Quality control and traceability are the basic requirements of tire manufacturers. Logistics, product, quality control and verification testing, as well as tires, need to be tracked at every step of the production process. Therefore, in order to achieve strict control of all production processes from receiving raw materials to final assembly and distribution, tire companies need reliable barcode reading solutions.
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Bottleneck of traditional tire reading scheme
But the bar code reading work in the tire industry is very difficult: it needs to read the bar code in all directions. Failure to apply the correct scanning technology can result in lost productivity, additional manual processing and additional compliance management costs.
At present, most tire companies use one-dimensional CODE128 code vulcanized label barcode. The biggest challenge of this tire reading application is that the barcode is attached to any radius inside the tire radius. The tire code is relatively small and narrow, generally below 10mm. The tire's all black surface will absorb light, and the quality of the tire barcode will be in the production process. Lower, and the contrast between the code and the background is usually very low, the bar code is easy to wear, and the code can only be read through a small gap under the wheel. Therefore, if tire companies do not use efficient scanning technology, it will increase labor, reduce work efficiency, and increase additional costs and costs such as information management.
Kunshan Runkun Automation Technology Co., Ltd. (hereinafter referred to as Runkun Automation Co., Ltd.) is a well-known enterprise specializing in the systematic integration of tire enterprises. It is committed to providing tire companies with better visual and reading solutions.
“In the past, we have been using the Datalogic reader, and a group of 5 readers read the bar code on the tire. When the barcode is below, the problem is not completely solved, resulting in a low reading rate, and 10 reading codes at the same time. The cost of the device is high.†The engineers at Runkun Automation said, “When we use the previous code readers, it is difficult to seamlessly connect them to the Siemens PLC operating the machine for the PROFINET bus.â€
However, PLC programming requires not only a lot of knowledge about the reader's proprietary interface, but also very time-consuming manual coding. Once the production process changes, you need to change the PLC code that communicates with the reader. Runkun Automation encountered considerable difficulties in programming the PLC to communicate with previous readers.
Under the harsh working conditions, DataMan reading performance is more than enough
At this time, a Cognex visual code reader in Suzhou suggested that Runkun Automation adopt the latest DataMan image expansion technology. This technology extends the field of view of a single reader by a factor of 1.5 and successfully solves the problem of large field of view reading. The DataMan reader has its own unique algorithm for decoding, making the reading speed and field of view very competitive. As a machine vision expert, Cognex has a unique advantage in image processing, and it has seen different effects in field applications.
The engineers of Runkun Automation pointed out that “we tried the DataMan 303X reader + Xpand15 on the roller production line of the tires out of the warehouse, and used four Master-slave networks to transmit data to the top and bottom of the roller line. The control room outside the meter has done a good job of code reading."
The engineers decided to increase the difficulty of the test. They placed the tire bar code in a very low contrast, very distorted, very fast condition, allowing the reader to try to read. To the surprise of the field engineer, the DataMan code reader successfully read the code under all kinds of bad conditions and it passed the test successfully.
DataMan makes PLC integration easy and convenient
At the same time, engineers are pleased that the DataMan reader can easily integrate with the PLC used to control the production line. The reader contains an Ethernet interface that can be connected to the plant network to enable it to communicate with all other devices on the plant network.
For the PROFINET Industrial Ethernet protocol supported by Siemens PLCs, the DataMan reader is also equipped with manuals, GSD files and sample code. DataMan readers and other Cognex vision systems and readers can be easily connected to PLCs and other common factory automation equipment using Ethernet/IP standards using GSD files.
The simple method greatly reduces the work of the engineer. In the first step, the GSD file is loaded into the Siemens programming software. GSD files are PROFINET configuration files that are used by the network configuration tool to help identify products and debug them on the network. The GSD file then assigns a label to the reader that contains the unique name and IP address of the reader. The final step is to define the input and output nodes. The engineer then writes the application based on the relevant code in the manual and defines the relevant logic algorithms.
The operating procedures of the reader and the roller line are also quite simple. When the tire is transported from one end to the exit section, DataMan transmits the signal to the PLC via the sensor sensing tire, which instructs the reader to acquire and read the image. The reader can successfully read the code almost every time the first attempt is made.
Cognex helps customers improve their market competitiveness
“XPAND image expansion technology and hotbars technology have enabled us to do a great job in the tire reading project, and we have performed very well. We are able to use cost-competitive to improve reading performance, reduce installation time, and reduce cost of ownership. Product strategy is excited.†Runkun Automation’s engineers said, “Currently, Cognex Extended Edition provides more powerful support for code reading applications, with more efficient image acquisition efficiency (.) Limiting the number of read failures, greatly increasing throughput and productivity, while reducing costly rework costs."
“Runkun Automation’s equipment has greatly improved reading performance with DataMan Vision Reader. Now with two DataMan 303 X + Xpand 15, our solution has fewer points of failure, lower overall cost, Easy to install and easy to troubleshoot, and many other advantages," Runchun Automation's engineers concluded, "the read rate is basically around 99%, and the use of HotBars technology, the distortion of the bar code, especially under the track, The device also shows good reading performance."
Field practice has proven that Cognex can achieve higher read performance with a smaller number of cameras!
Figure 2 Installation overall schematic
Figure 3 Scanning status of the bar code in the coincidence area
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