The new generation of the WebControl Surface System detects surface defects even with highly complex textures of films and technical web products.
Pixargus at the "ICE Europe 2017": The new generation of the WebControl Surface System recognizes surface defects even with highly complicated textures of films and technical web goods and ensures that waste minimizes and only faultless material is processed. The system combines for the first time 100% surface inspection with the dimension measurement in a sensor and penetrates through a multi-zone scanning into new viewing areas.
WebControl Surface (S) detects defects on challenging surfaces made of non-transparent or (semi-) transparent material as well as composite materials and adapts itself to the texture. Typical applications are all flat technical web goods, such as those used for the interior lining of vehicles.
Smart software hides intact interface
When analyzing the surface, an algorithm recognizes and hides the natural surface texture. So WebControl S finds bugs that seem to hide in the normal structure of the material. The system classifies, for example, irregularities in artificial leather / leather structures, weaving defects on glass fiber mats, so-called orange peel defects on dark, opaque films or compressed areas in nonwoven material, and even recognizes weak scratches. If the system finds an error, it triggers an alarm, optionally marking the affected area. An algorithm for detecting long defects - for example, scratches or weaving defects - also makes it possible to draw conclusions about defective rolls in the production plant.
Automatic adaptation to structure and color
The system works dynamically and adapts automatically to the surface structure and color of the material. Therefore, in contrast to inspection systems from other manufacturers, in most cases no complex teach-in of the surface structure is required; it is sufficient to enter only the relative amplitude of the texture ("roughness parameter") and the size of the smallest defect to be considered. A classification and error density management tool makes it easy to set up rules for detection and classification. In addition, the user can decide for himself which and how many errors he tolerates on a certain area.
MultiArea functionality through virtual camerasWebControl S features modular, multi-zone scanning - an innovation in image processing technology. The new MultiArea functionality extends the physical sensors with virtual cameras: Pro Camera can now any number of viewing areas (with different parameters such as defect sizes) can be set and different inspection tasks can be processed simultaneously. Pixargus' completely newly developed LED light-line elements combine the light energy on the material surface exceptionally well and thus create a high contrast. In addition, they are characterized by a significantly longer service life. All optical components are encapsulated to IP64. Remote access via Ethernet and IP-based communication not only enables fast system diagnostics, but also, in particular, changing and adjusting the parameter settings.
New machine vision software ensures easy operation
The application is controlled by a new machine vision software from the Würselener. Operation is via a swiveling multi-touch screen with further improved graphic display. Similar to modern tablets or smartphone screens, the user can select elements and change and adjust the size and position of objects with 2 fingers. A new autofocus accelerates the setup of the camera systems and thus the startup process.
Quality data in a quick overview
WebControl S provides measurement data and evaluations in real time and prepares the quality data for synopsis in a "fault map". Intelligent big-data analysis capabilities make the entire extrusion production process more transparent at key points.
Subsequent errors are avoided. The production can be optimally optimized. The system can be easily integrated into company networks, SAP environments and existing PDC and ERP systems, can be networked with other sensors and measurement systems, and can be integrated horizontally and vertically into innovative Industrie 4.0 applications. All system components can be managed remotely on the line and centrally via a server.
Scalable system for flexible applications
WebControl has a modular design and is available for material widths between 150 and 8,000 mm. Depending on the surface characteristics, Pixargus supplies the system with a camera resolution between 10 and 150 μm. For opaque products, it may inspect one or both sides. It works, depending on texture, at material speeds up to 800 m / min. The compact design and new assistance systems support the fast, flexible use of the inline system during the startup process and throughout the entire production period.
"We continue where others stop"
Dirk Broichhausen, Pixargus' Vice President Sales & Marketing, sees big benefits for the manufacturers of sheet products: "The manufacturers of surface inspection systems have so far concentrated on materials with a uniform structure, ie mostly on metals, foils and paper. With our new algorithms, we find surface defects reliably even against very troubled backgrounds. This can be compared to the successful search for the needle in a haystack. Or simply put, we continue where others stop. "In addition to quality assurance in final inspection, Pixargus' customers use the data to optimize production and prevent errors from occurring. For example, trends in the frequency of defects on the surfaces are detected in real time, so that immediate countermeasures can be taken. Operators can take corrective action immediately and sort out faulty material immediately.
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