Machine vision based web inspection and web break system
Ground-breaking technology improves web runnability and production quality in the sheet-manufacturing industry
The Industrial Internet is enabling giant leaps in production processes resulting in higher quality and advanced productivity. In the sheet-manufacturing industry, an innovative vision-based web inspection and web break system has brought significant improvements to producing fault-free quality. Ixonos helped Viconsys kick-start the development of their ground-breaking system.
Viconsys was based on the vision of an innovative system for the sheet manufacturing industry. The experienced professionals who set up the company wanted to develop a fully digital, highly computerized, distributed and scalable system that would integrate web inspection and web break analysis into one system. They had a solid understanding of the needs for and requirements of such a system, but low capacity to implement it on their own. Viconsys needed a partner that could provide a jump in development capacity without extra administrative overhead. Ixonos became a major contributor by providing a skilled and experienced development team and thus enabling the rapid development of the system’s software using advanced techniques.
With the help of Ixonos’ SW professionals we were able to rapidly increase experienced R&D capacity with small overhead costs. This significantly lowered both the financial and especially the schedule risk of our company in the “death valley” phase of the start-up.”
Ixonos provided Viconsys with a team of experienced enthusiastic developers to help create the SW for both the backend and the UI of their vision-based web inspection system. In addition to process data, the backend needed to be able to store and manage extremely high-quality digital video streams from over a hundred customized smart cameras, with very high total data input speeds. The content of each stream needed to be synchronized at a single image frame precision, in terms of both time and position of the web moving through the production machine. Ixonos’ team constructed the backend to be scalable with distributed .NET techniques, innovative techniques for storing large amounts of time-stamped video data and in conjunction with SQL database for storing the related analysis and inspection results as well as metadata.
The system’s browser application user interface was designed to be very easy to use, yet with powerful analysis possibilities. It was required to give a good overview of the status of the production machine and the quality of the produced product. It also needed to automatically adapt to showing break recordings even while the break was still proceeding through the production machine. Ixonos’ team helped develop the UI utilizing HTML5-application like techniques, with the web-browser view spanning over multiple high-resolution monitors and with dedicated gigabit-speed connections to the computers where the video-material and related information was being stored.
Viconsys’ ground-breaking system integrates web inspection and web break analysis systems, simultaneously showing real-time process status as well as allowing a synchronized view of how a fault found in inspection flowed through the production machine. By combining two separate systems into one, it brings clarity and space to the monitoring room. The system’s distributed and scalable architectures allow it to be used both in small and big systems, and enables expanding an already installed system step by step. The browser application UI is highly responsive and provides intuitively easy and clear user experience. It allows the user to view one to four synchronized video recordings and to instantaneously scroll the video streams backwards and forwards, at any speed controlled with the cursor movement.
Viconsys is an industry benchmark in the machine vision technology. Metso purchased Viconsys’ business in April 2010 and affiliated it to the Energy and Environmental Technology Segment to complement their product and service offering to the paper and other process industry.