High-Speed Camera ＋ data Logger = PLEXLOGGER The ultimate solution for dramatically increases the efficiency of evaluation and verification on site

Although very rare, there were cases in which irregular coiling or broken wires were observed in our self-manufacturing coil-winding machine. These phenomena occurred instantaneously phenomena and their causes were unknown; as a result, we have had monitor the machine until the defect recurred since these phenomena could not be predicted. This is a very inefficient method to resolve manufacturing problems and has been the source of much discontent.

In order to capture the moment when the wire breaks, the machine was modified such that the coil tension device transmits an error signal when the wire breaks and PLEXLOGGER was installed to automatically capture the defect upon being triggered by the error signal.
Since any defect can be automatically captured by PLEXLOGGER, we operated the systems round the clock while performing other tasks. The defect occurred three days later, and PLEXLOGGER captured the moment without requiring our assistance or monitoring.

We were able to confirm that the coil was trapped by the guide nozzle, and we took the necessary measures to modify the guide nozzle.

Thanks to PLEXLOGGER, we no longer face the problem of broken wires. When using conventional systems, we have had to monitor the facilities in which defective phenomena might occur continuously, round the clock, and check the timing of the recording manually. In contrast, PLEXLOGGER automatically records defective phenomena even if they occur only once in 10,000 products.

Since devices do not require attention until a defective phenomenon occurs, devices can be left unmonitored, and personnel can perform other activities.
Furthermore, although we had believed that the defect was caused by the coil tension device, the video image captured by PLEXLOGGER proved it otherwise. We realized that we had imagined the problem to be far more complicated than it actually was. Now, we have installed PLEXLOGGER in a different facility that frequently stops in a manner similar to that described above and are looking forward to analyzing the captured defect generation images.