TroublePad: an adaptive high speed camera system for industrial monitoring
High speed camera for production lines
TroublePad is a high speed camera solution that enables the identification of production line improvement points. It can be used alongside your existing industrial monitoring system. Easy to use and intuitive, our ultra-portable high speed camera system was created with industrial maintenance in mind. It will enable you to diagnose and understand the anomalies and defects in your production line and high speed machinery.
The TroublePad is aimed at industries that run production lines, such as the food industry, cosmetics, packaging or pharmaceuticals, etc.
Our development departments and our customers' personnel worked together to create the TroublePad, which is designed to facilitate maintenance and optimisation of industrial processes in any field (food processing, pharmaceuticals, bottling, manufacturing, packaging, cosmetics, automotive, paper, electronics, etc.).
What is TroublePad made up of?
The ultra-compact system consists of a high speed camera unit, a tablet with pre-installed software, a mounting arm and a convenient carrying case (9kgs).
It only takes seconds to install, even in the most confined spaces. It is fully mobile thanks to its integrated, directional LED lighting, with no unnecessary wires or power supply (approx. 2 hours stand-alone operation).
A power connection is required when TROUBLEPAD is used to capture a random event which, by definition, could occur at any time over a period of hours or even days...
An intuitive, intelligent and independent high speed camera
The TroublePad comes complete with preinstalled software on a touchscreen tablet.
Its intuitive user interface enables you to control recordings, visualise live images, see footage history and enjoy instant replay at slow speed so you can understand production line errors, which are usually impossible to detect with the naked eye, in real time.
The system also enables videos to be exported in AVI format.
Thanks to this intuitive camera you will be recording your first images just a few minutes after installation.
The TroublePad is an adaptive, intelligent, high precision device for optimal industrial vision.
It can be used as a complement to an existing industrial vision installation or as the sole monitoring device.
With the camera and TroublePad system, you can set recording speeds from 225 to 2,500 frames per second, and make operator-controlled and configured loop recordings of several hours' duration.
The (optional) Trigger Box provides control over the system and gives it autonomy.
The Box enables you to:
add markers to key frames,
store a few seconds before and after a signal from your sensors...
You therefore only keep the most essential recorded images. The Box has the added advantage of quickly identifying areas for improvement in the production line, preventing problems more effectively, and helping you to find solutions for each one.
With the Box, the TroublePad becomes a completely standalone device: the images that are filmed are automatically recorded, without the need for human intervention. It provides the system with an extra dimension.
The camera's technical features
From a technical point of view, the TroublePad system is extremely efficient and meets several types of requirements.
The TroublePad camera can operate at a frame rate of 225 to 2,500 fps.
The recommended camera speed is 570 fps with a resolution of 800x600 pixels.
It is also possible to use a more standard speed, 225 frames per second, with a higher image resolution (1280x1024).
Other speeds are also possible, such as 835, 1500 or 2500 frames per second, with lower image resolutions.
The camera is also equipped with a LED light unit, which can operate on batteries (5 AAA batteries) and power packs. It produces 600 lumens.
The optics include a housing with a macro zoom lens to ensure maximum precision when recording. The mounting arm supplied is a magic arm with an adjustable clamp. It adjusts to the camera and its lighting system.
The tablet's technical features
Our system also includes a 12-inch tablet with a powerful Intel Core processor, 8 gb RAM and a 256 gb SSD hard drive, which comes with a protective case and shoulder strap.
For those who require extra storage space, it is possible to select a tablet with a 512GB or 1TB hard drive. The larger capacity tablets can handle longer recording loops.
The very powerful software can record at several speeds, several resolutions, under operator control or independently (with the Box).
Several system accessories are available such as:
wireless TroublePad trigger
high-power lighting (12000 lumens)
hybrid cable (10, 20 or 50 metres)
battery kit for the lighting
wide-angle lens for the camera
512 GB tablet
clamps for quick attachment
detachable trolley for the carrying case
a suction cup for attaching the system
TroublePad's high speed video software is easier to use than any other.
It is the operational heart of the high speed video workstation.
The operator will be ready to record sequences using the high speed camera in a matter of minutes.
TroublePad high speed camera enables image acquisition speeds ranging from 225 to 2500 frames/second.
Setting recording speed
It is very easy for the operator to define a specific area of interest in the image, so as to only retain the most relevant part.
