 per minute. The challenge presented to Hamilton/ITS of Vidalia, Georgia was to provide a reliable “Fill & Cap” verification system for a new bottling line on behalf of Meridian Beverage Company of Atlanta.“The challenge is to kick out bottles that haven’t filled properly or have had the caps put on wrong.” Said Ray Hamilton, president of Hamilton/ITS.  “The new line runs almost non-stop at 375 bottles a minute so down time on our system wasn’t an option” he continued.

Cognex In-Sight 2000 sensors are the simple and affordable solution for verifying the presence of product and packaging features. Essentially a versatile “multi-sensor”, a single sensor detects features that would require multiple photoelectric sensors, or may not be within the capability of photo-electrics.

The sensor sensed 7 different features and sampled 5-7 snapshots of each bottle. The numerous snapshots reduced false negative responses. It self triggered, eliminating the need for an external sensor circuitry. Eliminating external sensors reduces costs of acquisition, design, installation and maintenance. After final in-place tuning, the system tested 100% f0r cap placement and proper fill level. Bottles were fed shoulder to shoulder and at 375 bottles a minute.

Tri-Phase Automation is a Cognex distributor in Wisconsin. We offer machine vision evaluations and technical support to help our customers solve their applications.

Cognex used in bottling line quality control

A customer Success story from Cognex

The automation solutions deployed in the Ottakringer Brauerei AG, Vienna, demonstrate the effectiveness and attractive cost/performance ratio of the Cognex Vision Sensor.

The main priority of the brewery’s maintenance department is the inspection of beer crates and boxes of cans to ensure they contain the correct amount. These tasks are performed successfully by the vision sensor solution from Cognex. In order to allow the brewery to develop an in-house solution, Schmachtl provided a test unit and specialist advice giving the maintenance team the flexibility to set up the checking station themselves. The ease of installation and operation as well as the simple programming of the system using a laptop computer proved significant advantages. The brewery was able to start automatically inspecting the boxes of beverage cans.

The Results

Their positive experiences with the checking system for boxes of cans encouraged the maintenance department to introduce the solution to further applications. The next step was to introduce a completeness check on the beer crates. This inspection method needed to be replaced with a more modern, more flexible and more reliable checking technology. The simple, space-saving design proved to be of great benefit, meaning that no fundamental changes to the conveyor line were required. Operating staff are able to program new jobs quickly and easily at any time using a laptop. With the new “Train and Go” capability, new characteristics can be programmed into a sensor even without a PC. When the job type on the production line is changed, the vision sensor can automatically switch over to as many as 16 different sensor configurations in real time. As a result, this checking station still possesses significant flexibility potential in terms of product range and characteristic selection.

Tri-Phase Automation is a Cognex distributor in Wisconsin. We offer machine vision evaluations and technical support to help our customers solve their applications.

Detection, alignment and inspection of product labels

Cognex always checks the label carefully for AstraZeneca.

An application solution story from Cognex

Problem

AstraZenec,one of the leading pharmaceutical companies in the world, needed to improve the accuracy of label detection in order to maintain production quality. The problem arose from the assistant system counting product labels as traditional electric-photo sensors often encounter errors when checking the edge of two neighboring labels. These sensors are not competent enough to meet such high speed production requirements. In order to reach zero defect level in production, AstraZeneca needed a more accurate vision system to count label numbers, to check whether the edge of the neighboring labels on the production line are correctly aligned and to raise the alarm when an error occurred.

Solution

AstraZeneca performed a series of tests on their production line using vision systems from Cognex as well as from several other vision suppliers. While they found that all the systems tested met basic production requirements, Cognex’s vision sensor stood out as the intelligent sensor capable of going further.

Benefit

Thanks to the stability and accuracy of this vision sensor, the quality of detection and counting is maintained and a high level of productivity is guaranteed. Costs are reduced while resolving a difficult problem. AstraZeneca is considering expanding the application to inspect date codes and inspect packaging.

Tri-Phase Automation is a Cognex distributor in Wisconsin. We offer machine vision evaluations and technical support to help our customers solve their applications.

100% Inspection Achieved. Orientation of Book Pages

Problem
A book manufacturer was experiencing high scrap and rework
costs in their bindery due to book pages being bound in the
wrong orientation. Standard photoelectric sensors could not
reliably check for page orientation due to variations in book
position. 100% manual inspection was not feasible at full line
speeds, forcing the quality assurance team to check only a few
samples per lot. Many incorrectly bound copies were missed
at inspection, resulting in high customer complaint rates.

Solution
A Cognex vision sensor was installed and its part
finding sensor identifies a reference feature on each set of
pages. The reference feature is used to locate an area on the
page stack where a dark mark should be visible when the
pages are in the proper orientation. It then uses a
contrast sensor to inspect that area for presence of the mark.
Use of the part finding sensor to locate the inspection area
provides consistent and reliable readings even when book
position varies. The sensor’s ability to store multiple settings
enables quick, easy job changeovers for different page widths.

Results

Quality was improved and customer complaints reduced by
enabling 100% inspection prior to book packaging. Yields
were increased and scrap and rework costs reduced via tighter
process control. High line speed was maintained because
the part finding sensor does not need separate external
triggering that would require additional time per inspection.

Tri-Phase Automation is a Cognex distributor in Wisconsin. We offer machine vision evaluations and technical support to help our customers solve their applications.

Tri-Phase Automation is a proud member of The Water Council

the-water-council-proud-member-logoTri-Phase Automation is an engineering based distributor with a broad breadth of innovative industrial solutions for the water and wastewater industry and we are a proud member of the The Water Council.

Our solutions range from the Internet of Things (IoT), remote monitoring & data acquisition, HMIs, PLCs, motion control, safety, sensors, to programming including panel builds and design.