High-Speed Color Measurement for Modern Manufacturing

Understanding how high-speed spectrometers measure color on manufacturing assembly lines provides a glimpse into the complex world of precision quality control and modern manufacturing techniques.

A spectrometer measures the amount of light absorbed or transmitted across different wavelengths. Color measurement involves analyzing the spectrum of light reflected off an object to determine its color.

In a typical setup on a manufacturing assembly line, a light source illuminates the product or material whose color we want to measure. This light source must remain consistent in its intensity and spectrum because any variation can influence the accuracy of the color measurement.

When the light hits the object, the object absorbs specific wavelengths of light and reflects others. The reflected light then enters the spectrometer. Inside the spectrometer, the light is dispersed, often with the help of a diffraction grating or a prism. This dispersion breaks the incoming light into its constituent colors or wavelengths, similar to a rainbow when sunlight passes through raindrops.

An array of detectors inside the spectrometer captures this dispersed light. Each detector is sensitive to a specific wavelength or a narrow range of wavelengths. By measuring the intensity of light each detector receives, the spectrometer builds a spectrum – a graphical representation of light intensity versus wavelength.

This spectrum effectively captures the color profile of the object, and a computation derives color values, typically regarding color spaces or systems like the CIELAB or RGB. These values provide a quantitative measure of the object's color compared to a standard or reference value.

In a manufacturing assembly line, the speed of this process is paramount. High-speed spectrometers capture and process data in real-time, allowing them to analyze the colors of objects as they race along the line. Suppose the color of a particular product deviates from the set standard. In that case, the system can instantly flag it for inspection or removal, ensuring that products maintain a consistent color quality throughout the production run.

The integration of high-speed spectrometers into manufacturing lines, coupled with sophisticated software, ensures that color consistency and quality meet the strict standards demanded by today's consumers and regulatory bodies. This method not only optimizes the quality of the final product but also minimizes wastage and enhances efficiency in production processes.

Micro-Epsilon stands as one of the top sensor manufacturers globally. For over 50 years, they have consistently provided reliable and high-performance solutions, especially in situations demanding high precision measurement or inspection. Their product line includes sensors for distance and displacement measurement, IR temperature measurement, and color detection, along with systems for dimensional measurement and defect detection.

The Micro-Epsilon colorCONTROL ACS7000, color measurement system, recognizes reference colors through direct comparison and distinctly identifies individual colors based on their coordinates in the color space. Equipped with a high-speed spectrometer, the colorCONTROL ACS7000 excels in applications that require online examination of colors and shades with utmost precision.

AP Corp.
(508) 351-6200
https://a-pcorp.com

Micro-Epsilon Introduces scanCONTROL AIK Adapter for Cognex® VisionPro® 2D/3D Analysis Software

Cognex® VisionPro® 2D/3D analysis software is a powerful computer vision software developed by Cognex® Corporation and specifically designed for use in manufacturing and industrial automation applications. This software combines 2D and 3D vision technologies to analyze objects, parts, and components comprehensively.

The software utilizes sophisticated algorithms to analyze images and detect defects or anomalies in manufactured goods. It can accurately measure product dimensions, angles, and shapes and detect even minor defects, such as scratches, cracks, and other imperfections. The software can also compare components and ensure they meet specific quality standards.

Micro-Epsilon released their scanCONTROL AIK adapter for VisionPro® in response to Integrator requests for compatibility with better-performing and lower-cost sensors. Now Integrators can switch directly to scanCONTROL sensors without problems! 

The Micro-Epsilon scanCONTROL AIK adapter for Cognex® VisionPro® (a small software tool) is available for download for free from Micro-Epsilon's download area. The AIK adapter is developed closely with Cognex® and supports all current scanCONTROL models (LLT25xx, 29xx, 30x2, 30x0).

For more information in New England, contact AP Corp. Call (508) 351-6200 or visit https://a-pcorp.com.

