Vision Inspection System

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Vision Inspection System

With production requirements taking up to 10 years to traditionally inspect, the addition of a vision system increased cycle time by 30% and allowed for higher production output.

A customer required an inspection of proprietary, cylindrical product that, at current production rates, could take over 10 years to inspect the currently needed production. Using machine vision to automate the inspection process, and Cognex cameras, AeroSpec created a rotational system that reduced cycle time and actually improved upon the customer’s requested throughput in an eight hour shift. After having been in production for years, no service calls were requested and the system remains in production today.

CUSTOMER CHALLENGE

The customer required an inspection system capable of measuring over 10,000 holes located upon a cylindrical surface ranging from sizes of .250” to .020; system throughput requirements where such that the system needed to complete inspections in two minutes.   In addition to the performance challenges, the system would need to survive the manufacturing environment where it would reside. The system would need to  run 120 cycles per day, 365 days per year for up to 10 years and handle product loads weighing up to 60lbs. Ergonomics were crucial  due to the heavy loads and manual nature.  HMI screens would need to be intuitive, easy to read, and guide operators through the process.

AEROSPEC’S APPROACH

Utilizing our extensive background in Cognex Machine Vision, AeroSpec developed a robust inspection solution using the Cognex 5604 line scan camera.  The system rotary spun the 60lb products at nearly 30 RPMs while the line scan camera was synchronously actuated in the Z-Axis.  AeroSpec software precisely stitched all motion and inspection data for a comprehensive inspection output report of 100% of holes.  Knowing this was a manual station; ergonomics were a primary concern.  The physical features where mocked up and tested with client input with varying sizes of material in dimensions and weight.

SOLUTION IMPACT

AeroSpec created a solution that met all the customer’s requirements including surpassing cycle time by 30%.The completed solution was able to output 480 cycles per 24 hour day or 160 cycles per eight hour shift, meeting and surpassing the requirements 120 cycles per day. The customer now has the ability to precisely locate manufacturing issues and rework them within minutes.  The added capability is a key improvement to their workflow and bottom-line.   The equipment has been operation for year and required zero service calls for repair or maintenance.

SOLUTION GALLERY

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