SubscribeEven though production procedure and process design has been well engineered, it is often difficult to see exactly what the machine is doing at optimum manufacturing speed, information which can help the engineer to improve production speed and productivity.
Simple misalignment of components can present serious problems and a break down in the production process. The use of high-speed video allows Production, Design and Test Engineers to fully evaluate mechanical processes during production.
The Olympus i-SPEED has been designed with these issues in mind, it can be set up and utilised on line quickly and easily. No specialised training is required and the unique Control Display Unit (CDU) allows the operator to control the speed and performance of the Camera, as well as provide instant review of the recorded video, at user variable playback speeds.
The implementation of 'Record On Command' (ROC) allows the operator to set up, and leave, the camera on a production line. Any standard TTL (+5v) can be used as a trigger for the camera, as long as the trigger is in the 'on' position, the camera will record, once the trigger signal stops the camera will stop recording. The operator can then return to the camera and review video of the highlighted, triggered fault only.
Measurements for angular displacement, distance and speed can be made on the CDU and the recorded video downloaded, for library purposes or further evaluation, either by compact flash card, or by Ethernet connection direct to a PC or laptop.
Case Study: Turner Packaging
Recent production disruption at Turner Packaging in West Horndon, UK, was solved using an Olympus i-SPEED, High-Speed Camera. Turner Packaging produces high quality custom transit packaging for the Manufacturing Sector. Machine reliability, facilitating speedy response to customer's requirements, is an essential element of their operation. So when a problem with their cardboard stapling machine was proving difficult, and costly, to resolve, specialist Engineers were brought in, but were unable to identify the cause. The Olympus High-Speed Camera was set up to view the problem area. The Camera was then triggered to capture the point in the machine cycle at which the fault was occurring.
Just one view of the resulting video replayed in slow motion, allowed Turner Packaging to pinpoint the problem - insufficient tension on the staple head return mechanism resulted in the staple misalignment and shearing.
The simple addition of an extra return spring resolved the problem, allowing production to resume immediately and output to increase to optimum levels. "The problem with our machine was proving to be time-consuming and very costly," said Geoffrey Carter - Managing Director, Turner Packaging. "Prior to the use of a High-Speed Camera, resolution of this problem was reduced to guesswork. Repair costs were escalating to no avail. The immediate analysis afforded by the slow-down view enabled us to repair the fault ourselves within minutes of viewing the film."
"We have also used the i-SPEED to increase process efficiency and to improve the procedures involved in the production of custom routed foam inserts."
The Olympus i-SPEED is being utilised effectively by numerous manufacturing organisations involved in the design, implementation and day to day use of packaging machines - the combination of ease of use, high specification and low price, means that organisations who have always wanted high-speed video to improve their efficiency and profitability, have the opportunity to benefit from this important inspection and test procedure.