The surfaceCONTROL 3D 2500 Snapshot Sensor for Surface Inspection of Large Objects

The Micro-Epsilon surfaceCONTROL 3D sensor is ideally suited to the automated inline inspection of geometry, shapes, and surfaces on diffuse reflecting surfaces. The 3D snapshot sensors work according to the fringe projection principle, which allows direct 3D measurement of components. The sensor includes a large measuring field and a high measuring range depth with z-axis repeatability of up to 3.0 μm. Three models cover different measuring areas. 

Captured images transfer to the external SC2500 controller and are processed quickly into 3D data via the Gigabit Ethernet interfaces. The 2D/3D Gateway II supports EtherNet/IP, PROFINET, and EtherCAT connections. 3DInspect, DefMap3D, and Inspection Tools are powerful software tools that enable precise 3D measurements and surface inspection. GigE Vision compatibility also allows easy integration into third-party image processing software. The comprehensive SDK for customer software integration rounds off the software package.

surfaceCONTROL 3D Sensor Features:

• Large objects max. 650 x 495 mm
• High measuring range depth up to 300 mm
• Acquisition time from 0.5 s
• Highest precision up to 3.0 μm
• Digital interfaces (via controller 2500): GigE Vision/GenICam
• Digital interfaces (via 2D/3D gateway): Gigabit Ethernet (GigE Vision / GenICam) / USB2.0 / PROFINET / EtherCAT / EtherNet/IP 

surfaceCONTROL 3D Sensor Application Examples:

• 3D inspection of geometry, shape detection and surface inspection
• Automation, production and process monitoring as well as quality control
• Non-contact measurement of diffuse reflective surfaces in the Stop&Go process
• Shape, position and surface inspection

For more information about Micro-Epsilon Products in New England contact:

AP Corp.

https://a-pcorp.com

(508) 351-6200

Now Representing Sensuron - Ultrafine Distributed and Continuous Strain & Temperature Sensing

AP Corp is pleased to announce its selection as Sensuron's New England and Upstate New York Authorized Representative.

ABOUT SENSURON
Starting as an informal partnership with NASA and a formal licensing agreement in 2011, Sensuron began developing off-the-shelf fiber optic sensing systems and then designing cutting-edge fiber optic sensing platforms that allowed companies to consolidate their testing and measurement solutions. Sensuron is now a leading global provider of distributed strain and temperature sensing platforms for applications across industries and is now expanding to liquid-level and 2D deflection.

Sensuron's fiber optic sensing technology enables engineers to perform structural testing, design optimization, structural health monitoring, thermal mapping, and shape sensing with an efficient, robust, and simple-to-use tool.

AP Corp is proud to be representing Sensuron in all of New England and Upstate New York. For more information call (508) 351-6200 or visit this web page.

AP Corp.
One Tara Boulevard
Suite 200
Nashua, NH 03062
www.a-pcorp.com
508-351-6200 (office)

Combat the Hazards of Plastics Screw and Barrel Wear

This post is abstracted from an excellent article from Plastics Technology Online
written by Jim Callari. Read the full text here.

Industrial-grade screw and barrel wear cuts throughput speeds, producing scrap before shutting down. For the first time, technology is making progress in unraveling the mystery of screw and barrel wear. 

There has been a lot of injection molding machine innovation in the past year. And now, Glycon Corp. has the technology to test wear within the plasticating device. Glycon is in the first phase of rolling this technology out in the industry. It will concentrate on extrusion and blow molding. 

With this capability, they have developed the technology to calculate the rate of wear and predict future wear. This data determines the most cost-effective time to replace these components.

Glycon has been working on measuring wear since 1986 gained their first patent as Great Lakes Feedscrews. The company expanded the invention to include measuring barrel wear and was awarded additional patents in 2006, 2007, 2008, and 2019. 

