Frame-by-Frame Analysis and Diagnosis of a High-speed Packaging System Using Fastec InLine Network-ready Camera Vision Equipment
2012 ASEE Annual Conference & Exposition Proceedings
Akram Hossain is a professor in the Department of Engineering Technology and Director of the Center for Packaging Machinery Industry at Purdue University Calumet, Hammond, Ind. He worked eight years in industry at various capacities. He is working with Purdue University Calumet for the past 24 years. He consults for industry on process control, packaging machinery system control, and related disciplines. He is a Senior Member of IEEE. He served in IEEE/Industry Application Society for 15 years
... ciety for 15 years at various capacities. He served as chair of manufacturing Systems Development Applications Department of IEEE/IAS. He authored more than 25 refereed journal and conference publications. In 2009, he as PI received NSF-CCLI grant entitled A Mechatronics Curriculum and Packaging Automation Laboratory Facility. In 2010, he as Co-PI received NSF-ATE grant entitled Meeting Workforce Needs for Mechatronics Technicians. From 2003 through 2006, he was involved with Argonne National Laboratory, Argonne, Ill., in developing direct computer control for hydrogen powered automotives. He is also involved in several direct computer control and wireless process control related research projects. His interests are in the area of industrial transducer, industrial process control, modeling and simulation of mechatronics devices and systems, wireless controls, statistical process control, computer-aided design and fabrication of printed circuit board, programmable logic controllers, programmable logic devices, and renewable energy-related projects. Hamza Kadir is currently a graduate student in mechatronics engineering technology at Purdue University. He has previously worked in the fields of application of a new SS7-Sigtran protocol interchanger for communication between Remote Terminal Units and a Supervisory Control and Data Acquisition system, and smart grid solutions in a third world country such as Bangladesh. He has also worked in the field of evolution of mobile backhaul in 3G. He has worked for Ericsson and Areva T&D in Project Management and Network Deployment, and for Grameenphone (a Telenor company) in design engineering. He has received his B.Sc. in electrical and electronic engineering from Islamic University of Technology, Bangladesh. His research interests lie in the application of automation and robotics in the packaging industries. Abstract High speed camera vision system is a vital tool in the modern industry. The industry now-a-days are known for their high speed manufacturing processes. A delayed downtime may cost a company millions. Similarly an inaccurate operation of certain machinery parts of a packaging machine may cost highly. Therefore, the quickest possible method to resolve a fault or even tuning is most advisable. This is where a high speed camera system comes into use. High speed imaging is a technique used for specific motion analysis and troubleshooting purposes. This may include applications in fast operating industry machinery, crash impact testing for automobiles and so on. It is when photography is conducted in a very high rate ranging from 250 frames per second and higher. This may range up to as high as several thousand frames per second depending on the application and budget. For example, if a motion sequence at 600 frames per second is captured and played back at 30 frames per second, a smooth continuous motion or a frame by frame playback of that event can be viewed. It can be studied for improvement, tuning or solving a malfunction which cannot be done with the naked human eye or standard video framing (approximately 25-30 fps). Availability of such a tool can greatly reduce machinery downtime in a fast moving packaging system. This paper will talk about troubleshooting a problem of a certain cam profile between two screw conveyors in series. The two screw conveyors are required to function in a certain cam profile which will transfer a fixed number of bottles to the next machine in a process. This transfer process often works properly at low speed (e.g. ten containers per minute) but at high speed (e.g. 300 containers per minute) its functionality deviates from the desired pattern. In such a case, to observe and analyze the problem, a high speed imaging tool reduces troubleshooting time significantly. Such problems between two servomotors can be found in machines such as orienters, transfer screw conveyors, stackers, palletizers, high speed cutter and so on.