Conveyor systems are essential for transporting items efficiently within manufacturing and warehouse facilities. Different conveyor types each have roles to play in handling, sorting, packaging and shipping products. As technologies advance, conveyors are gaining powerful new capabilities.
Vision systems are becoming increasingly common on conveyors to automate quality control and inspection tasks. Cameras can detect defects, verify codes or labels, and even identify products as they move down the line. Some vision systems use machine learning to continuously monitor for anomalies. This allows issues to be caught earlier before further processing. The inspected data generated from vision systems also provides insights to optimize processes over time.
This article will explain how different types of conveyors work, their key functions and benefits, and emerging technologies that are optimizing conveyor systems.
- Automated Inspection and Identification
One way conveyor systems are becoming smarter is through integrated automated inspection and identification capabilities using machine vision. Specifically, conveyors can now perform basic optical character recognition and barcode scanning using integrated camera systems to automatically identify items as they pass by on the belt in real time.
Furthermore, conveyors equipped with advanced camera systems coupled with artificial intelligence can perform more sophisticated visual inspection tasks. For example, they can detect surface defects, missing or incorrectly labelled components, and even measure dimensional attributes like weight, size and fill levels.
As a result, automated inspections using the camera vision systems on conveyor systems save significant time and labor compared to manual inspection methods. Staff no longer need to visually check each item; instead, the computer vision on the conveyor can scan hundreds or thousands of products per hour using integrated cameras.
- Simple Measurement
Moving beyond basic identification, some advanced conveyor systems have integrated measurement capabilities using computer vision. For instance, integrated scale modules using load cells can accurately measure the weight of items passing over them to ensure products meet specifications. Additionally, proximity sensors detect the presence, order, and spacing of items on the belt.
Photoelectric sensors even allow for dimensional measurement of attributes like height, diameter, and length. Utilizing these simple measurement tools combined with advanced camera vision systems, conveyors gain more analytical intelligence to perform functions like fill-level verification, foreign object detection, and dimensional sorting.
- Precise Positioning
Precise positioning is another emerging capability for modern conveyor systems. Conveyors can place products into very exact locations using techniques like integrated machine vision combined with servo-controlled belt drives, pusher arms, and tilting divert mechanisms.
For instance, picking and placing robots to assemble electronics requires accurate millimeter placement of components for high-speed assembly. Computer vision systems precisely locate items on the belt and guide servo motors to positioning accuracies within fractions of a millimeter. In packaging, containers need to be precisely positioned for automatic lid or sleeve application using computer vision to guide position.
- Optimized Quality Control
Leveraging automated inspection data and simple measurement abilities provided by integrated computer vision systems, conveyor systems can help optimize quality control operations. Specifically, real-time insights into production parameters gathered from the vision systems can automatically identify and divert any out-of-specification items.
Computer vision on the conveyors can also provide early warnings when processes drift out of optimal tolerances detected through visual inspection. This enables proactive intervention and continuous improvement through data-driven decision-making based on visual results. Furthermore, inspection and measurement results from the conveyor vision systems can be used to manage in-line rework stations dynamically.
- Useful Real-Time Data
To fulfill their quality control and operational optimization promises, conveyor systems must be capable of capturing and transmitting useful real-time data. This begins with integrating identification, measurement, and computer vision technologies directly into the conveying equipment. Advanced camera systems provide a continuous stream of visual inspection data. Then, leveraging open connectivity standards like the Industrial Internet of Things (IIoT), this raw sensor and image data from the integrated vision systems can be aggregated and made accessible.
Whether communicating wirelessly to cloud-based analytics platforms or integrated MES/ERP systems, today’s smart conveyors equipped with computer vision generate terabytes of operational and visual inspection intelligence from monitoring production in real time.
- High-Quality Hardware
While software and IT solutions can enhance conveyor systems, it all starts with durable, high-performance hardware components. Reliable conveyor belts, rollers, drives, diverters, structural frames, and integrated computer vision systems enable the high-speed, high-precision movement and inspection required in most applications.
Critical aspects like precise synchronization between belt speed, diverters, and other mechanical actuators guided by visual feedback from the integrated cameras must be guaranteed through robust mechanical execution. Furthermore, environmental factors like dust, moisture, vibrations, and temperature fluctuations on the plant floor create demanding operating conditions for both the conveyor’s mechanical and electronic components, including the computer vision systems.
- Precise Positioning Capabilities
Montech’s flexible conveying systems are renowned for their extremely precise positioning controls. Using advanced servo motors and machine vision technology, Montech can place products on the conveyor belt with sub-millimeter accuracy. This high degree of precision allows customers to achieve very tight tolerances, such as those required for small electronics assembly.
Custom-Tailored Designs
In addition to precision, Montech is also known for its custom-tailored conveying solutions. Montech’s engineering team works directly with each customer to thoroughly understand the specific flow of materials, production rates, and constraints of their facility. This collaborative process allows Montech to develop highly customized conveying systems perfectly suited to integrate into any production environment or application seamlessly.
Whether a small turnkey system or complex multi-line conveyor is required, Montech has the flexibility and expertise to customize its platforms accordingly. This commitment to truly custom designs for each unique customer’s need is a core part of Montech’s success in the conveying industry.
