A filler machine adds powder to a dose pouch. If the douce pouch is not properly opened, then the product is spilled onto the bottom of the machine.
Cognex InSight program was developed to profile the outside shape of the dose pouch. If the center gap distance and area were too small then the filling is skipped for that dose pouch.
2D barcode label was applied to the end of a syringe. Labels that are wrong or placement is out of specifications need to be rejected.
Cognex Smart camera was added to an existing label applicator machine. The syringe was rotated and 4 images were acquired. The 2D matrix on the barcode was verified against the SKU read in from the PLC. The label position was gauged relative to the tip of the syringe and all 4 images were used to calculate the label skew.
Motor components are assembled in stages, with the base attached to a carriage that moves through the assembly line. After the rotor is mounted in the stator the alignment needs to be checked.
Due to inconsistencies in the placement of the motor base on the carriage and the tightness of tolerances, a single top-down view and gauge approach were not viable. A stereo camera setup allowed for the end of the rotor and stator to be individually identified in 3D space. From there concentricity measurement and plane parallelism could be calculated.
Car interiors are often customized for their material, trim, and user features. Variations may be subtle and batch runs are small. An end-of-line inspection system is needed to ensure the product that was assembled matches the build ticket.
A camera with a bright field and dark field configuration was mounted to the end of an ABB robot. The operator loads an assembled car door interior onto an open nest and presses the Inspect bottom. The robot would move to 20 different locations on the backside of the car door interior, triggering the camera/lights, and then requested the operator to rotate the fixture. The robot then moved to 6 different locations, triggering the camera/lights for each.
A mock display is presented to the Operator for pass/fail of all zones. The operator had the ability to select a zone to see the image taken and individual pass/fail results for each Poka-Yoke item.
After the bearing raceway has been machined to a sized blank, the possibility exists that the surface may have underfills, pitting, or other blemishes. Such non-conformances need to be removed and repaired before the additional value is added to the product.
The product is placed into an encoder roller system via an overhead robotic system and is imaged with a line scan camera. If variations in the surface finish are detected, the product is moved to a secondary inspection area, other wise it is moved onto the next step in the process.
A robotic system applies Loctite to various holes on an engine block. Insufficient application of Loctite can create quality issues.
An additive in the Loctite causes it to fluoresce if illuminated with UV lighting. Cognex InSight camera with a Blue bandpass filter image the Loctite application for presence and bead width and continuity.
The product is placed by a robot into a thermoformed package. If the product is not properly placed into the individual pockets it can create a problem with the top foil seal.
Cognex InSight and pattern matching were used to verify the product was seated correctly in the individual pockets. The product line was stopped for non-conformance.
From new to end of life, welding tips used to spot weld the housing to the band create varied results. From time to time, a weld would fail to fully engage and would produce a light or no weld.
5000 images were collected and annotated, then applied to a neural network-based descision engine (predecessor to modern deep learning algrothims). System performed well after new tips were broken in after 2000 cycles. (Average life cylce of tips 35k - 40k)
Dashboard displays manufactured by automotive suppliers must have all the gauges (speedometer, tachometer, engine temp, etc.) calibrated before shipping.
The operator places the product into a test docking station, and the gauge is provided a signal for 3 different values. The PC-based vision system determines the angle of the needle on the gauge and provides the value back to the test docking station. The 3 data points are used to calibrate the gauge, and values are saved to the EPROM of the dashboard display.
An Automotive manufacturer needed to verify the correct roof has been placed on the vehicle prior to robotic welding.
PC-based Vision system identified key features of 6 different possible roof configurations and verified a match based on the VIN barcode.
An Automotive manufacturer needed to verify the correct fender has been placed on the vehicle prior to robotic welding.
PC-based Vision system identified key features of 4 different possible fender configurations and verified a match based on the VIN barcode.
Tier 1 automotive supplier manufactures car frames. Mounts that are bent or incorrectly mounted on the frame need to be detected before additional value is added to the product.
PC-Based vision system located and profiled the mount that was welded to the frame. An alert was raised if the location or deformation was outside of tolerance by more than 1/4 inch.
Fenders are welded to a truck bed by welding robots. Misaligned fenders need to be detected and corrected before the truck bed proceeds to the next step in the process.
The PC-Based vision system used structured light to detect and measure fender location on the truck bed. Rejects were flagged, and an alert was raised to the Operator.