MEDICAL DEVICE - AUTOMATED INSPECTION

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Customer Need

A medical device company was performing manual sampling Quality Control on a product line and wanted to upgrade it to 100% automated inspection. They required the system to integrate into the current production line and as well as be contained within a required footprint. The system had the following requirements:

  • 3 second cycle time
  • Overall Equipment Effectiveness greater than 97% during FAT and SAT
  • 15 different pieces of the part needed to be inspected
  • Capable of inspection two different products
  • Vision system processing station
  • Result monitor
  • Controls cabinet/HMI
  • Reject bay
  • Reject label printer
  • Offload conveyor

Solution

CSC designed and fabricated a system with a chain driven roller conveyor had actuators below the roller to raise stoppers so that parts would line up and allow for the inspection. Along the conveyor were sensors that triggered these, as well as a station to blow off any dust. The line camera inspected the parts as required. All parts that failed inspection were removed and pushed to the reject bin. A printer was integrated to print labels so that failed parts could be labeled.

System Components

60" Shuttleworth Roller Conveyor

Keyence XG Vision Controller

Keyence 5MP Color Camera

Telecentric Lens

Industrial Thermal Label Printer

Mitsubishi FX3 PLC

Mitsubishi 7" Touchscreen

Keyence Miniature Photelectric Sensors

Keyence Digital Laser Sensor

Success

Four systems were fabricated and integrated into the customer's production lines. All systems have been up and running for 3 daily shifts since installation with no issues. Since the original order, two additional systems have been fabricated and delivered.