Keyence Vision System Integration: Conveyor Line Camera Upgrade for a Food Manufacturing Facility
Sector:
Food & Beverage
Type:
Obsolecence Upgrade, Software
Platform:
Allen Bradley, Keyence
Certification:
CE / UKCA
Summary
DelaControl designed, built, and commissioned a control system upgrade to integrate a Keyence machine vision camera system with an existing conveyor line at a UK food manufacturing facility. The solution replaced hardwired discrete I/O connections with an Allen-Bradley CompactLogix-based gateway, enabling the vision system to communicate over Ethernet I/P — and was fully tested at DelaControl's Bristol office prior to site installation.
Challenge
An existing Keyence camera vision system on a conveyor line relied on hardwired discrete signals passing directly between the conveyor control system and the camera controller. A new Keyence system was being introduced that only supports Profinet and Ethernet I/P communications protocols, meaning the existing hardwired I/O arrangement was no longer compatible.
A means of bridging the existing hardwired signals from the conveyor into the new network-based vision system was required, along with all associated control panel modifications, PLC software, and site installation works.
Solution
DelaControl designed and built an Allen-Bradley CompactLogix-based control solution to act as a gateway between the conveyor system's hardwired discrete I/O and the new Keyence vision system communicating over Ethernet I/P. The system was installed within the existing control panel enclosure, with a new 300 × 300 × 210 mm stainless steel enclosure provided to house the Keyence vision system equipment.
The hardware scope included an Allen-Bradley CompactLogix controller (1769-L18ER-BB1B), a combined digital input/relay output module (1769-IQ6XOW4), a 16-point relay output module (1769-OW16), and a Point I/O 24 VDC source output module (1734-OB8). Keyence equipment — including the smart camera, LED ring light, polarising filter, PoE switch, monitor, and associated cabling — was procured and supplied by DelaControl.
PLC software was developed by DelaControl to handle the translation of signals between the conveyor system and the Keyence vision system. Programming of the vision system itself was carried out by Keyence. A full drawing pack (schematics and general arrangements produced in EPlan and AutoCAD) was produced, together with a bill of materials and cable schedules.
Prior to site installation, the complete system was set up and factory acceptance tested at DelaControl's Bristol office with the customer invited to witness testing. Panel modifications were then carried out on site during a planned production shutdown.
Key Facts
• Allen-Bradley CompactLogix 1769-L18ER-BB1B controller with dual Ethernet ports
• 21 discrete I/O points (1 digital input, 20 digital outputs) interfaced between conveyor system and Keyence vision system
• Keyence smart camera (VSL320CX) with LED ring light, polarising filter, PoE switch, and monitor supplied by DelaControl
• New 300 × 300 × 210 mm stainless steel enclosure for vision system equipment
• Full factory acceptance test completed at DelaControl's Bristol office prior to site installation
• PLC software developed in TIA Portal V18; vision system programming by Keyence