Loop recording (loop duration is defined by the operator) enables continuous recording for several hours, and recording can be stopped either manually by the operator or automatically by an external "machine" trigger.
Playback and slow motion
The sequences that are filmed by the TroublePad high speed camera are automatically recorded, without operator interaction. The stored sequences are easily accessible for review and analysis, with ajustable playback speeds.
Sequence editing / Creating an AVI
It is very easy to isolate a sequence so as to keep only the most relevant part. An AVI file is created at the click of a button, at a frequency defined by the operator.
Ease of use and efficiency are our bywords!
Controlling the system through external triggers
As an option, the TroublePad high speed camera can be set up as a slave to your production line and/or robots!
TroublePad's trigger box can be used to start and stop recording, to mark key frames, to retain a few seconds before and after your sensors' signal....
The aim is simple....to only keep what you need!
Using the trigger box will help you to easily spot and solve random and infrequent events on your production line.
The TroublePad camera acts as a real "watchdog" for you production line.
Recommended speed 570 frames/sec at 800*600 resolution Standard speed 225 frames/sec at 1280*1024 resolution Other possible speeds 835 frames/sec at 640*480 resolution
1500 frames/sec at 500*300 resolution 2500 frames/sec at 320*240 resolution
Lighting Adjustable 96 LED, operating on batteries (5*AAA)
Power 600 lux. Mass 195 gr.
Optics C mount 8-48 mm macro zoom lens With Close up lens: 1D, 2D, 4D, 10D
Mount 'Magic' arm with variable friction for high speed camera and lighting
Tablet 12 inch tactile screen Intel Core Processor – 8 Gb RAM – 256 Gb SSD disk With protective case and shoulder strap
Carrying case overall dimensions 575x470x205 mm Weight 9 kg
Key software features Loop recording
Long recording time
Backward or forward playback
Adjustable playback speeds
Video overview of TroublePad high speed camera
Our high-speed camera filming the application of lids on yoghurt pots
Our Trouble PAD high-speed camera in operation in the pharmaceutical industry
Viewing a label press setup with a Trouble PAD high-speed camera
Pasta making in slow motion with Trouble Pad (#agro-food)
Analysis of a champagne bottle capping line using a high-speed camera
Clairefontaine papermaking factories and the Hamelin group manufacture paper for a variety of applications. The paper can be used to make notebooks, reams, folders, etc. Their sites have special machinery for manufacturing, cutting and assembling sheets. Manufacturing operations are carried out at high speed.
The sheets are handled by high-speed machines. Occasionally, jams or other problems can occur while operating the equipment. It is therefore essential to be able to identify the cause of these malfunctions.
To avoid machine stoppages due to paper jams when making reams of paper, envelopes, notebooks, etc. for example.
Paper, jamming, guillotine, paper trimmer, sheets, binding, high speed, high speed video, high speed camera, high speed, high speed video
First, a special machine lays out and cuts large sheets that are stacked in batches of 500. The reams of paper are then wrapped. These layout and finishing operations require the machinery to be perfectly adjusted and all components to be in good condition.
The Trouble Pad camera displays the stacking and cutting sequences. Maintenance technicians can access slow-motion images of the machinery in operation. They can accurately identify the fault and act quickly to adjust settings or replace components as required. The slow-motion feature is a real boon when searching for phenomena that are impossible to see with the naked eye !
Conclusion : Thanks to the Trouble Pad system, the Clairefontaine papermaking factories and the Hamelin group have access to information that would be impossible to detect with the naked eye. Slow-motion images simplify machinery tuning and maintenance operations. The Clairefontaine paper mills and the Hamelin group have been using Trouble Pad at their production sites since 2018.
Vaccine/drug manufacturing line
Many pharmaceutical laboratories are using increasingly complex production lines, with high production rates and safety requirements. The production of vaccines, drugs, injectable vials, insulin for diabetic patients, etc. is carried out on special machinery that can cope with the high production rates. However, high-speed production rates mean it is not always possible to have a clear idea of the mechanical phenomena that can occur during the manufacturing process.
Vials, blister packs, graduated syringes or medical pens are made up of many sub-components (embossed aluminium strips, seals, glassware, tubing, etc.). Several operations are required to ensure that all these parts, once assembled, comply with the customer’s specifications and that the machinery does not become out of sync. In addition, machinery may exhibit random behaviour during different operations. The manufacturers use high-speed Trouble Pad cameras to catch phenomena that are impossible to see with the naked eye! The slow-motion images provide new information.
