Automated Inspection Using Machine Vision Southwest Research Institute Manufacturing Systems Department Presented by Clay Flannigan November 3, 2009 Automated Inspection Using Machine Vision

Overview Background on Southwest Research Institute Brief Review of Machine Vision Applications for Automated Inspection

Facts About Southwest Research Institute® Founded in 1947 501 (c)(3) nonprofit corporation Over 3,300 employees Over 1,200-acre facility in San Antonio, TX 2.1 million sq-ft of laboratories & offices Over 900 patents 33 R&D 100 awards Facts about Southwest Research Institute. Established in 1947 501 (c)(3), per the IRS: “To be tax-exempt as an organization described in IRC Section 501(c)(3) of the Code, an organization must be organized and operated exclusively for one or more of the purposes set forth in IRC Section 501(c)(3) and none of the earnings of the organization may inure to any private shareholder or individual. In addition, it may not attempt to influence legislation as a substantial part of its activities and it may not participate at all in campaign activity for or against political candidates.” [http://www.irs.gov/charities/charitable/article/0,,id=96099,00.html] Of the >3,300 employees, approximately 2,750 work at the SwRI facility in San Antonio The 1200 acres is almost a ‘city-within a city’. SwRI has control of all internal utilities and land, making it possible for SwRI to rapidly respond to a client requirement that involves facility or infrastructure modification Capital-intensive operation. Most clients simply cannot afford to invest in R&D facilities the way SwRI has, because R&D facilities rarely show the kind of return on investment that most stockholders demand. SwRI’s facilitiies are made 100% available to our clients, without restrictions typically associated with manufacturing demands Patents: As part of a long-held tradition, patent rights arising from sponsored research at the Institute are often assigned to the client. SwRI generally retains the rights to Institute-funded advancements. 33 R&D 100 awards, with the first R&D 100 award issued in 1971. That averages out to almost one per year…

SwRI® in the Early 1950s Early SwRI on the grounds of Essar Ranch, photo reportedly taken in 1950, but the presence of some of the buildings suggest the photo was really in the early 50’s.

SwRI® Today Shot in 2007, this overview of the SwRI facilities occupies more than 1,200 acres in NW San Antonio. More than 3,300 employees work in more than 2.1 million square feet of laboratories, offices and workshops. Research volume reached $563 million in 2008. At the close of FY08 research areas were spread across xx Departments in 11 technical divisions, and covered the complete spectrum of engineering and physical sciences.

Operational Characteristics Revenue from Contracts Applied RDT&E Services Physical Sciences & Engineering Broad Technological Base Capital Intensive Operation Internal Research Program Over 4,500 Projects per Year Operational characteristics. SwRI sustains its business SOLELY on the basis of contract revenue. While the majority of SwRI’s work is in Applied RDT&E, SwRI also conducts Basic Research as well as Limited Production in specific areas Our focus is Physical Science and Engineering, distinguishing us from our sister organization – the Southwest Foundation for Biomedical Research Our broad technology and customer base prevents unbalanced reliance on a single program area. SwRI is able to adapt and respond to the ebb and flow of government funding cycles and industrial investment in R&D. SwRI invests in its facilities and equipment so that its customers do not have to. SwRI’s IR&D program is instrumental in positioning SwRI ahead of its customer’s needs; enabling more rapid transfer of technology and more dynamic response to external market forces.

SwRI Divisions Aerospace Electronics and Information Technology Applied Physics Applied Power Automation and Data Systems Chemistry and Chemical Engineering Engine, Emissions and Vehicle Research Fuels and Lubricants Research Geosciences and Engineering Mechanical and Materials Engineering Signal Exploitation and Geolocation Space Science and Engineering Training, Simulation and Performance Improvement List of eleven divisions and an internal research and development program.

Food Technologies Analytical Chemistry Formulation and Product Development Micro-Encapsulation Materials Environmental and Mechanical Testing Manufacturing Systems List of eleven divisions and an internal research and development program.

Manufacturing Systems Staff Multidisciplinary: electrical, mechanical, industrial engineers Process Improvement Engineering Manufacturing Process Design Lean Manufacturing Quality Management Facility Planning Training & Consulting Services Automation Engineering Robotics Machine Vision and Sensing Technologies Custom Automation Development Modeling and Simulation System Integration

Food Engineering Experience 200+ Food Industry Projects Over Past 10 Years Currently Providing Services for Several International Processors in Snack Foods, Gum, Ice Cream, Cereal Analytical Chemistry (Chemical Composition) Micro-Encapsulation (Formulation) Line Efficiency/Capacity Improvements Product Quality Improvements New Line Simulations for Production Capacity Verification Packaging Development Automated Gauging System for Cutting Application

Machine Vision Background

What is Machine Vision? Technologies that Allow Computers to “See” Sense Environment Analyze Make Decisions or Measurements Components Camera Optics Lighting Processing Software Output Device

What is Machine Vision Good For? Automated Inspection Dimensional Measurement Counting Quality Control of Raw Materials Verification of Final Products Process Control Automation Guidance Security & Surveillance

Machine Vision Experience SwRI actively involved in Machine Vision since 1980 Research & Development Prototypes & Testing Complete Systems 1980 - Navy and Air Force robotics projects with vision 1985 - Industrial inspection and control using machine vision 1990 - Precision measurements, vision guided robotics 1994 - Intelligent Transportation System applications 1997 - Thermal infrared applications 1999 - Motion detection / automated surveillance 2001 - 3D imaging 2002 - Adaptive models

Food Application Examples

Contaminant Inspection Package Seal Inspection Specialized Lighting (Back Lighting) Highlights Contamination Seal Contamination

Defect Inspection Glass Bottle Inspection Illumination Used to Highlight Bottle Defects Line Scan Camera Rotated Bottle High Speed

3D Inspection Laser Line Triangulation 3D Profile of Packages in a Case Used to Verify Case Count

Robot Guidance Camera Locates and Identifies Liquor Bottles Color and Pattern Detection Robot Replaces Missing Bottles

Process Control Micro-Encapsulation Vision Used to Monitor Droplet Formation Feedback Controls System Parameter (Pressure, Flow)

X-Ray Inspection Potato Contaminant Inspection Dense Particle (Rock) Detection Rot (Low Density) Detection Hollow Heart (Void) Detection

Thermal Imaging Measure Temperature Differentials Evaporative Cooling Highlights Water Droplet (Simulated Puncture) Water Droplet

Typical Project Steps Proof of Concept Testing (Laboratory) Initial Phase Requirements Definition Prototype System Hardware Software Interfaces Production System Build, Install, Commissioning Training, Documentation

Thank You! Clay Flannigan Clay.Flannigan@swri.org (210) 522-6805