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CHALLENGE

To prevent the injection of counterfeit products into the supply chain, the print shop manufacturer had a client request to serialize all the products that get placed onto consumer shelves, along with inner boxes, master cases, and pallets.


SOLUTION

A custom ASP.Net application was developed to augment the manual process of packing products into inner boxes, master cases, and stacking them on pallets. The system generated barcode labels and printed them to a Zebra printer. These labels would get affixed to the product and boxes. The product was scanned with a Cognex Dataman handheld ID Reader prior to being backed into a box. Once the box was filled, the barcode box was scanned, and all the relational data was stored in a database. Similarly, the filled inner boxes would be added to the master case, scanned, and stored relational data. Master boxes were then added to a pallet, and once the pallet was full, a pallet flag containing all the master cases, along with total product and inner box counts.


TAGS
ID Reading, Barcode Reader, Data Collection
CHALLENGE

QR code and human-readable text on the trading card would occasionally not match, either due to misconfiguration by the Operator or buggy remote software by the Vendor.


SOLUTION

The system was deployed with surplus stock in less than two weeks, using 4VT's standard framework and a VisionPro Quickbuild script. Cards were fed onto a vacuum belt, triggered by a photoeye, and if there was no match, the system would blow the product off at the air gap between the vacuum belt and the accumulator belts at a rate of 10 cards per second.


TAGS
ID Reading, OCR, Consumer Products, PC-based Vision
CHALLENGE

A scheduling system dictates the components to be assembled on a diesel engine head.  This information is written to an RFID tag that is attached to a carriage.  The client needed a way to validate the correct engine head was loaded onto the carriage and get its information (production date, parent, and serial number) married to the RFID tag. (7) different head types will need to be handled by this system.


SOLUTION

Multiple Cognex Dataman cameras are oriented in a work cell.  As the carriage enters the work cell and stops, an RFID reader gets the part type and passes that to the HMI software, which triggers 1 or 2 cameras.  The cameras extract the date, parent, and serial number for a 2D matrix dot pin barcode, and the HMI software writes the data to the RFID tag and an edge database.  If the parent number is not valid for the current part type, the error is flagged for an operator to review.  In the event of a poor barcode, the operator can enter the information manually.


TAGS
ID Reading, Automotive, Barcode Reader, Data Collection
CHALLENGE

2D barcode labels are automatically applied to the tub base of a washing machine.  Occasionally the label has poor print quality or is not applied correctly.


SOLUTION

Using Cognex Dataman Barcode reader a custom script was created to handshake between the barcode printing/label applicator.  After the label was applied the Dataman Reader verified that the label was readable and the data matched.


TAGS
ID Reading, Consumer Products, Barcode Reader
CHALLENGE

A large national conveyance company installed a conveyor and carton routing system.  The Cognex Datamans (image-based barcode reader) ran well, but once the refrigeration system went online, the label reading on the cartons became unreliable.


SOLUTION

Moisture and the cold environment caused the cartons' labels to wrinkle, and excessive packing tape by newly trained operators created hotspots on labels.  An off-the-shelf cross-polarizing lighting assembly was unavailable at that time, so an existing dual lighting unit was modified with polarizing film and a polarizing filter added to the camera's lens.  


TAGS
Identification, ID Reading, Pharmaceutical, Barcode Reader, Data Collection
CHALLENGE

Inkjet printer applies a lot and date code on round vitamin bottles.  Jams or other printing issues can make the lot or date code unreadable.


SOLUTION

Smart Camera was added to the system downstream from the Inkjet printer.  System was presented with multiple instances of character from 0 - 9 and trained.  PLC pushed the current Lot/Date code to the camera and the Smart Camera verified that it was a match.


TAGS
Identification, ID Reading, OCR, Consumer Products, Packaging, Smart Camera
CHALLENGE

2D barcode label was applied to the end of a syringe.  Labels that are wrong or placement is out of specifications need to be rejected.


SOLUTION

Cognex Smart camera was added to an existing label applicator machine.  The syringe was rotated and 4 images were acquired.  The 2D matrix on the barcode was verified against the SKU read in from the PLC.  The label position was gauged relative to the tip of the syringe and all 4 images were used to calculate the label skew.


TAGS
Gauging, ID Reading, Inspection, Medical Devices, Smart Camera
CHALLENGE

Product number, manufacturing date, and index are pressed into the surface of the railroad bearing.  Since the characters are on a dial, if an individual character doesn't properly roll to the next character a duplicate serial number can be generated of the character is not fully formed.


SOLUTION

The product was rolled until a laser sensor located the first character.  A Cognex InSight line scan camera imaged the full length of the string and a pattern match was performed on each character. 
Due to the variance in surface finish and impression depth (as the character die wore down), multiple images over the whole production were collected and a composite image for each character was generated.  The composite image of the character was used to generate the pattern classifier. 


TAGS
Identification, ID Reading, OCR, Industrial Products, Barcode Reader, Line Scan, Smart Camera
CHALLENGE

A large print shop was contracted for coupons.  The coupons are serialized and encoded with a 1D barcode to prevent fraud. 


SOLUTION

Cognex Dataman with an HMI was used to ensure readability.  The operator entered the start and end sequence of the serialization.  Dataman would send a reject/stop signal to the PLC if the barcode was not readable or out of sequence.


TAGS
ID Reading, Consumer Products, Barcode Reader
CHALLENGE

RSS stacked codes are printed on the side of a pharmaceutical package.  Readability is a must.


SOLUTION

.Cognex Dataman was used to read the RSS stacked code, and when the quality grade of the printed barcode fell below a threshold grade, an alarm was signaled.


TAGS
ID Reading, Pharmaceutical, Barcode Reader
CHALLENGE

Ice containers getting filled with the wrong product, if uncaught until later can create a costly recall.


SOLUTION

Prior to filling multiple Cognex barcode readers oriented around the ice container looked for a 2D barcode and verified that it matched the SKU provided by the PLC


TAGS
ID Reading, Consumer Products, Food and Beverage, Smart Camera
CHALLENGE

Ice containers getting filled with the wrong chocolate-covered ice cream nuggets, if uncaught until later, can create a costly recall.


SOLUTION

Two Cognex InSight cameras were set up on opposite sides of the oval container.  Pattern matching was done on the picture label to verify the match based on the SKU.  On the ingredient label, the UPC code was verified against the SKU.


TAGS
ID Reading, Pattern Matching, Consumer Products, Food and Beverage, Smart Camera