To ensure that the machine settings are suited to risk-free high-speed production, that productivity is optimal and that the machinery does not get out of sync. To enable maintenance staff to understand production incidents, using.
Caps, capsules, liquid, medical, pharmaceutical, high speed, high-speed video, high-speed camera, high speed, high-speed videos
The manufacturers use high-speed Trouble Pad cameras to catch phenomena that are impossible to see with the naked eye ! High-definition slow-motion replays of the phenomena provide new information, enabling technicians to quickly reset their machinery.
Pharmaceutical companies such as Pfizer, Aptar, Novo Nordisk, Lilly, Sanofi, GSK, and others have been using Trouble Pad for several months at their manufacturing premises.
Gebo Cermex, SIDEL and ZALKIN specialise in the engineering and manufacture of packaging lines for a wide range of market sectors: from food and beverages to pharmaceutical products, as well as cleaning and hygiene products.
FMachines require fine-tuning and adjustment prior to shipment and installation at the end customer’s premises.
To understand malfunctions to be able to adjust machines quickly during production.
Many adjustments are required in order to ensure the packaging machines function correctly during assembly/manufacture. Operators are faced with high-speed sequences that cannot be broken down by the naked eye.
The Trouble Pad camera makes it possible to break those sequences down. Technicians can then identify precisely the improvements that need to be made thanks to the slow-motion images.
The machines are quickly adjusted, and promptly shipped and installed on site.
In addition, field technicians can take the camera kit on site to save time on certain delicate adjustments. The slow-motion footage saves valuable time on their callouts.
Conclusion : Thanks to the Trouble Pad high-speed camera, setup and adjustment times are improved.
Gebo Cermex has been using Trouble Pad since 2018 at its Lisieux production site. Sidel and Zalkin have several portable camera kits that enable technicians to use slow-motion images on site, or on lines that are being installed worldwide. The Trouble Pad slow-motion feature is a precious asset in every manufacturing process!
The Hager and Schneider Electric groups are major players in the electricity industry, and both have many production sites in France and abroad.
The sites manufacture electrical components (circuit breaker components, etc.) and have state-of-the-art manufacturing lines.
To carry out component assembly operations and ensure stability of finished products (spring units, small metal components, etc.).
To adjust machine positioning, improve machine settings, stabilise sequences, avoid assembly defects, tune machinery on the assembly chains.
Malfunctions, defects, electrical components, circuit breakers, high speed, high-speed video, high-speed camera
To guarantee production quality, technicians must ensure that the line is not disrupted by sudden movements. These movements sometimes occur at random. In addition, there are many different items, requiring fine machinery adjustments for each new production run..
The high-speed Trouble Pad camera detects the disruptive movements, which are invisible to the naked eye. Maintenance technicians can view slow-motion images of the mechanical parts as they move. They can precisely identify the defect and act on the appropriate parts of the machine.
The slow-motion images are easily accessible, as the installation of the Trouble Pad high-speed camera only takes a few minutes !
Conclusion : Thanks to the Trouble Pad high-speed camera, motion detection enables technicians to quickly correct defects, with minimal shutdown times.
HAGER and Schneider Electric use several Trouble Pad systems at their different production sites.
Context : ROXANE St LEGER (Perenchy site in Northern France), Eaux Cristaline / EVIAN Savoie / BADOIT Saint Galmier / VOLVIC / MONT ROUCOUS / NIAGARA WATER / NESTLE WATERS/ Aqua Sant’Anna / REFRESCO EAUX have different production sites in France and abroad with many high-speed bottling lines, each of which has a TROUBLE PAD high-speed video kit.
Random phenomena can cause synchronisation issues and defects on high-speed bottling and labelling lines.
To fix machine malfunctions, improve machine tuning, reduce production outages, using slow-motion images to help maintenance or production technicians.
Malfunctions, defects, bottling, high speed, high-speed video, high-speed camera
The machines must be perfectly tuned to maintain production rates (50-70,000 bottles /hour). There are many parameters involved: new capsule design, empty bottle weight, size variations. Random desynchronisation events can occur in the machine cycle and shut down production.
