The aim of the project was to reduce the duration of measurement activities and to achieve greater repeatability of results by using a vision system for automatic measurements.

The customer wanted to verify the assembly of the panel with the overlay with high accuracy and to control the repeatability of the process of gluing these two components together. Low quality products are a result of e.g. decalibration, wear or incorrect machine settings, which may result in potential complaints.

Initially, the customer used ad hoc means of manual quality control using calipers. The method was effective; however, due to low productivity, the idea to automate came up.

Implementation workflow.

Due to the variety of assemblies, components and surface reflectivity, a ready-made solution existing on the market could not be used.

The engineering staff of Etisoft Smart Solutions designed a tailor-made solution for our client, meeting all the functional requirements. Thus, the vision system design ultimately consisted of two 2D cameras, a blue laser, mechanical structure, electrical part and designed system automation. The 2D camera was sufficient for the task, and the laser met the potential for error from surface reflectivity. A second 2D camera was attached to the vision system to read the QR code to assign the result for the panel under test.

At this stage, it is also possible to select different variants of solutions and compare them with each other. This allows you to select the necessary number of mobile robots and the required infrastructure (docks, charging stations, pallet storage, etc.).

Faced benefits and challenges.

After the first implementation tests of the vision system, it turned out, as expected, that the machine has a higher repeatability and accuracy of results than manual measurements.

The project manager indicated that the project team handled very well the biggest challenge during the implementation which was a major redesign of the entire system after receiving the templates and performing the first tests with the originally intended hardware.

The lack of space was also a design challenge – the stand was limited to a europallet due to our client’s requirements.

The project involved a standard engineering team that consisted of an automation engineer, a programmer, two machine vision specialists, a mechanic, an assembler and a project manager.

The whole machine has been assembled and tested in Etisoft Smart Solutions headquarter and was sent to the customer as a free-standing stand. Installation time at the customer’s site was limited only to plugging in the machine and performing acceptance tests.

The above described implementation of the vision system in the industry is another of the implemented by Etisoft Smart Solutions. If you are wondering whether the automatic quality control systems will work in your company – contact us!

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