Automatic control of alpha-numeric pipe marking

Mallenom Systems has successfully completed implementation of VISCONT.Pipes system for automatic recognition of numerical pipe markings on the production line at the pipe plant in Russia. The company implemented the project as a turnkey contractor. The purpose of the implementation was to improve the accuracy and speed of product recognition during pipe manufacturing and packaging processes, which resulted in significant improvements in production performance.

The system covers 14 control points in different areas of the shop with different pipe movement conditions - from progressive rotation to movement on driven rolls. The system demonstrates accuracy of operation and reliability of integration with external devices and the external production management system.

It reads the unique pipe markings that ensure single-valued identification of each pipe. Pipes are marked in several ways:

• Manualy - the operator applies marking with white paint using stamps.
• Automaticaly – marking is applied by a special marker.

Regardless of the marking method, the VISCONT.Pipes system performs key functions:

• Detection of pipes in the control area
• Providing a video image of the pipe number
• Maintaining a database of detected numbers
• Image storage with the possibility to view and edit the recognition results.
• Integration with external devices (sensors, stack lights) via dry junction (input/output)
• Automatic transfer of recognition results to the enterprise data infrastructure management system.
• Access settings with administrator and user rights differentiation.

The automatic marking recognition system includes the following components:

• A machine vision camera to capture the images of marked pipes.
• A specialized illuminator to provide quality lighting in the inspection area.
• Switching and power supply cabinet, that ensures stable operation of the system.
• Stack lights signaling the reading results (success or error).
• Image processing server which includes the operator's workstation.

The system supports several modes of operation, which are customized in VISCONT software for each control point:

1. Automatic - Fully automatic recognition and data transfer to PIMS without operator intervention, regardless of the results obtained.
2. Semi-Automatic - In case of uncertain recognition, the operator corrects or confirms the number; the data is then sent to an external system.
3. Manual - The operator confirms or corrects each number manually.

Operation principles for a single control point: The system operates 24 hours a day, with possible maintenance breaks. When a pipe moves through the control point, a pipe sensor is triggered, which sends a signal to the system. The camera then takes a series of images, which are analyzed by the VISCONT software for markings. The results of pipe markings recognition are automatically transferred to the external system, and only then the next pipe is processed.

This project was an important technological challenge for us, requiring high coordination with the customer's production departments. Implementation of the VISCONT.Pipes system ensured prompt recognition of pipes with incorrect or unprinted markings. Owing to its integration into key areas of the manufacturing process, the company is able to fully control and trace products at all stages of production.

Mallenom Systems provides advanced machine vision and industrial control solutions to enterprises. The VISCONT.Pipes system has become an integral part of modernizing production processes, significantly increasing their efficiency, improving quality control and reducing the probability of spoilages. The technological solutions offered by our company allow enterprises to maintain high standards at every stage of production and remain competitive in the market.