Counting Many Different Hardware Parts

[jmpugh]

We have around 100 bins that each contains different pieces of hardware...screws, hitch pins, springs, washers, ect. We assemble this hardware into custom kits for customers. The parts included and quantities all vary from kit to kit.

Alot of these parts are small enough that counting them by hand is a royal pain in the butt and it takes hours. We are looking into using a vision system to count these parts. We make enough off these kits to justify the cost. Is this something that can be done with NI Vision? I am familiar with LabVIEW but don't have much experience with NI Vision.

It also would be ideal if after counting, a machine could bag the parts. I was just curious if anybody has any experience/ideas with such a system?

I'm thinking we must use a vision system just due to the fact that doing it by weight is just not accurate enough and there are too many bins to setup a vibratory

bowl feeder for each one.

Thanks for any help folks!

-- Jason (layoffs are looming and this system could be my meal ticket)

[yaHeard]

Hi Jason,

It sounds like your application is a great candidate for a vision inspection system.  The first thing I would suggest is the NI Vision Builder for Automated Inspection (VBAI), which has built in functions to locate, identify, and count objects without programming.  VBAI also includes many examples that will do pass/fail inspections and counting of parts like what you are needing.  You can read more about VBAI here.  One of the parameters you will also need to keep in mind is lighting.  If all the different parts can be distinguished by shape, then one of the more accurate ways to setup the system would be to use some type of back lighting on the parts.  This will help with the edge detection.

If you would like to have an embedded system, you also have the option of going with either one of the Compact Vision Systems or the new Smart Cameras, which are industrial, high-quality image sensors combined with a processing core to run Vision Builder AI right on the camera.

[jmpugh]

Thanks for your help Carlton! I'll definately look into this as part of a solution.

While there are several parts that vary drastically in shape, there are several that don't. We are looking for any way we can speed up this sorting / bagging process so maybe if we can use a vision system to count around 60% of the parts, that will speed us up considerably.

Happy New Year and thanks again for the help!

-- Jason