PSA's fast track to cost-effect Machine Vision for Industrial Printing

Professional Software Associates, Inc. (PSA) is a Florida-based company that has been delivering innovative IoT and railway solutions globally for over 30 years. PSA strives to engineer solutions that not only meet but exceed clients' expectations in performance and reliability. They provide end-to-end services for IoT product development, including hardware design, firmware development, and connectivity. In their collaboration with Toradex to develop a cutting-edge Machine Vision System for printing manufacturers, they found a partner with a shared commitment to excellence.

Highlights

High-speed machine vision with Toradex at the core

PSA was tasked with developing a cost-effective automated solution to visually detect film defects in industrial printing processes operating at such high speeds that human spotters cannot detect. Using the Toradex Colibri iMX6ULL System on Module, they created a machine vision system capable of accurately detecting print defects at speeds of up to 1000 meters per minute. The Colibri iMX6ULL module was instrumental in meeting customer requirements in terms of power consumption, reliability, and connectivity, paving the way for a rapid path to the deployment of substantial cost savings.

High-speed imaging

PSA's solution features a high-speed 120 fps HD video camera by e-con Systems with a global shutter, capable of detecting objects moving at 1000 meters per minute.

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Real-time data processing

The image data is processed by the Colibri iMX6ULL System on Module, featuring an Arm Cortex-A7 CPU, before being passed on for a cloud AI-powered real-time fault detection.

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Peripheral interface management

The module's onboard Toradex BSP manages all peripheral interfaces: a USB camera, Ethernet, external relays, encoders, and alarm system.

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Choosing Toradex's Colibri iMX6ULL System on Module (SoM) was pivotal in our development of a defect detection solution with a high-speed camera, enhancing the precision and efficiency of our client's product. The Colibri module stood out for its compact, powerful design, allowing us to innovate without compromising on performance and pass on the cost benefits to our customer.

John Hertrich

CEO, Professional Software Associates, Inc.

PSA journey with Toradex

The challenge: Outperforming the human in the loop

PSA was contacted by a flexo printing facility, a leading manufacturer of flexible packaging and self-adhesive labels. Because of the extremely high operating speed of the slitter machine used to cut the printed film, human spotters missed up to 90% of film defects. PSA received the mandate to develop a cost-effective, automated solution that would outperform the human spotters, preventing their client from shipping defective printed films to their end-customers.
The solution: The powerful, cost-effective Colibri IMX6ULL System on Module

The choice of Toradex's Colibri iMX6ULL System on Module (SoM) allowed the team at PSA to rapidly develop and debug an industrial prototype incorporating a high-speed camera, elevating the precision and efficiency of their products. The module's compact form factor, competitive price point, and ease of integration enabled them to develop a highly cost-effective solution without compromising performance.
The outcome: A fast track to deployment with substantial savings

Combining the Colibri iMX6ULL SoM and Toradex's support, PSA deployed their solution in production two weeks ahead of the expected deadline, demonstrating their efficiency and effectiveness in project execution. Their implementation resulted in 30% savings compared to alternative solutions while reducing the number of defects by a remarkable 90%, resulting in a projected ROI of around one year.

Our partnership and experience with Toradex was significantly enhanced by their exceptional software support. In the intricate realm of technological solutions, a partner that provides thorough support is crucial. With Toradex's assistance, we were able to deliver a superior product to our client in the printing industry.

John Hertrich

CEO, Professional Software Associates, Inc.

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Low-End Starter Kit

Verdin AM62 Quad 2GB Wi-Fi / Bluetooth IT

Dahlia Carrier Board

Cable for Wi-Fi/Bluetooth Antennas (U.FL) 100mm U.FL to RP-SMA

Dual-Band Wi-Fi/Bluetooth Dipole Antenna

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Up to four Cortex-A53 1.4 GHz processors
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