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Package Inspection Systems

COGNEX CONTROL RELIABLE INSPECTION SYSTEM

The Cognex CRIS enables our clients to take advantage of fail-to-safe, control relaible product package inspection while utilizing Cognex components including imagers such as the Dataman and Insight, in addition to Cognex displays such as the VisionView. The CRIS from Sensors Integration also incorporates an Allen Bradley PanelView Plus HMI, CompactLogix PLC, and RFID reader for controls access. Download the brochure under "Documentation" for more information.

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CRIS 360 DATALOGIC CONTROL RELIABLE INSPECTION SYSTEM

The CRIS with Datalogic machine vision is ideally suited for high speed image processing for applications where patterns may be the only available aspect of the label to read (no code). This CRIS version uses the new Datalogic MX-E processor and M series cameras. It also incorporates an Allen Bradley PanelView Plus HMI, CompactLogix PLC and Allen Bradley 10in image viewer to use the vision program and review product images.

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SICK CONTROL RELIABLE INSPECTION SYSTEM

The Sick CRIS employs Sick laser scanners such as the CLVs and imagers such as the Lector series to provide fail to safe, control reliable product package inspection. Sick's laser scanners are easy to set up and can read linear codes easily, even when damaged or when obscured by shrink wrap. For 2D codes the Sick Lector series imagers are compact and easy to install. The system also integrates an Allen Bradley PanelView Plus HMI, CompactLogix PLC, and RFID reader for control access.

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FAIL TO SAFE SYSTEMS

"Fail to Safe" is a patented concept created by Sensors Incorporated that is designed to provide the optimal product inspection system. At its core, the system assumes every product is assumed to be a "fail" until it is proven "safe."

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Vision Systems & Lighting

PATTERN PROJECTORS FOR 3D VISION

LED Pattern Projectors from Opto Engineering and Smart Vision Lights are designed for 3D profiling and for the measurement of objects with complex structures or inclined planes. They are successfully used in applications like quality control for food and packaging, reverse engineering, dimensional measurement of electronic components, and robot guidance for pick and place and alignment applications.

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VISION SYSTEM LIGHTING

When a vision system is having difficulty due to changes in the target (speed, size, finish, texture, color, etc.), updated lighting can often help the system continue to perform.

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Barcode Products We Integrate

COGNEX BARCODE SCANNERS

Cognex industrial, image-based barcode readers decode 1D and 2D codes, from printed labels to the hardest to read direct part mark (DPM) codes in manufacturing and logistics applications. Industry-leading read rates, advanced technology, modular options, and easy setup help reduce costs, optimize performance, increase throughput, and control traceability.

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DATALOGIC BARCODE SCANNERS

Engineered for applications that are not permanently monitored by operators: Bar code reading for track & trace, Omnidirectional stations for sorting and tracking, Image processing for inspection and quality control, OCR and OCV for verification, Most used industrial interfaces and protocols, Easy integration in any industrial installation

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SICK BARCODE SCANNERS

SICK fixed mount bar code scanners speed up logistics and automation. The excellent read properties secure the process flow even if bar codes are bad or damaged. The high scanning frequency allows for high process speeds at the same time. Easy interconnectivity and high ease of use also offer advantages during operation. The compact connectivity saves time and money.

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COGNEX SCAN TUNNEL

Multi-sided omni directional scan tunnel for reading all sides of a case/package.

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DATALOGIC SCAN TUNNEL

Multi-sided omni directional scan tunnel for reading all sides of a case/package.

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SICK SCAN TUNNEL

Multi-sided omni directional scan tunnel for reading all sides of a case/package.

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4D PRO MODULAR INSPECTION SYSTEM

Sick has developed a full line of barcode scanners, vision cameras, and RFID scanners with mutually compatible connectors and software. This allows us to add components to systems as they require additional functionality. For example, this application required the reading of case barcodes through shrink wrap with the CLV690. The customer later needed to verify that the pallet had been fully loaded to prevent stacking problems, and we were able to add a volumetric scanner, the VMS, on to the existing system.

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BARCODE QUALITY EVALUATION

Because barcodes are the basis of so many data-acquisition systems, it is important to have an approach to verifying the readability of those codes.

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LOW CONTRAST BARCODE APPLICATIONS

When it is not possible to control the quality of printed barcodes, particularly from outside sources, there can be a huge impact on system throughput. Sick's low-contrast technology offers both a method of reading low quality barcodes, and a means of providing qualitative data for grading the codes. Sensors Integration offers code quality testing, as well as installing the correct scanners for the application.

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Application Examples

CANDLE LABEL DETECTION

Detecting a product label is a common application in automation. That effort can be made more difficult as the demand for attractive packaging results in inconsistent shapes and colors. In those situations our experience leads to unique solutions.

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BROKEN DRILL BIT DETECTION

By detecting problems as far upstream as possible, Sensors Incorporated minimizes the costs of reworking parts outside of the system.

