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Control Element Housing Inspection

    MV Center Systemy Wizyjne Sp. z o.o.


Application description

We are proud to present one of the applications made by the MV Center Systemy Wizyjne company using the 3D technology. The described project included: selecting the equipment, designing the control system, creating inspection software and integrating the whole with the existing machine.

The application was based on the control of many small and shiny elements in the housing of the control element used in the automotive industry. The following elements were inspected:

  • Control of the presence of sensor, the presence of three steel wires (sensor legs) and the accuracy of the clamping of these legs in the welding process
  • Control of the presence (or lack thereof, depending on the references) of capacitors placed in plastic sockets, the presence and position of steel capacitor wires and the correctness of their crimping during welding
  • Control of the presence and correct position of the pins supplying the system with electricity
  • Control of the presence and correct positioning of the gasket around the cover

Inspection examples are shown below:

Fig. 1. Example of sensor pin representation on the scan and in the real set.
Fig. 2. An example of the representation of the capacitor legs and the capacitor itself in a real system and in an image created from a 3D point cloud. The lines indicate the measurement points of the capacitor leg height.
Fig. 3. Detection of the presence and position of the clamped capacitor pins.

During the inspection of the wires, system checks whether they were bent in the plane of the cover and in height in relation to the clamped pins, as well as whether they were properly cut (they were not too short or too long in relation to the position of the clamped pins). In addition, the vision system detects pins that could not be welded / squeezed tightly enough or the clamping lugs which could cause pin’s damage by changing their geometry and position.

The inspection of the correct positioning of the rubber gasket consisted in checking the presence and height of the tooth located on the circumference of the gasket. When someone places the seal turned 180 degrees, the asymmetrically positioned tooth is deeper than when the seal is properly seated. An example of a gasket arrangement is shown below:

Fig. 4. An example of a gasket representation in a real layout and on a 3D scan.

Below are examples of defects detected by the vision system:

Fig. 5. Examples of crooked and unbent pins.

Components

A 3D scanner using a laser line was used to collect the point cloud. In the described application, it was decided to use the LMI scanner - Gocator 2330, whose resolution and field of view best suited to the inspection parameters. The repeatability of the measurement in the X and Y axes was obtained approx 0.075 mm, while in the Z axis it was approx 0.02 mm.

The servo drive with the control provided by Mitsubishi Electric was responsible for the movement of the scanning head. The Advantech industrial computer with a touch operator panel was used as the central unit.

To create an extensive inspection MV Center decide to use the Adaptive Vision Studio library in version 4.10. Advanced tools for filtering 3D point clouds and an extensive library of the 2D and 3D tools, allowed for 100% error detection with almost zero False Reject number (OK details on the limit of detection were treated as details NOK).

Operator panel

To display and change the system control parameters, it was created an extensive operator panel with the possibility of saving logs of each introduced change and each controlled item. Additionally, the panel displays all occurring errors and displays error zones on the plan of the controlled detail.

Fig. 6. A screenshot of the operator panel.
Fig. 7. Fragment of the report generated during the inspection.