The human eye is not a sufficient tool for quality monitoring in the process industry. Machine vision is the solution for monitoring requiring quick data processing. The technology has developed in giant leaps in the 21st century.
Relying on its innovation, the Jyväskylä-based company Viconsys Oy develops monitoring technology based on picture processing and utilising the latest knowledge in the fields of camera and lighting technology, picture analysis and artificial intelligence.
"Intelligent camera technology detects defects and deviations in the process. Paper manufacturing is a typical example of a process monitored with machine vision, but the technology can be utilised in a number of other industries with flat-sheet processes to monitor," says Hannu Ruuska, Managing Director of Viconsys Oy.
Information is collected from cameras placed at various phases of the process. Real-time picture analysis is the most demanding part of the monitoring; it requires, as Ruuska puts it, "a hundred Pentiums' worth of power."
"Viconsys technology provides the customer with real-time production data. If a deviation is detected, the system immediately displays the problem - e.g., a hole in the paper sheet - in a picture."
"In addition, the software offers an array of other information, such as suggestions for causes of the problem. It costs a lot of money to stop the paper manufacturing process, so the reasons behind problems should always be discovered."
The picture material collected from production is analysed using mathematical methods that have been developed in co-operation with the University of Jyväskylä. Viconsys has also co-operated with Jyväskylä Polytechnic in the field of picture analysis. Ruuska believes that machine vision expertise of global significance will gradually accumulate in Jyväskylä.
When you look at completed paper against the light, you can see a texture. The mathematical methods aiming at finding deviations are applied to this texture. Picture analysis is also applied to other targets around the world.
"Machine vision development has accelerated in the 21st century. The 9/11 events in New York in 2001 gave it a boost: machine vision devices were needed in public places and transportation in order to quickly discover abnormal activities in crowds."
Viconsys' key employees have previous experience from machine vision-related business operations and, relying on this experience, they wanted to commercialise their own innovative product idea. The company was established in March 2005 and has since employed some 30 experts in product development.
The company turnover for 2006 is estimated to reach EUR 3.5 million. In five years it is estimated to be as high as EUR 30 million.
"A good innovation, experienced people and enormous markets. We have all the prerequisites for quick growth in place."
Photo (above): "The process and quality machine vision system developed by Viconsys serves, for example, the paper industry. Over 90 per cent of our customers operate abroad, says Managing Director Hannu Ruuska.
Photo (below): A paper machine's production rate is 30-40 metres per second, so the human eye cannot detect deviations in the sheet. Picture of paper machine #4 at the M-Real Kangas factory in Jyväskylä.
By Timo Sillanpää, Photos by Petteri Kivimäki