COGNEX INTRODUCES THIRD GENERATION CHECKER VISION SENSOR
No PC required for setup and configurable as either a Presence or Measurement Sensor

Cognex^® Corporation (NASDAQ - CGNX), the world’s leading supplier of machine vision systems and vision sensors, has added the Checker^® 3G series to its award-winning Checker vision sensor product line. With simple setup, integrated part detection, lighting, I/O and job change all in a rugged IP67 housing, Checker 3G is the easy, reliable and affordable way to verify all products or parts on the line.

With Checker 3G, the user chooses whether to configure the sensor as a presence sensor or measurement sensor.  Presence sensors verify that features are present.  Measurement sensors verify that features are the correct height, width and/or diameter.  In either mode, there is no limit to the number of part features that a single Checker can “check”. Checker is also able to detect and track over 6,000 parts per minute in varying positions along the production line, overcoming imprecise part positioning and delivering consistent, precisely timed pass/fall results. No other sensor, vision sensor, or vision system can do this.

The new Cognex offering does not require a PC for setup. Instead, the SensorView^® Teach Pendant, with its unique One-Click Setup™ technology, allows the user to set up jobs right on the line and has them running in a matter of minutes. A single teach pendant can be used to set up any number of Checker 3G sensors and can remain connected for real-time application monitoring.

The SensorView Teach Pendant is a compact, rugged, panel-mount display for both the Checker 200 and 3G series of vision sensors. More than just a display, SensorView provides production statistics and a user-definable view of the parts that Checker is inspecting. This enables operators to easily monitor their production process, change jobs, or retrain patterns without a PC.

The key to the simplicity of the Checker is its One-Click Setup.  By simply clicking on the feature in the image that you want to inspect Checker automatically creates a sensor, learns the features attributes and sets the appropriate pass/fail criteria.

“Customers value the simplicity and power in Checker all-in-one vision sensors because they offer a cost-effective option for inspections that are too difficult for traditional sensors. One difference is that Checker understands what parts actually look like, no matter how complicated,” said Pascal Dorster, Vision Sensors Business Unit Manager. “The Checker 3G extends the versatility of the Checker product line so customers can save time and money with an easy to use, affordable and reliable system.”

The Checker 3G series joins the existing Checker 200 series which features additional I/O, encoder-based part tracking, an industry standard ladder logic editor for custom logic and the ability to inspect smaller features over a larger area.  The Checker 3G is currently available.

For more information, or to download free trial software, visit http://www.cognex.com/3G/.

COGNEX DEVELOPS AN ON-LINE TOOL TO CALCULATE COST SAVINGS FROM USING VISION TECHNOLOGY
Helping manufacturers evaluate how much savings can be achieved by investing in vision

Cognex^® Corporation (NASDAQ - CGNX), the world’s leading supplier of machine vision systems and industrial ID readers, today announced the availability of a new on-line tool to help manufacturers understand the benefits that can be achieved through the use of machine vision and industrial identification. “In these difficult economic times, optimising product quality and reducing manufacturing costs is more important than ever. Our new Cost Savings Advisor makes it really easy for manufacturers to calculate the cost reductions they can achieve through using Cognex vision and ID systems” says Peter Neve, Vice President of Global Marketing for Cognex. He added, “It also acts as a great check list to ensure that all potential savings from using vision are identified.” The Cognex Cost Savings Advisor was designed to help customers evaluate a cost savings plan for vision inspection, automation or identification applications.

The free tool can be found at www.cognex.com/costsavings. Users are asked a few simple questions about each vision application. The tool then calculates the potential cost savings that could be achieved by implementing Cognex solutions on the customer’s production lines. Additionally, the results highlight other potential benefits that customers may not have previously considered.  A wide range of cost savings opportunities can be estimated within three main sections: product inspection applications, automation guidance applications and identification/traceability applications.  Once the results are calculated, a record of the evaluation can be printed to share with colleagues. Cost management is a global concern; Cognex, as a global corporation, recognizes this and is pleased to offer this tool in nine languages: Chinese (Simplified and Traditional), English, French, German, Italian, Japanese, Korean and Spanish.

COGNEX EXPANDS INSPECTION CAPABILITIES OF CHECKER VISION SENSORS
Model 252 adds pass/fail inspection of height, width, and diameter

Cognex® Corporation (NASDAQ - CGNX), the world’s leading supplier of machine vision systems and vision sensors, has expanded its Checker vision sensor product line with the Checker® 252 model. The 252 includes all inspection capabilities of the award-winning Checker vision sensor family, plus additional software sensors that verify height, width, and diameter and deliver reliable pass/fail results on high-speed production lines.

Key to the simplicity of the Checker 252 is its One-Click Setup™. By simply clicking on the center of the part feature to be inspected, an image of a familiar caliper appears and locks on the edges of the part feature, sets the minimum and maximum thresholds, and learns edge polarity…all automatically.

“With its unique screen caliper, the Checker 252 makes pass/fail measurement verification simple and reliable” said Pascal Dorster, Vision Sensors Business Unit Manager. “Manufacturers in many industries, such as automotive and packaging, can now verify dimensions of parts with very low-contrast edges and solve a wide range of measurement verification tasks not possible with photoelectric sensors.”

