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MachineInspection and measurement

AOI Sklopka - optical inspection machine

An automated optical inspection machine that uses two cameras to inspect production parts as they pass on the conveyor belt and automatically separates correct parts from defective ones.

SolidWorks CAD render of the AOI Sklopka machine
Control
Siemens S7-1200 + SIMATIC HMI
Actuators
Festo pneumatic cylinders, conveyor belt
Sensors
2x Basler industrial camera with ring light
Image processing
PC with custom OPKO machine vision software
Safety
Emergency stop, safety doors
Design
Stationary unit in a protective enclosure
How it works

Dual-camera station for in-line inspection

The parts come into the machine on the conveyor belt and are positioned in place for optical inspection. Two Basler industrial cameras with ring lights capture the part from different angles and send the images to an industrial computer (PC).

On the PC, custom-developed OPKO optical inspection software processes the images, decides on the correctness of the part and passes the result to a Siemens S7-1200 PLC. Correct parts go on for further processing, while Festo pneumatic cylinders separate defective parts into a separate box.

Control

Interface and control logic

A standard operator interface: a Siemens SIMATIC HMI panel with a rotary operating mode switch and start and emergency stop pushbuttons below it.

Physical control station

  • HMI panel (Siemens Simatic)
  • Rotary operating mode switch
  • Start pushbutton and emergency stop
  • Status signal light

Functionality

  • Display of inspection cycle status and steps
  • Configuration of optical inspection parameters per part type
  • Manual control with appropriate permissions
  • Display of alarms and errors
Installed equipment and features

Technical details

Dual-camera station with Basler cameras

Two Basler industrial cameras with LED ring lights capture the part from different angles for more reliable defect detection.

OPKO machine vision software

The cameras send images to an industrial computer (PC), where custom-developed OPKO software analyzes the image and decides on the correctness of the part.

Festo pneumatics

Festo pneumatic cylinders, controlled by a signal from the PLC, separate correct parts from defective ones at the output.

Siemens S7-1200 control

After image processing, the PC sends the part status to the PLC, which uses it to coordinate part positioning, camera triggering and separation at the output.

Protective enclosure

The machine is built in a closed aluminum enclosure with safety doors to protect the operator.

Gallery

Control cabinet and camera station

Siemens SIMATIC S7-1200 PLC and safety relays in the control cabinet of the AOI Sklopka machine
Siemens SIMATIC HMI panel with control buttons on the AOI Sklopka machine
PC with OPKO optical inspection software for image processing in the AOI Sklopka machine
Two Basler cameras with ring lights at the optical inspection station of the AOI Sklopka machine
Video

Machine in operation

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