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CAP DETECT

A common application for vision is verifying whether a cap is present and in its proper position. In this application the customer needed a compact camera with red lighting. The camera and its cables also needed to be able to withstand heavy washdown with strong cleaning agents. Sensors Integration specified the Cognex 7050, a Smartvision IP69K Red Brick Light and an APG IP69K camera enclosure.

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DETECT STRAW ON DRINK BOX

In addition to the obvious customer service reason, monitoring the straw position is critical to keep the packaging process from malfunctioning. A straw protruding from the carton can jam cartoners or shrink-wrappers. Baumer's VeriSens camera, used in conjunction with lighting that only illuminated the straw, is a rock solid solution.

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VISION MICROSCOPE

Manufacturers of precision parts have long faced the challenge of being forced to use microscopes to produce their products. A major medical device manufacturer wanted to enhance their process through the use of a vision system replacement. Click "Documentation" to download the whitepaper on Sensors' solution to their application!

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ICE CREAM INGREDIENT MONITORING

To prevent errors in the ingredient mixing process at an ice cream plant, the Basler Scout GigE camera was used to scan each bag of dry ingredients as it was conveyed to the mixer. Used in conjunction with conveyor controls, the customer's SQL database of the hundreds of different ingredients, and the Cognex VisionPro, manufacturing errors were nearly eliminated and throughput increased.

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BROKEN DRILL BIT DETECTION

To help a customer detect when they had a broken drill bit to avoid damaging their equipment or the stock, Sensors Integration used a camera to measure the length of the drill bits in the fixture.

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DATALOGIC PATTERN SORTING TOOL

Datalogic's new pattern matching tool, the PST (Pattern Sorting Tool), is a new approach to sorting applications. This patented algorithm is able to find thousands of different patterns in an extremely effective way, allowing products to be sorted regardless of orientation, perspective distortion, or partially obscured targets.

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SNAP RING INSPECTION

A manufacturer needed to verify that two snap-rings and a washer were in place before the fixture could move to the next station. Using a backlight, the camera was programmed to look for the stacked parts to verify their presence. If the stack was too short, or if there was a silhouette out of place, it was a fail.

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CATHETER INSPECTION STATION

A local medical technology company found a re-occurring issue with their production process. As they manufactured their tube devices, they would experience stresses in the sheathing, which could later result in tears and breakages. To solve their production problem, they turned to the experts at and Sensors Integration.

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MEDICAL TUBE SHEATH INSPECTION

A local medical technology company found a re-occurring issue with their production process. As they manufactured their tube devices, they would experience stresses in the sheathing, which could later result in tears and breakages. To solve their production problem, they turned to the experts at Sensors Incorporated and Sensors Integration.

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YOGURT LID INSPECTION AND PRODUCT CHANGEOVER

A Fortune 500 food manufacturer was facing a challenge: they needed to inspect the seal of their yogurt cup lids. To complicate matters, their marketing team was introducing a new 2mm shorter style cup that would help reduce production costs. Invariably this forced the lid inspection system to be adjustable to accommodate the changing cup heights. Having had success with Sensors Incorporated in the past , this large Consumer Packaged Goods (CPG) company turned to Sensors again to design, prototype, test and integrate a wash-down rated system. Download the PDF whitepaper under "documentation" to read more!

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Knowledge & Technical Reference

BARCODE QUALITY EVALUATION

Because barcodes are the basis of so many data-acquisition systems, it is important to have an approach to verifying the readability of those codes.

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DESIGN FOR VISION INSPECTION

To "Design for Inspection" is to consciously design product packaging to not only be attractive to customers, but to ensure it can be inspected reliably and efficiently. If the product is designed from inception with an eye towards inspection, the end result is optimal for both sales and manufacturing. Click "Documentation" for the full PDF!

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ENCLOSURE RATINGS DEFINED

This document breaks down the International Protection (IP) and NEMA enclosure rating codes.

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FAIL TO SAFE

"Fail to Safe" is a patented concept created by Sensors Incorporated that is designed to provide the optimal product inspection system. At its core, the system assumes every product is assumed to be a "fail" until it is proven "safe" Click "Documentation" for a PDF download!

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FOOD SAFETY MODERNIZATION ACT - FSMA

Initially enacted in 2011, enforcement of the new regulations in the FSMA begins in September 2016. Let us assist you with your compliance program with our popular CRIS (Control Reliable Inspection System).

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OPTICAL FILTERS FOR MACHINE VISION

Optical filters are not just an accessory, they are a necessity. The right filters can save thousands on equipment, and can make the difference between an application on the edge and an application with excellent repeatability.

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ROBUST LIGHTING FOR MACHINE VISION

The lighting professionals at Advanced Illumination do an excellent job of defining the critical considerations for lighting machine vision applications.

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USING SAFETY SCANNERS AS LIGHT CURTAINS

In applications where the lack of space or the presence of heavy traffic preclude installing light curtains, a safety laser scanner is often an effective solution.

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WHAT TO CONSIDER: BARCODE BASICS

This concise, handy guide explains the key factors to consider when choosing a barcode scanner. Code size, orientation and distance from the scanner all have an impact.

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