Case Study: Automating Visual Inspection for Medical Device R&D with Keyence XG-X

Project Scope: Enhancing R&D Quality Control & Data Collection Through Automation

A pharmaceutical company developing a medical device sought to automate its visual inspection process in order to improve quality and process control as well as to enable digital data acquisition. 

As the client moved beyond the research and development phase, concerns arose regarding data acquisition and quality control during the visual inspection of their medical device. Until this point, inspections were done with the naked eye, leading to subjective results. While a machine vision system was the clear solution to enhance precision and reliability, the challenge lay in integrating it with their existing Beckhoff control system. Given its R&D purpose,  the new system needed to be adaptable, allowing for quick modifications with minimal downtime.

Solution Design: A Unique Keyence XG-X Application

After thoroughly assessing the client's requirements, Industrial Robot Help leveraged our expertise in machine vision and Keyence technology to develop a proof of concept using the Keyence XG-X, showcasing its accuracy and flexibility. One of the goals for the vision program was to calculate and display a percentage change from start to finish during the device production. The XG-X has an area tool which converts the captured image into binary data (black-and-white pixels) and measures (counts the number of pixels) of either the white or black area. By comparing the change in pixel count we were then able to calculate and display a percentage change as the device was being produced. 

This application of the Keyence XG-X is highly unusual and required some out of the box thinking on our part. In a typical installation, the XG-X would take a single image of a widget or part while the part was passing by on a conveyor belt, giving a pass/fail result based on defined parameters. The XG-X would be triggered, run through a program one time, then the next item on the belt would arrive and the process would repeat. Here we were using the XG to scan one item that changes over time. This required the program to loop through a set of instructions until a condition was met. Luckily, here at IRH we have many years of combined programming experience, and we are no strangers to using loops. 

Programming the vision system to calculate a percentage was only half of the battle. We then needed to achieve the issuing of commands to the XG-X from the client’s Beckhoff controller at different stages of device production. Thankfully, communication using EtherCAT is supported by the XG-X. Working closely with the client’s in-house team, we were able to seamlessly incorporate the two systems, first by establishing communication, and finally issuing commands from the Beckhoff to the XG-X.

Results: Improved Inspections and Better Data

IRH successfully delivered a fully functional, customized vision system that met all of the client’s specifications, integrated seamlessly with their Beckhoff PLC control system, with a turnaround time of roughly 3 months. This solution provided a more objective and accurate visual inspection while providing the client with valuable data to assist them with future business decisions.