Wear and tear challenges are well documented over the years, and plastic processors know the symptoms. Many machine operators compensate by making changes to the screw speed or temperature settings. The problem is, both of these changes would ultimately result in lower efficiency and higher scrap rates. 

The new system called EMT (short for Electronic Measurement and Tracking), includes Glycon's flite-scan eddy-current sensors mounted in one or more positions within a SmartBarrel. These barrels also have SmartPorts, another innovative technology offered by Glycon. 

Measurements will be conducted routinely at the processor's plant by field technicians using a Flite-Scan sensor. Several eddy-current sensors were tried over the years. Multiple sensor manufacturers were collaborated with, but all ran into failure at high temperatures in the plasticating units. 

Micro-Epsilon, a leading manufacturer of sensors that measure displacement, distance, position, vibration, dimension and thickness, was the eventual choice because their sensors proved much more robust and provided reliable readings up to 600 F. 

The EMT system is not only to analyze the data to determine the optimum time to replace or repair worn screws or barrels to optimize productivity but also to relate the wear to:

• Materials of screw/barrel construction.
• Screw/barrel alignment. 
• Polymers being processed.
• Impact of abrasive fillers.
• Performance related to wear, including production rates, cycle times, energy consumption, melting rates, head pressures and melt temperatures.

The Glycon EMT system's advantages are that it provides precise measurement of the wear on the OD of the feedscrew and the barrel's ID and its simplicity and cost-effectiveness. It allows maintenance personnel to plan to measure intervals and to schedule changeouts at convenient times based upon wear-rate data rather than 'running to failure' and having to run inefficiently or not at all.

For more information about the new Glycon technology in New England and Upstate New York, contact AP Corp. Call them at (508) 351-6200 or visit their website at https://a-pcorp.com.

Distance Measurement for Reflecting Surfaces with Universal Laser Sensor

Plastics, mirrored glass, or metals have highly reflective surfaces and require special laser sensors to measure displacement and distance. Displacement and distance measurements on strongly reflecting surfaces challenge conventional, diffuse reflection laser sensors. 

Laser sensors such as the Micro-Epsilon optoNCDT 1750DR provide a real-time surface compensation feature that controls exposure time that produces stable signals. This type of laser sensor operates on the principle of direct reflection, aligned so that the angle of incidence is equal to the angle of reflection. Proprietary algorithms compensate for the back-scattered, high-intensity light—all of this in a compact design, including an integrated controller (no external control unit is required).

Mounting and wiring are easy. A mounting template enables the user to align the sensor correctly. The laser class 1 rating on which the optoNCDT 1750DR operates is another advantage. Additional safety precautions are not necessary since the emitted laser power does not exceed 390 µW. Users have the choice of an intuitive web interface which can operate the laser sensor from a browser.

For more information in New England, contact AP Corp.

AP Corp.

https://a-pcorp.com

508-351-6200

Micro-Epsilon Laser Profile Scanners: scanCONTROL LLT3000 and 2500

Micro-Epsilon scanCONTROL LLT3000

The scanCONTROL LLT3000 laser profile scanners impress in 2D/3D measurement tasks with high precision and dynamics. With a high resolution sensor matrix and high profile frequency, the scanners are designed for precise profile measurements in dynamic processes.

Micro-Epsilon scanCONTROL 2500

The scanCONTROL 2500 laser scanners are specially designed for industrial measurement tasks. Compact design, versatility and high signal stability result in an excellent price/performance ratio especially for measurement tasks involving large quantities.

Laser profile scanners from Micro-Epsilon are among the highest performing profile sensors with respect to accuracy and measuring rate. Equipped with powerful processors and highly sensitive optical components, these scanners ensure precise profile measurements on nearly any type of surface. While they can be integrated in various environments, the scanners also impress with a compact design which includes an integrated controller.

For more information about Micro-Epsilon products in New England, contact AP Corp. Call them at (508) 351-6200 or visit their website at https://a-pcorp.com.