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

We manufacture various types of conveyor machines. The uses of a conveyor machine in image inspection are as follows: to inspect products (conveyed goods), to remove works that fail to pass the inspection test, and to transfer the works that pass the inspection test to the next stage in good condition and without damage. The conveyor machine conveys cut paper and not rolled paper, and the stability of the paper during its conveyance is an issue of great importance. As the conveying speed reaches the maximum value of 200 m/min, it is impossible for us to track the condition of the paper with our eyes. Further, most of our machines have a customized design according to the work size and usage. Therefore, it is difficult to identify problems in the design step. We had to spend a great amount of time on the inspection after assembly. Since we used our KKD (Kan: instinct, Keiken: experience, and Dokyo: courage) to deal with any defects, we ended up accumulating experience instead of developing technology. Later, we came across the compact and portable PLEXLOGGER that could simultaneously obtain high-speed video and analog waveforms. We introduced the PLEXLOGGER because we thought we could utilize it in various situations.

Watch the movie to check the actual speed -> Conveyor machine_actual speed.wmv

This example shows a process that can be used to examine a discharging unit that transfers about several hundreds of products in batches to the next stage at a conveyance speed of approximately 150 m/min.

A high-speed camera records the conveyance, and in addition, the analog signals of a control motor and an optical sensor are recorded.

When the control motor is operated, recording of data from the motor and optical sensor is not synchronized, and therefore, there is a time lag between the two data. If this time lag is not known accurately, the video recorded by the camera cannot be used to identify problems in the works.

To solve this problem, we use PLEXLOGGER, which can simultaneously record a video and waveform data to check the amount of delay and identify the best timing.

Watch the status before adjustment

PLEXLOGGER allows a frame-by-frame playback of high-speed videos recorded at the site, as well as analysis of the amount of delay by using a time-axis measurement function for analog signals. With this function, we can immediately judge whether we can decrease the timing by a few seconds, or if this is not possible, we can examine if we can respond to problems by changing the conveyer position or length. Furthermore, as the data can be quickly downloaded onto the PC by using the LAN function, we use the flow line analysis function of the analysis software “PLEXLOGplus,” which is provided as an accessory, to visualize any problems in the works. We also use the angle measurement function to determine the angle of the guide. Thus, we utilize PLEXLOGGER for various purposes.

Watch the status after adjustment

Since the conveyance speed of 200 m/min means that a work moves by 3.3 m in one second, it is impossible for people to check condition of the work by visual inspection. On the other hand, with PLEXLOGGER, we can watch the behaviors in slow motion and obtain the analog signals simultaneously, which enable us to observe behaviors that are otherwise not observable and to determine the solution to a problem. Thus, we are able to dramatically reduce the number of steps required for the examination of actual machine accounting in about half of the development processes.

In addition to this, as PLEXLOGGER is light in weight and compact, we can take PLEXLOGGER along when visiting a customer’s site in case of trouble. PLEXLOGGER is also very helpful because our customers in food factories, where it is difficult to obtain appropriate lighting for a highly sensitive camera, allow us to bring it to the site to examine a conveyor unit.

Since the data obtained depends on the technology and not on the experience of people performing the inspection, differences in the data recorded by designers and service engineers were reduced and the overall quality of the data improved.