The vision system helps automotive suppliers achieve great quality gains and labor savings
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The transmission control module (TCM) manufactured by the automobile supplier is the key to vehicle performance, so it needs to be fully tested to verify the mechanical integrity of each device coming off the assembly line. Suppliers are not satisfied with manual inspections, because such inspections can never be completely accurate. The supplier’s principle is that a low-quality work piece cannot be omitted. Suppliers also want to be able to provide documentary proof that can be used to prove that each artifact has been initially verified when problems arise in the future.
The automotive supplier has worked with Universal Instruments to develop an automation solution that can provide 100% quality assurance at the lowest cost. The customer has decided to use a laser marking system to track at the individual component level. The challenge Universal faces in this application is to read the one-dimensional code on the chassis, the two-dimensional data matrix code and text on the product, and to detect the power and signal ports on the product to ensure the mechanical integrity of the product. These operations need to be completed in a very short time and within a limited space.
Francois Caudrillier, head of product management and solution integration at Universal Instruments, said: “The application involves a very wide range of difficult vision tasks.” It is no longer what to find three different vision systems to solve these three extremely difficult challenges. problem. But using three different systems will greatly increase the complexity and solution cost. Another problem is that the three traditional vision systems may not be installed in the narrow range of a single device at all. Cognex In-Sight® 5100C (the photo shows an earlier but similar inspection station in which the vision system used is an earlier model of Cognex vision system) provides a solution to these problems. This system can read two-dimensional data matrix codes and perform optical character recognition and size detection. The ability to use a single vision system to meet all application needs can save time and money, because we only need a single setup environment and a single interface to work on the entire project.
Caudrillier said: “Cognex has provided us with a great help in this application. We send product samples to them, and then they develop lens imaging and lighting solutions based on the application. This help enables our engineers to Concentrate on other aspects of the project.” The solution developed by Universal Instruments utilizes the 1500 mm wide Polaris Junior assembly cell. The Polaris Junior unit features a 3-axis pallet driven by a guide screw and controlled by a Galil motion control card with a repeatable positioning accuracy of 0.0004 inches. An Omron programmable logic controller (PLC) defines the location and sequence of detection operations.
Compared with manual detection, the new detection system has a continuous improvement in accuracy. Every automobile supplier understands that even if there is only one unqualified workpiece in the product delivered to the customer, it is a dangerous thing. In addition, it also knows that there is always a risk of error in manual inspection. The automotive supplier took measures to ensure that every component can be 100% automated inspection, almost completely eliminating the possibility of error. In addition, the use of machine vision can eliminate the need for manual inspection, thereby greatly saving costs. The supplier plans to expand the scope of machine vision applications in the future to ensure that it can continue to meet and exceed customer expectations.
About Cognex
Cognex Corporation specializes in the design, development, manufacturing and sales of machine vision and industrial systems or visual equipment. Cognex’s vision and ID systems are widely used in various inspection, identification and guidance applications throughout the manufacturing and distribution processes throughout the world. Cognex is a global leader in the machine vision and industrial ID industries. Since its establishment in 1981, it has installed more than 800,000 systems around the world and has earned more than $3 billion in cumulative revenue. Cognex is headquartered in Natick County, Massachusetts, with regional offices and distributors in North America, Europe, Asia, Japan and Latin America. For more information, please visit Cognex Corporation online at http://www.cognex.cn.
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