Cosmetic packaging production line using LabVIEW software integrating vision and robotics

The Solution:
Using the DENSO ImagingLab robotics library, two DENSO SCARA HSS-45552 model robots were integrated with a vision system developed using two National Instruments PCI-8254R image acquisition cards. The entire robotic cell was programmed using LabVIEW software and the National Instruments Vision Development Module.

For Vetraco's line of powder cases, we had to position the face brushes precisely.

ImagingLab is a high-tech company that helps system integrators, equipment manufacturers and users adopt innovative machine vision and robotics technologies with minimal investment and reduced learning curve. Our solid academic background, extensive system integration experience, knowledge of NI imaging tools and software, and continuous updates on the rapidly evolving machine vision technologies are attributed to our more than 20 years of experience in the global artificial vision market.

Vetraco, a recognized leader in complete assembly and packaging lines for cosmetics, selected ImagingLab as their preferred technology partner for machine vision and robotics due to our long-standing partnership.

For Vetraco's cosmetics compact production line, we had to accurately position facial brushes in delicate fixtures (80 mm x 20 mm) that would later be placed in the compacts. We placed the brush boxes in an 8-slot shuttle at a production rate of 80 pieces per minute. In addition, since different batches may have different brush shapes and box types, the system had to be flexible and easy to use for the line operators.

Developing an easy-to-use packaging system

To achieve a rate of 80 pieces per minute, we installed two “twin” robotic stations. The brushes are loaded onto a programmable feeder (FlexFactory Inc. model SX-240 Anyfeeder feeder), which vibrates the brushes to separate them for the robot to pick up. The Anyfeeder feeder interacts with the robotic station via a LabVIEW library.

A system based on a PCI-8254R image acquisition card, an AVT 1400×1000 pixel CDD camera, and custom infrared lighting from ImagingLab captures images of the brushes, determines their position, and transmits coordinates of where parts can be picked up to the robot. If there are no parts to pick up, the system vibrates the Anyfeeder to place more brushes under the camera. The system has four possible vibration modes—forward vibration, backward vibration, uniform vibration, and load more parts—to initiate actions based on information from the vision system.

We place eight trays of brush boxes in fixed positions in front of the robot. The position of the brushes on the feeder is random, and the vision system has to find the position and orientation of each part, because each brush must be placed in its box in the correct orientation. In addition, the robot has multiple grippers to deal with four brushes, so the vision system must identify and find the position of four brushes during each picking cycle. When a tray is full, a new tray will arrive. The robot cell operates 24 hours a day, seven days a week, rejecting any defective parts.

The vision system is used to guide the robot and provide quality control of the parts by measuring dimensions and verifying integrity. Using the DENSO ImagingLab Robotics Library, we have achieved a rigorous integration of vision and robotics. As a result, users can calibrate the image and robot with just one operation.

Programming, prototyping, and testing industrial robots

LabVIEW Applications

Using the LabVIEW software platform, we were able to quickly and successfully program, prototype, and test new robotic applications. Another major advantage of using the LabVIEW software platform is the ability to design and customize graphical user interfaces.

Because the same LabVIEW program will run on everything from PCs to NI smart cameras, we have a lot of flexibility in choosing NI hardware for our system. In addition, NI standards allow for rapid integration of products, reducing project development time and cost.