Iterative Design to Modernize a Manufacturing Inspection System
"Ever since you rewrote the architecture to this inspection software, I have been impressed with your response time to get new features implemented!"Challenge
Our customer needed to modernize their inspection system. They knew generally what they wanted, but didn't have the expertise to create an excellent system. They also needed to be able to repeatedly implement, test, and modify quickly.
Solution
We rearchitected the existing code allowing for features to be more easily added and tweaked. Our integration experience made it easy to integrate with the hardware that the customer had already selected and perform all necessary functions in a new and modernized system.
Introduction
Vistec builds web inspection systems that quantify and classify defects in continuously manufactured paper, tissue, foil, film and textiles. These materials are manufactured in long runs of thin material and then coiled up. Before the material is rolled up, it needs some level of quality assurance. Since it is manufactured and rolled in one procedure, it must be inspected while it is manufactured. As part of their digital transformation, the older, analog system needed to be updated to stay relevant, cost effective, and competitive. Vistec found they needed to improve their software offering including modern hardware and digital analysis. Rather than try to write software themselves to interface with their laser and camera systems, they turned to Endigit to leverage LabVIEW and the NI platform to stay competitive.
Process
Vistec had some existing LabVIEW software that we began to leverage into the new solution. We quickly realized that starting over would lead to a better software architecture and though it would seemingly delay the early features from being completed in the system, it allowed for much quicker iteration and better functionality. This turned out to be a great decision because there was a lot of iteration that took place.
Endigit worked similarly to an internal R&D team. We would implement the requested features and give Vistec an application to work with and test. Then they would give feedback and we would make changes and improvements on those features. We continued to work this way as we added more and more features until they were ready to launch the product. It was very efficient to iterate, because it is costly to try to determine all of the details of what the finished product should do and even when you take that time, most of it changes anyway.
Endigit worked similarly to an internal R&D team. We would implement the requested features and give Vistec an application to work with and test. Then they would give feedback and we would make changes and improvements on those features. We continued to work this way as we added more and more features until they were ready to launch the product. It was very efficient to iterate, because it is costly to try to determine all of the details of what the finished product should do and even when you take that time, most of it changes anyway.
Results
The resulting software, LIS (Laser Inspection System), interfaces with line scan cameras, lasers, frame grabbers and data acquisition cards to inspect material for defects. LIS performs all configuration, calibration, inspection, analysis, alarming and logging real time. LIS instantly provides images of defects to the operator, along with shape, size and location information leading to very quick responses to the defects. LIS also uses configurable digital outputs to trigger sprayers to mark the edge of the product for easy location down the line. This feature allows very precise measurements and identification of defects rather than purely identifying that a defect was detected. LIS classifies defects based on size, shape, depth, frequency and even repeatability, which is common when using any rollers in the system. At the end of a roll, LIS provides summary reports including a map of defects, defect counts, summary of sizes, etc.
Benefits
- Increased speed of defect detection
- Improved accuracy
- Decreased time to identify the cause of defects
- Increased speed of defect detection
- Improved accuracy
- Decreased time to identify the cause of defects
Hardware
- National Instruments multifunction DAQ card
- Matrox frame grabbers
- Laser line scanners
- Industrial cameras
- National Instruments multifunction DAQ card
- Matrox frame grabbers
- Laser line scanners
- Industrial cameras
Software Modules
- Vision Development Module
- Vision Development Module