Blen-Cal Electronics Industries, Inc, headquartered in West Deer Park, NY, develops and manufactures inspection devices for the packaging and pharmaceutical industries. The company''s system assures that the product being inspected is in accordance with the users'' criteria. These have included glue line inspection, label placement, label alignment, barcode inspection, and label glue inspection, among others.
In business since 1961, the firm supplies unique solutions for its clients'' quality control concerns. Although small by global standards, Blen-Cal is well regarded in the pharmaceutical industry, which has strict standards for quality control mandated by the federal government, including a requirement that manufacturers institute complete review of all products prepared for shipment.
Application
This application requires a system that can scan a symbol on the product package to determine its legibility and integrity. In conformance to the new FDA labeling mandates, the system must verify all types of 1d and 2d codes, including the RSS and composite symbologies. It must be able to read up to a maximum of three different codes per package, maintain an inventory of "good," "bad," and "no reads," and have the ability to mark or eject the offending package and stop the production line on wrong read conditions or when consecutive rejects occur.
The system also requires a Teach mode and a Test mode. The Teach mode inputs the correct information into the system by exposing the correct package to the scanner and recording the needed information. The Test mode checks that the system is operating to specification. A Bypass mode is also provided for the user, and a system is provided to enter the required codes manually through the touchpad on a touchscreen HMI. The codes may be archived as Recipes for frequently produced product.
As these devices are installed on existing production lines, it is imperative that the equipment can be mounted and made operational with minimum interference to production schedules.
Solution
The scanner used in the system is a commercially available high performance reader that determines the quality and integrity of the package presented. G.C.F., Inc designed and provided the hardware and software program required for the system, which uses Schneider Electric''s Compact Twido® Programmable Logic Controller and 10.4 in. color Magelis® touchscreen HMI.
Each scanner is assigned its own Twido PLC to allow for the flexibility needed for the application. The second communication port option is used to communicate with a single Magelis HMI using Modbus® RS485. This helps minimize cost when using multiple scanners. The Twido PLC''s I/O features are utilized to control machine functions and to provide a "handshake" between cameras when multiple scanners are used. An output relay contact on the "master" Twido is used to interface with the user''s production line control as required.
A password regimen is provided so that only authorized personnel can manipulate sensitive areas, such as Teach, Test, or Bypass mode. An array of sensors provides a means of sensing that a package is present, a trigger to start scanner operation and a means to insure that the scan has taken place. The logic for this operation resides within the PLCs.
Benefits
- Sensor monitors
- Fail-safe operation
- Large color MMI
- KISS features
Three systems of the single scanner variety have been installed at an end user''s site. These have been validated for use and are CFR11 compliant. Blen-Cal principals feel that this system has the potential to be their largest selling product.