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Diameter Inspection

    I2 VISION INDUSTRIAL INTELLIGENCE


Reliable vision system for inspecting dimensions of the manufactured part is a crucial element of every modern manufacturing process. Engineers from I2 VISION INDUSTRIAL INTELLIGENCE have prepared an inspection of roundness and dimensions of the inner diameter of tempered steel rings with tolerances up to +/- 0.1 mm using Adaptive Vision Studio. The application also performs different operations on datasets based on access levels.

Inspection aim

Inner diameter of the tempered steel rings had to be inspected both for roundness and dimension.

Additional requirements were, as follows:

  • Ring diameter could range between 30 - 60mm.
  • Inspection tolerances could be up to +/-0,1mm.
  • Inherent small dust particles should not be detected as failures.
  • The application should allow the user to: generate datasets for new rings, store datasets
    as well as select datasets based on corresponding password-protected access level.

Components

The following components were used for preparing and performing the inspection:

  • Adaptive Vision Studio software.
  • IPC with Pentium N4200 and 16 DIO.
  • A GigEVision compliant grayscale camera with a sensor resolution of 5472*3648 px.
  • Telecentric lens with a magnification factor of 0,137.
  • Telecentric backlight

Solution

Basic task:

Completing the basic task required us to implement the following steps:

  • Setting values for diameter and tolerances, saving and uploading them via HMI.
  • Performing the system calibration (camera and world plane calibration).
  • Performing the inspection of the diameter along 12 vectors,
  • If the diameter along a vector was out of range, 4 additional vectors around this vector were evaluated as well. Depending on the settings and the results, the part would be kept or defined as bad.

Additional task - Presence Check:

As an additional task, we were asked to implement a simple check whether the ring was in position, before performing the main inspection of the ring. This additional job consisted of the following steps:

  1. The ring rolls into the inspection area.
  2. Vision system checks if the ring is in the right position.
  3. Next, the ring is fixed and stabilised in the calibrated plane.
  4. Actual evaluation cycle is started.

The presence check was necessary due to the fact that ring sizes could vary from 30-60mm and no standard optical or inductive sensor managed to detect all ring variants reliably.

Author: Herbert Pichler (herbert@iqv.at)