The automation solution deployed by Ottakringer Brauerei AG fully demonstrates the powerful features and satisfactory price/performance ratio of the Cognex Checker 101 sensor. The company's deployed inspection stations ensure that the number of products in the beer and beer boxes is correct.
Check with Checker!
Customer satisfaction has played a decisive role in the highly competitive brewing industry. Autodesk Beer is required to ensure that each package is loaded with the correct number of zero-defective products and that this quality assurance measure reduces customer complaints. As Austria's second largest beer company, Autodesk is able to increase the yield and quality of its products and reduce costs by using Cognex's intelligent Checker 101 high-speed sensors. Image sensors are increasingly used in areas that were previously dominated by standard sensors. At Autodesk Beer, smart sensor technology was successfully applied to the assembly line, which expanded the sales of the product and played a vital role in the company's fierce competition in the contract bottling market.
Intelligent sensor technology ensures the quantity and quality of products
The primary task of the Autodesk Brewery Maintenance Department is to verify that the number of products in the beer and beer boxes is correct. Otaklin contacted the image processing department of Cognex's partner, Schmachtl Ltd. The team from the company identified Autodesk's production automation needs and priorities. These needs can be met by Cognex's Checker 101 image sensor. In order to be able to develop an internal solution for Autodesk, Schmachtl provides testing tools and expert advice so that the maintenance team can build test stations flexibly and autonomously. The system has great advantages, its installation and operation is very simple, and the system can be easily programmed with a single laptop. Autodesk began an automated inspection of the number of beer cans in January 2006. The process is as follows: Each box is transported by a conveyor belt and then inspected by a Checker sensor installed to ensure that 24 cans (the correct amount) of beer are contained, and the final package is packaged in a shrink film. The test results are transferred directly to the production control system, so the production process is improved and the production data is easily obtained by the management.
Fast and scalable: from beer cans to beer crates
Due to the excellent performance of the inspection system, the maintenance department decided to expand the application range of the solution - that is, to test the beer box. This test method requires the use of more advanced, flexible and reliable detection techniques. The company used to use a complex system with many sensors installed. The company's internal maintenance department decided to use the Checker sensor in February 2006 and completed the deployment by March. Because Checker's design is simple and compact, there is no need to make fundamental changes to the conveyor structure. Checker will check the beer box on the conveyor belt to make sure it is loaded with the correct number of beer bottles. Checker can also check if the lid of the beer bottle is light or dark, thus providing an additional quality check on the bottling line. The intelligent detection system can automatically adjust according to different volume of beer boxes (18 bottles, 20 bottles and 24 bottles) to ensure the correct number of products in the box. When it is necessary to change the type of work, the operator does not need to modify the settings of the test station. The test station now operates in a 2 to 3 shift and can be tested at a rate of approximately one beer per second. Thanks to the use of standardized interfaces, it is convenient to integrate Checker into the control technology of the production system. If any errors are found, Checker can make the pipeline automatically stop working.
Operators can quickly and easily plan new job types at any time with a single notebook. Thanks to the new features of Checker's “smart learningâ€, even without the need for a PC, new features can be programmed into the sensor. When the type of work on the pipeline changes, Checker can automatically convert 16 different sensor configurations in real time. Therefore, the inspection station has great flexibility in terms of product range and feature selection.
Successful internal solutions enhance the company's image
The intelligent solution designed to improve product quality has been well received by customers and has enhanced the company's image. Autodesk is considering applying the solution to other aspects.
Checker - specifications and data
Compact, stand-alone, one-stop solution for small size and durability, protection class IP67
Simple configuration and installation integrated LED illumination and lens up to 500 frames per second direct process integration (no PLC required)
No external trigger industrial input/output interface integrated USB 2.0 interface
24 VDC operating voltage "smart learning" function size: 53.2 x 129.2 x 45.9 mm
Cognex Company Profile
Cognex specializes in the design, development, manufacture, and sale of machine vision systems (or so-called "visual computers"). Cognex is a global leader in the machine vision industry. Since its founding in 1981, Cognex has sold more than 350,000 machine vision systems with a cumulative operating income of $2 billion. Cognex's modular vision systems division (headquartered in Natick, MA) specializes in machine vision systems that can be used in a wide range of automated production areas for non-continuous manufacturing and to ensure their quality. Cognex's Surface Inspection Systems division (headquartered in Alameda, Calif.) specializes in machine vision systems for inspecting the surface of continuously manufactured products such as metals, paper, and plastics. In addition to its head office in Natick, Massachusetts, Cognex has regional offices in North America, Japan, Europe, and Southeast Asia.
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