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Plastic Element With Gasket Assembly Check

    MV Center Systemy Wizyjne Sp. z o.o.


Inspection description

We present to you one of the applications made by MV Center Systemy Wizyjne company using the 3D technology. The scope of the described project included: the selection of the equipment, development of the vision software and integration of the vision system with the production line.

The application performs assembly correctness check of a plastic element with a gasket at two assembly stands within one workstation. The scope of vision control includes:

  • checking the presence and clamping correctness of the gasket catches on the plastic element,
  • control of the correct contiguity of the gasket to the plastic element,
  • checking the presence and clamping correctness of the connector mounting clip,
  • control of the presence and type of the connector, depending on the selected reference,
  • checking the compliance of the symbols placed on the plastic element and the seal with the symbols given in the reference.

While checking the clamping of the gasket catch, its position is determined in relation to the edge of the plastic element, both in the fitted plane of the plastic element and its height. (Fig. 1)

Fig. 1. Measurement of the distance (purple) between the measuring point on the edge of the plastic element (green) and the point on the edge of the gasket catch (orange).

Inspections of the connector assembly and the correct contiguity of the gasket consisted of calculating the distance between the measuring points and the designated plane. (Fig. 2).

Fig. 2. Measurement of the distance between the designated measurement point (violet) on the edge of the mounting clip (green) and the designated measurement plane.

Depending on the reference specified by the PLC, reference symbols are checked on assembly elements, as well as the type and place of assembly of the connector. Inspection of reference symbols is to distinguish symbols between "0" and "+" in the image obtained from 3D-> 2D conversion (Fig. 3).

Fig. 3.Symbol inspection a) point cloud representing a symbol in 3D space b) obtained symbol image as a result of conversion in 2D space.

The type of the connector is determined by the width of the computed bounding box of the given surface. The Region of Interest of the particular inspection changes depending on the specified reference (Rys. 4).

Fig. 4. Computed bounding box (green) of the given connector’s surface (orange) used for the width determination.

Applied components

In order to grab the point cloud we used laser triangulation sensors. In the described application, we have decided to use SmartRay scanners - ECCO 55.050 which resolution and field of view were best suited to the given inspection parameters.

Bosch servo drive was responsible for the scanner movement, which was controlled using a Siemens PLC controller. The vision system was deployed on an Advantech industrial computer with an installed Profinet interface module, which allows communication with the PLC.

Adaptive Vision Studio version 5.0 was used to develop a complex inspection application. The availability of advanced tools for 2D and 3D analysis, tools for communication using the PROFINET protocol and the ability to design HMIl allowed it to meet all of the project's requirements.

HMI

Two access levels have been added to the developed HMI. The first level allows the operator to view the inspection results, scanner connection status and the currently selected reference. The inspection results are indicated by rectangular indicators and drawn ROIs of particular inspections on the images obtained as a result of 3D-> 2D conversion.

The second access level allows you to display the exact results and change the reference parameters.

Fig. 5. HMI Screenshot.