The installation of a machine vision system at Living Ceramics’ grinding plant has meant a step forward in its operations, as well as a significant improvement in efficiency and quality.
The main objective of this project was to implement an artificial vision solution for the detection of the alignment of ceramic pieces with relief.The machine is designed to discriminate and classify between good and defective parts before being boxed, after simple parameterization of the machine by the operator depending on each model and relief.
The machine vision system, consisting of two high-resolution cameras and a KEYENCE 3-core controller, was mounted on a custom-designed metal structure for the grinding line. This allowed optimal regulation of cameras and lighting according to detection needs.
The system allows automatic detection of the part for real-time image processing, thanks to a high-precision encoder and sensor installed on the line.
Automatic part detection, thanks to a high-precision encoder and sensor, made real-time image processing possible. In addition, a control panel was implemented with an advanced HMI from Control Ceramics that facilitated the parameterization by the operator of the values necessary for the system to automatically classify the parts according to the defects detected, and the notification of problems by means of light signals.
Several works were carried out, but above all the symbiosis of both teams (Ingesom – Living Ceramics) made that each stage of the project was successfully completed:
Engineering study and technical documentationWe conduct an engineering study to understand the customer’s specific requirements and document all the technical specifications necessary for the implementation of the system.
Pilot test in a production plant with chambers with cameras, to validate the suitability of the solution.
Programming and configuration of the vision systemAdvanced algorithms were developed to ensure accurate and fast detection of defective parts.
PLC and HMI programmingWe configured the PLC to interact efficiently with the vision system, and to use a light beacon to notify the operator in case of defective parts detection. In addition, we programmed a 10″ HMI to facilitate operator interaction with the vision system.
Installation of the new control panelWe installed a new control panel to house the controller and PLC, ensuring that all components were safely and efficiently integrated.
Factory testing and commissioningWe perform rigorous factory testing to ensure the correct operation of the system prior to implementation. Once the tests were completed satisfactorily, we proceeded with the start-up in the grinding plant.
Operator trainingWe provided comprehensive training to ensure that they were fully trained to manage the system effectively.
We appreciate the close collaboration between our team and that of Living Ceramics.
The machine vision system has significantly improved efficiency in their production processes, enabling them to offer the highest quality products to their customers.