When Machines Can Monitor Themselves
Consistent quality, very few rejects, reliable part and batch tracking,
added transparency: The use of vision
sensors for quality control directly in the production
process offers a number of benefits. Depending on the task at hand, you need to
have the right vision solutions, which allow for quick and efficient
integration into your machine.
The later an error is detected in the production process, the more costs
it incurs and scrap material it causes. In light of this, it is therefore
essential to detect errors as early as possible. At the same time, the
evaluation of quality attributes enables users to identify any measures needed
in production facilities or for production material. Vision sensors are ideal
for dealing with these issues. Their spectrum stretches from 2D monitoring for
simple production features and operating material attributes to high-end tests
using 3D vision systems. Rejects and costs are cut as a result. Yet another
benefit: The individual images from the vision sensors are stored and kept
available for a later date – perfectly in keeping with the principles of
Industry 4.0 and added transparency. Vision solutions used to be used primarily
for monitoring production material at end customers. However, an increasing
number of machine manufacturers and OEMs are joining the trend of incorporating
the issue of quality control into their machines and plants – another step towards
creating complete solutions for the end customers.
The benefit
of inline Quality control is, that it detects errors at their source:
Vision
sensors like the Inspector conduct
ongoing checks of the punched contours or holes directly in the process.
Irregularities or errors in the punching process are therefore detected
immediately and with full reliability. An added bonus even for the flexible
production of small batch sizes: The operator can access pre-defined test
parameters when changing a batch or use functions to modify the parameters himself
– so you don’t need to be a vision expert. The results of the thorough check
are evaluated in the vision sensor itself and passed on accordingly.
Are all of
the holes and recesses in place and correct? To conduct a full quality check
after processing a motor block, an Inspector vision sensor not only checks that
all contours and holes are in place, it also makes sure they are the right
shape. Any parts that have not been processed correctly can be rejected before
further processing. The production process can then be stopped in good time,
for example, if you need to replace any damaged tools. Furthermore, the sensor
uses taught-in features to identify the individual parts. This information is
sent to the control unit for the next machine in the line so that the
production process can be modified if necessary.
The plastic
and rubber industry requires a high level of efficiency and economy with a
consistent level of quality. The use of vision solutions offers a number of
benefits: For instance, a vision sensor can check whether an insert has been
placed correctly into the injection molding machine’s mold. Having the
component in the right position prevents damage to the tool and, as a result,
reduces machine downtime, while at the same time improving the quality of the
part in question. In the production of injection- molded plastic parts, the
quality of the final product also depends on a number of factors, such as
temperature fluctuations, fluctuating quality in the plastic granules, etc.
Inline quality control using vision sensors can also offer advantages in this
case: Errors such as over- or underfilling are detected reliably so that faulty
parts can be safely separated and ejected.
When welding
or cutting metal panels, the quality of the welding caps on the welding gun or
laser cutting device has to be monitored on an ongoing basis. Welding caps wear
off as the processing time increases, requiring them to be replaced. An
Inspector 2D vision sensor checks defined parameters, such as shape and
diameter, and detects irregularities that cannot be tolerated. The operator can
then replace the welding caps in good time so that product quality remains
consistent.
Powerful 3D
vision solutions make a valuable contribution to the quality of the final
product. For example, the Ranger E 3D
vision sensor can generate an exact image of the surface of the board when
processing sawn timber. As a result, potential errors and undesirable
irregularities on the board, such as cracks, gaps, spots, rot, resin, or knots,
can be clearly detected. This inline quality check using 3D vision solutions is
equally well suited for the production of flat glass and plastics.
Original article from SICK posted on SICKUSABlog
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