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Frame-by-Frame Analysis and Diagnosis of a High-speed Packaging System Using Fastec InLine Network-ready Camera Vision Equipment

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2012 ASEE Annual Conference & Exposition


San Antonio, Texas

Publication Date

June 10, 2012

Start Date

June 10, 2012

End Date

June 13, 2012



Conference Session

Instrumentation in Education

Tagged Division


Page Count


Page Numbers

25.649.1 - 25.649.13



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Paper Authors


Akram Hossain Purdue University, Calumet (Tech)

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Akram Hossain is a professor in the Department of Engineering Technology and Director of the Center for Packaging Machinery Industry at Purdue University Calumet, Hammond, Ind. He worked eight years in industry at various capacities. He is working with Purdue University Calumet for the past 24 years. He consults for industry on process control, packaging machinery system control, and related disciplines. He is a Senior Member of IEEE. He served in IEEE/Industry Application Society for 15 years at various capacities. He served as chair of manufacturing Systems Development Applications Department of IEEE/IAS. He authored more than 25 refereed journal and conference publications. In 2009, he as PI received NSF-CCLI grant entitled A Mechatronics Curriculum and Packaging Automation Laboratory Facility. In 2010, he as Co-PI received NSF-ATE grant entitled Meeting Workforce Needs for Mechatronics Technicians. From 2003 through 2006, he was involved with Argonne National Laboratory, Argonne, Ill., in developing direct computer control for hydrogen powered automotives. He is also involved in several direct computer control and wireless process control related research projects. His interests are in the area of industrial transducer, industrial process control, modeling and simulation of mechatronics devices and systems, wireless controls, statistical process control, computer-aided design and fabrication of printed circuit board, programmable logic controllers, programmable logic devices, and renewable energy-related projects.

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Mohammad A. Zahraee Purdue University, Calumet

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Mohammad A. Zahraee, Ph.D., P.E., is the professor of mechanical engineering technology and Assistant Dean for Graduate Studies at Purdue University, Calumet. Zahraee has authored and co-authored a large number of papers and conference proceedings in the areas of mechanical engineering technology education and assessment, as well as technical papers in the areas of structural and mechanical vibrations. He is a past recipient of ASME Ben C. Spark Medal, SME Outstanding Faculty Advisor Award, and Merl K. Miller Award for best paper in computers in Engineering Journal. A TAC of ABET national Chair in 2009, he served ABET as a volunteer in capacities of Program Evaluator, Commissioner, Chair Elect, and National Chair for more than 18 years.

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Hamza Kadir Purdue University Calumet (College of Technology)

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Hamza Kadir is currently a graduate student in mechatronics engineering technology at Purdue University. He has previously worked in the fields of application of a new SS7-Sigtran protocol interchanger for communication between Remote Terminal Units and a Supervisory Control and Data Acquisition system, and smart grid solutions in a third world country such as Bangladesh. He has also worked in the field of evolution of mobile backhaul in 3G. He has worked for Ericsson and Areva T&D in Project Management and Network Deployment, and for Grameenphone (a Telenor company) in design engineering. He has received his B.Sc. in electrical and electronic engineering from Islamic University of Technology, Bangladesh. His research interests lie in the application of automation and robotics in the packaging industries. Email:

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Frame by Frame Analysis and Diagnosis of a High Speed Packaging System Using Fastec InLine Network-Ready Camera Vision EquipmentAbstractHigh speed imaging is a technique used for specific motion analysis applications. This mayinclude applications in fast operating industry machinery, crash impact testing for automobilesand so on. It is when photography is conducted in a very high rate ranging from 250 frames persecond and higher. This may range up to as high as several thousand frames per seconddepending on the application and budget. For example, if a motion sequence at 600 frames persecond is captured and played back at 40 frames per second, a smooth continuous motion of thatevent can be viewed. It can be studied for improvement, tuning or solving a malfunction whichcannot be done with the naked human eye or standard video framing (approximately 25-30 fps).The mechanism uses a charge-coupled device (CCD) or a CMOS active pixel sensor forrecording the high speed imagery into DRAMs.High speed camera vision system is a vital tool in the modern industry. The industries now-a-days are known for their high speed manufacturing processes. A delayed downtime may cost acompany millions. Similarly an inaccurate operation of certain machinery parts of a packagingmachine may cost highly. Therefore, the quickest possible method to resolve a fault or eventuning is most advisable. This is where a high speed camera system comes into use. A one-second event can be stretched into ten minutes of frame by frame playback. This playback can beanalyzed for a deviation from the expected behavior. Thus a fast solution may be suggested.Availability of such a tool can greatly reduce machinery downtime in a fast moving packagingsystem.This paper will discuss the results of using high speed camera vision system in two specificindustrial applications. The first application explains how the camera was used to fix theorientation of packaged material, in this case bottles, due to inaccurate cam profile of the screwconveyor. This screw conveyer operates at very high speed, 500 bottles per minute. Due toinaccurate cam profile of the screw conveyer, 5% to 10% of bottles come out with wrongorientation. It is shown how the installation of high speed camera vision system, allowingcapturing of 1000 frames per second of the orientation process, and frame-by-frame analysis ofthe operation, guide the investigators to find a solution to the inaccuracy in the orientationprocess. The second case discusses how such camera was used to investigate the high noise inhigh speed conveyor system and verify if the shaft misalignment was contributing to the noise.

Hossain, A., & Zahraee, M. A., & Kadir, H. (2012, June), Frame-by-Frame Analysis and Diagnosis of a High-speed Packaging System Using Fastec InLine Network-ready Camera Vision Equipment Paper presented at 2012 ASEE Annual Conference & Exposition, San Antonio, Texas. 10.18260/1-2--21406

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