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

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

3. 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.” [
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 That averages out to almost one per year…

4. 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.

5. 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.

6. 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.

7. 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.

8. 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.

9. 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

10. 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

11. Machine Vision Background

12. 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

13. 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

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

15. Food Application Examples

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

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

18. 3D Inspection Laser Line Triangulation
3D Profile of Packages in a Case
Used to Verify Case Count

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

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

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

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

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

24. Thank You!
Clay Flannigan
(210)