The high-speed Trouble Pad camera detects these slippages, which are invisible to the naked eye. Maintenance technicians can view slow-motion images of the mechanical parts as they move. They can identify the specific defect thanks to the high-speed Trouble Pad camera. In addition, there may also be a security issue for personnel given the speed of these machines.
The machine can then be recalibrated, quickly and safely. The High-speed Trouble Pad camera is a precious asset and the slow-motion images are accessible in just a few minutes !
Conclusion : Trouble Pad reduces production shutdown times and improves line productivity.
Moët and Chandon Veuve Clicquot (Epernay/Reims 51), LVMH Group, has several production sites in the Marne and many high-speed bottling lines.
Putting muselets (braided wire) and aluminium caps on champagne bottles.
To fix machine malfunctions, improve machine tuning, and reduce production outages.
Malfunctions, defects, bottling, high speed, high-speed video, high-speed camera
The machines must be perfectly tuned to maintain production rates. There are many parameters: the type and thickness of the capsule, surface condition and size variations. Random desynchronisation can occur in the machine cycle and shut down production.
The high-speed Trouble Pad camera detects these slippages, which are invisible to the naked eye. Maintenance technicians can access slow motion images of the mechanical parts as they move. They can identify the specific defect thanks to the slow motion.
The machine can then be recalibrated quickly.
Conclusion : Production downtime has been reduced thanks to Trouble Pad and the slow-amotion images,
MOET AND CHANDON and Veuve Cliquot have been using the Trouble Pad high-speed camera at their production sites for several years.
Paper production line
Ontex manufactures hygiene products (incontinence briefs), KIMBERLY Clark and ESSITY make paper tissues. ONTEX, KIMBERLY-Clark and ESSITY have several production sites in Europe. Many different manufacturing operations are carried out at high speed: folding, assembly, cutting.
Assembling absorbent paper sheets that make up the incontinence brief. Rolls of tissue paper, cutting, assembly, packaging of tissues or absorbent paper.
To ensure that the sheets stay flat before assembling the finished product. To ensure that piles of tissues remain in position during the packaging process.
Hygiene, medical, sheets, Folding, cylinders, rotation, high speed, high-speed video, high-speed camera
During the production process a machine is used to cut precise lengths of sheets of absorbent paper. Technicians must ensure that rotating cylinders are perfectly adjusted so as not to break the flow of these cut sheets.
With the tablet that is connected to the Trouble Pad high-speed camera, the operator can see the sheet as it is passes over a spinning roller. The ultra-fast rotation of successive rollers can cause the sheet to fold over on itself. This crease usually causes quality defects on the finished product. Similarly, when making absorbent or tissue papers, the machines operate at very high speed and require incredibly precise settings.
The machinery’s movements are invisible to the naked eye. Maintenance technicians can see the mechanical parts moving in slow-motion using the Trouble Pad’s high-speed video footage. They can install the TroublePad camera in parts of the machinery that humans cannot access, to identify the defect that they would otherwise be unable to see. Setting up the camera only takes a few minutes!
The source of the disruptions can then be identified, and quality improved.
Motion detection enables technicians to view the position of the roll of paper. As a result, defect (creasing) detection occurs earlier in the process and avoids quality defects on the finished product.
ONTEX has been using Trouble Pad since 2018 at its production sites in France and Spain.
Essity Gien, Kunheim and Mannheim use it … as does Kimberly-Clark in Rouen.
Christopher MALLERON-FONTAINE - Maintenance Manager - Isigny Ste Mère - France
We used to use Go-Pro type cameras as part of our maintenance tasks on packaging machines.
After realising the technical limitations of this type of camera, we turned to a professional model, the TroublePad camera by Claravision.
This equipment is very effective in its role, and we have been able to achieve unprecedented results.
On certain machines, which move at very high speed, we have been able to detect defects that the naked eye could not pick up. Using the software to slow down the footage, we were able to remove these defects very quickly.
Plus, thanks to its trigger command and loop mode, we were able to set the TroublePad camera on long surveillance (3 days, 24hr/24) and automatically only retain the footage with the fault we were looking for.
The software is easy to use and intuitive: our technicians can use it after only an hour’s training session.
Claravision’s technical department is very responsive if we need advice or help with using it.
The Troublepad camera has become a tool in its own right in our maintenance department, helping with diagnostics, and we encourage our technicians to use it as much as possible.
Jay - HP Inc. - USA
The TroublePad has been very good troubleshooting upgrade for HP inkjet cartridge manufacturing.
