Terry Dodson, the Director of Engineering at New Frontier Technologies, discusses the cutting edge of technology for industrial automation and controls with Lonnie Worthington, the Motion Control & Vision Group Manager. This project uses a Gocator imaging sensor and Machine Vision to detect small flaws and potential breaks in a manufacturing facility’s interlock conveyor belts. This line profiler provides a 3D image map of the belt as it moves and tracks missing pieces. It includes an indexing feature for end-of-shift verification by the operator.
Because there is no automated and integrated technology deployed to perform belt defect detection during production cycles, there is high risk of an undetected belt break which could lead to broken belt pieces becoming part of the product stream.
Client Challenges
NFT’s client performs preventative maintenance inspections on their Solid and Open-Web (mesh) conveyor belts on a regularly scheduled basis. However, the results of the inspection program are inconsistent, as the inspections are performed visually by employees who have multiple job responsibilities. NFT’s client wanted to ensure that advanced technology was integrated not only into the preventative maintenance process, but deployed in real-time defect detection and annunciation to increase production efficiency, minimize the potential for product contamination from damaged belt material, and reduce conveyor shutdown expense.
NFT Technology Solution
Working in tandem with their client, NFT considered multiple moving conveyor belt “detection” and “inspection” technology solutions. The NFT hole and belt break technology detects defects for two types of belts – Solid and Open-Web.
NFT’s hole and belt break detection solution utilizes 3D laser scanner technology that scans a moving conveyor belt from above. For Open-Web belts, the solution alarms when the scan determines that one or more links in the web mesh are broken. It does this by looking at the area of the gaps between links, and alarming when any gap is larger than expected. For Solid belts, the tool is configured to detect when the laser signal does not reflect back from the belt surface due to a hole in the belt.
As part of the solution, there is a “start of belt” indicator on the belt, so that the software can distinguish between new defects and those previously detected.
Data regarding each defect results in X and Y belt coordinates that are communicated to the supervisory PLC. For each belt defect, the location and size (area) are recorded and tracked, so that only new or altered defects
will signal for an automatic belt stop or operator intervention.
As part of the belt cleaning/belt inspection process, the system can be commanded to index to each known defect and stop, allowing an operator to visually inspect all defects and make a determination about overall belt health.
Client Outcomes
After detailed research, specifications development and performance testing, NFT and their client determined that implementing the 3D scanning, measurement, and control technology would not only combine the benefits of an advanced automation and integration system for belt defect detection, but would also leverage the experiential value of human supervisory inspection and decision-making.
The Result
The result is significant reduction of risk and cost associated with potential product contamination, unexpected belt shut downs and supply chain disruption. Additionally, by integrating a flexible technology solution in the production workflow, NFT’s client can easily adapt to evolving safety, sanitation and compliance requirements.
Key Performance Data Conclusions
- Minimizes need and variability of supervisory oversight
- Allows for Preemptive Control, Command and Reduction of costly production line shutdowns
- Reduces expense associated with product rejections and spoilage
- Provides protection of company brand reputation and mitigation of legal and recall potential
New Frontier Technologies is an end-to-end industrial systems integrator, offering turnkey operational & technology solutions to the Food & Beverage industry. If you'd like more information about how NFT can develop solutions for your food or beverage plant that uncover and integrate real-time operational data with business information, helping you improve profits, please get in touch with us!