Best Scientific have recently installed a new vision system solution configured to expedite a quality control inspection process. We visited our client Pall Corporation, after they expressed concerns their current system may be inefficient, dated, and missing out on new innovations available.

Consultation:

Our first step in making the system more efficient was to fully understand this QC process, so we can start to build the functionality required into the system. The fundamentals of this process were:

• Inspection of Filters for quality control.
• Manual Inspection of 40-60 units a day.
• Required magnifications of 5x and 10x.
• Particle counting.
• Measurement of fibers.

Our next step was to evaluate the current equipment used to complete this task and identify where improvements could be made.

• Based around old Olympus BH compound trinocular microscope.
• Eyepieces and analogue camera used to visualize sample.
• 5x and 10x biological objective lenses.
• Swan neck oblique illumination of sample.
• Microscope XY stage used for orientation.
• Measurements obtained using eyepiece graticule.
• Physical reference grid for particle counting.

Our last step was to learn more from users, about their experience working with the current system. Most importantly collecting feedback on the pros and cons they encounter with the equipment and QC process every day.

• Microscope eyepieces are uncomfortable to use for long periods (40-60 inspections a day)
• Analogue camera is low resolution, difficult to see particles of interest on the monitor.
• Graticule measurement is subject to interpretations by different users, so measurements can be Inconsistent.
• Calibration (focus positions) could be altered from user to user, again causing inconsistencies.
• XY stage well received for aiding particle counting as can quickly move through the field of view, but the control know is uncomfortable for users as positioned too high.
• Users liked the swan neck light guides as were non-invasive and easily adjusted.

Design Brief:

With these consultations accumulated, it was possible to combine them into a detailed design brief that would be used to configure the new system against.

1. Replace now old microscope-based solution with a camera only vision system.
   • To solve problem of uncomfortable eyepieces by not including them.
   • Stops Users varying focus positions via eyepieces, to keep system calibrated.

2. Maintain inclusion of manual XY stage under optical vision system, for orientation.
   • Solution To include ergonomic low drive control for user comfort.

3. Provide Metrology incident light lenses for inspection of materials.
   • Previous solution used life science lenses not appropriate for materials applications.
   • MET lenses will be long working distance, higher resolution, and application suitable.

4. Build in digital camera with software control.
   • Solve problem of poor resolution on current solution.
   • Software to be pre-calibrated for accurate click and drag, repeatable measurements.
   • Software to provide particle counting aids to the users, click to count with exportable totals.
   • Include Image capture, so users can create inspection reports.

5. Include upgraded illumination system with rigid light guides.
   • Convert to modern LED for improved efficiency and colour temperature.

6. Hardware properties required.
   • Small footprint machine (not much space in Lab)
   • Only two lenses / magnifications needed, 5x and 10x (Specific to their process)
   • Mid-range cost and efficient to run (Budget tight for this upgrade)
   • Easy to use intuitive operation (As will be used by many staff members)

Solution

With the design brief set I was able to select products from the Best Scientific portfolio to create a custom-made optical inspection system, tailored to the client’s process.  Equipment list and rationale for doing so is explained below.

Promicra 2/3” digital camera and software suite

I wanted a digital camera with largest possible sensor to increase FOV on the system. This is because the 5x and 10x Magnifications were not able to be changed as are inherent to the QC process. 2/3” was the maximum sensor size supported by below Opto GmbH vision system, so that was chosen.

The Promicra camera was also good resolution at 5mp showing users more detail of what they needed to see. I packaged the camera with Promicra software and relevant modules that aid with Manual counting and live measurements. There is a simple mouse click counting element to the software, so the user can clicks on objects of interest and the software will count them, and provide totals for report export. The software also has an intuitive measurement facility for click and drag line measurements. I calibrated the system with a stage micrometer on installation on the client’s computer.

Opto GmbH fixed magnification optical vision system

This modular optical system allows for various configuration of properties and functions. In this instance I added a nose-piece to the bottom of the system so that the user could quickly change between 5x for counting to 10x for measuring. The TV tube between the nose-piece and camera provided a perfect anchor point to mount the system to as well as deliver the image to the camera.

Nikon Metrology LWD objective lenses 5x and 10x

I combined Nikon lenses with this system for many reasons. Firstly, they have an RMS thread which is an interface the Opto nose-piece supports. Secondly, they conform with the relevant tube length of the optical system to give the requested 10x and 5x at the camera. Thirdly because these lenses are LWD and configured for MET applications, therefore fit for purpose. Lastly because Nikon MET lenses are some of the best available.

Starlight LED light source with rigid goose neck fibre light guides

This LED module gives a powerful, reliable, and economical LED illumination solution. The robust heavy housing will allow the LED source to remain in place while the user adjusts the rigid goose-neck light guides. Simply to use and importantly robust as a moving part.

Euromex manual XY stage with low drive controller & hardware (base, pillar, focus head)

It was important to maintain the movement of the sample for the client’s process, so I selected this simple manual XY stage and custom mounted it to the base. The control knob is so positioned to allow the user to rest comfortably and can be rotated for left or right handed operators. The hardware also included course and fine focus for easy adjustment.  Overall, the package fits neatly together to keep the footprint small.

Summary:

I felt that the three-part consultation process was key to the success of this configuration. Taking time to understand the QC process gave us a clear instruction of what the system needed to achieve. Studying the current system gave inspiration on where specific equipment could be upgraded. Talking to the users focused attention to areas where improvements needed to be introduced. Combining all this information gave info to work with, and enabled the final solution shown.

I also completed delivery, instillation, calibration, and a short session of instruction for the users. Making sure they could adapt to the changes and benefits of the new system  If you have specific micro inspection needs or want solutions to streamline inspection process, please do consult with us for a tailored proposal. Email james@bestscientific.co.uk