Our older cameras were large and so were the lights – it could be difficult to get good angles on moving parts that were inside of machines or behind guards.
With the TroublePad, we can easily mount the camera and lights inside the tool. The software has been very good – the ability to keep the camera running on a loop using various triggering options gives us a lot of flexibility.
Maybe the best thing of all is how self-contained it is. With older high-speed camera setups, engineers would have software installed on their personal laptops and you’d have to deal with drivers, Windows configurations, etc.
With the TroublePad, anyone can just grab the camera case and everything they need is inside it.
WHAT IS THE SYSTEM'S RECORDING CAPACITY?
The system enables video recording on a 256 GB hard disk. It is also possible to add extra storage space if this is not sufficient, with an (optional) 512 GB or 1 TB hard drive.
HOW MANY FRAMES PER SECOND CAN I SHOOT?
The system allows for recording speeds from 225 up to 2,500 frames per second, and recording in a loop.
IS THE CAMERA WATERPROOF?
The standard TroublePad system is not waterproof, but there is an IP67/68 waterproof version that includes protective housing for the camera and lens, dedicated IP67/68 waterproof lighting and IP67/68 waterproof tablet protection.
CAN I REVIEW THE FOOTAGE REMOTELY?
You can view the footage wherever you are thanks to the integrated software on the tablet. Either by sharing your videos instantly on the cloud or via remote control software.
HOW EASY IS IT TO STORE FOOTAGE SHOT WITH TROUBLEPAD?
The filmed sequences are recorded directly onto the hard disk and saved there for replay and slow-motion analysis purposes. Playback speed can be adjusted. Once you have detected the error in the production line, you can choose to retain just the sequence you are interested in, deleting the other sequences to free up space.
CAN I USE MULTIPLE CAMERAS WITH TROUBLEPAD?
Each camera has its own system and its own case. Each TroublePad system has one camera with which to monitor your operations. However, it is possible to use several systems and therefore several cameras.
WHAT IS THE CAMERA'S RESOLUTION?
The resolution of the camera can be adjusted. For high resolution images, select 1280*1024; but it is also possible to have a lower image resolution: 640*480, 500*300 and 320*240.
We recommend a resolution of 800*600 pixels and a camera speed of 570 frames per second in most cases.
WHAT IS THE MAXIMUM CAMERA SPEED?
The camera can capture up to 2500 frames per second with a resolution of 320×240 pixels.
IS TROUBLEPAD EASY TO USE?
The TroublePad system is extremely straightforward. It takes only a few minutes to install, and then you will be able to record your first images right away. The user interface is very intuitive and gives you the ability to control everything seamlessly (recording, playback, speed, live view…). You can place the camera in the most appropriate place to monitor your production and react to any issues.
DO I NEED TRAINING TO USE TROUBLEPAD?
Using TroublePad requires no training. Just watch our installation and introductory video to find out how to install your system.
IS THE SOFTWARE SUBSCRIPTION-BASED?
No, once you have bought the TroublePad system, it is all yours! There are no subscription or rental costs.
CAN I INSTALL THE SYSTEM ON ANY TYPE OF MACHINERY?
The system is mounted on a telescopic arm, which is included in the case. The arm can be turned in whatever direction you wish. You can then attach the camera and make all the necessary adjustments (zoom, lighting, sharpness…). You can install the system in the tightest of spaces, the system’s portability is a definite asset.
WHAT DOES THE TROUBLEPAD CASE CONTAIN?
The TroublePad case contains
the touchscreen tablet with pre-installed software, protective cover and shoulder strap,
the ‘magic’ arm,
a 600-lumen light box and battery,
a zoom lens,
a cable to connect the tablet and camera.
ARE THERE ANY OPTIONS?
Several accessories are available to complement the standard system provided in the case.
For those who require extra storage space, it is possible to select a tablet with a 512GB or 1TB hard drive. Also available are: a magnetic base, a more powerful light (12,000 lumens), a wireless shutter release, a trigger box, a hybrid cable, a battery kit for the light, a wide angle lens, a camera stand, clamps for quick attachment, a removable trolley for the case and a suction cup for the system.
CAN I GET A RUGGED TABLET?
The tablet comes with a protective shell and a shoulder strap, which are provided in the system case. As an option, a rugged tablet can be provided in lieu of the standard tablet.