As with other Checker models, the 252 is available with the Cognex SensorView^TM 350, a compact, industrial, panel-mount display. The Checker 252 will be available in November, 2008. For more information, please visit http://www.cognex.com/checker252.

Overhead console assembly verification

VISION SENSORS FACILITATE “BUILD-IN-SEQUENCE” STRATEGY FOR HEADLINERS

In-line checks confirm presence, position, color and orientation of parts for JIT assembly of X400 Jaguar headliners

Summary: Cognex In-Sight 1000C vision sensors are being used in a highly integrated assembly line making headliners for the X400 Jaguar car. Johnson Controls Automotive has installed the line to meet the demands of a new contract, and a special feature is that automated vision systems are used as an integral part of the assembly process, checking for the presence, position and orientation of components such as grab handles, labels and foam spacers. Electrical checks confirm that console lamps are working properly and customer color choices are also confirmed correct before shipment. Headliners are built-in-sequence to JIT production demands from the Jaguar line, so the line is highly time- and quality-critical. Image archiving supports full traceability.

The new X400 Jaguar headliner line is at the JCA Speke plant on Merseyside. Headliners (interior linings for the roof) are assembled in response to a ‘broadcast’ call from Jaguar, which manifests itself at the JCA factory as a sequence of bar code labels, which automatically supervise the assembly line.  The task is to assemble the headliners in the same sequence as the cars they belong to, ensuring that color schemes, fittings and various optional extras match exactly the customer’s order.  The aim is for finished headliners to be transported to the Jaguar line ‘Just in Time’ (JIT) to be installed in the correct car as it arrives at the assembly point. A production rate of 40 headliners per hour is targeted, which means that each headliner takes approximately 90 seconds to complete.

This ‘build in sequence’ strategy poses critical production challenges, says Nick Bradburn, Manufacturing Engineer. “The starting point for us was the need to replace an old line which relied on mechanically-positioned optical sensors for checking the product and which therefore needed lots of maintenance.”  JCA was seeking to improve their delivery integrity and build quality in keeping with their continuous improvement policy and their aim to exceed customer expectations. This would also handle the increased policy warranty responsibilities of the car industry and underwrite the vital ‘JIT Sequenced Environment’.

The challenge is ‘rigorous’ according to Bradburn. “We only assemble two types of headliner - one for saloons and the other for estates - but the task is complicated by the multiple choices of colors and fittings (Intrusion Sensor, Park Aid, Moonroof etc.) available to the customer. When other variants are included - such as international differences in the Garage Door Opener (GDO) and SRX options frequencies - it means that hundreds of headliner variants are possible - all of which must be proved correct and tested in the correct build sequence at high production rates.”

The assembly/test process

The first two tables of the new 4-table assembly line concentrate on adding parts such as locator clips, visors, foam blocks and some electrical items to both sides of the headliner substrate -the hidden (or B) side first and then the visible interior (or A) side next. At each table the bar code label is scanned first and the correct parts are delivered using a KANBAN system. The processes here are purely manual with no vision checking.

Tables 3 and 4 differ in having overhead gantries about 3 meters high above each table, on which four Cognex In-Sight 1000C vision sensors connected via Ethernet in a Vision Area Network (VAN) look vertically down on the headliner. Here, scanning the bar code also tells the inspection system what test parameters to use and instructions are passed serially to a master camera in each VAN, which then passes on the data to the other three cameras over the Ethernet.

Each Cognex In-Sight 1000C camera is a full-featured CCD camera with on-board processing capability that can undertake its own set of ‘inspection’ tasks separately from the central controller.  The ‘C’ indicates that it is fitted with additional hardware to enable the Hue, Saturation and Intensity of its target to be assessed, allowing it to confirm that the correct color parts are fitted.  The VAN is also connected to a web server that transmits captured images to a central storage and archiving facility.

In detail, the headliner is placed on Table 3 with its (hidden) Side B uppermost. First, the presence and orientation of foam blocks is confirmed, then the locator clips. The grab handle spacers are checked to ensure there are zinc on the front and plastic on the rear as well as whether or not there is a Moonroof.

The major item fitted on Table 3 is the Master Plan Console (MPC) - the module above center of the driver’s head in the finished car, which contains courtesy lamps, switches, microphone, GDO and similar items. Once again there are many different configurations, so the correct MPC is selected by scanning the next kanban part, the match between headliner and MPC is then confirmed / declined on the HMI. Once the correct MPC is in fitted, the overhead Cognex cameras are triggered and the position, orientation and content of the MPC are checked, with the results showing on a nearby monitor.

Once a ‘pass’ has been confirmed, the headliner is placed on Table 4 with its (visible) Side A uppermost. Scanning the bar code label tells the test system whether the headliner is for USA, Canada or the rest of the world and gives correct options for the `eCheck’, which appear as a series of bulleted check points on a nearby monitor screen. The first job is to plug the main wiring loom into a fixed test system that checks continuity of the electrical items. A ‘green’ bullet indicates a pass and the operator next triggers the vision system manually to look for the presence of ‘lamps’ in the off state, and to perform some other checks including looking for the correct air bag label on the underside of the visor.  The Cognex cameras are automatically re-configured with a smaller aperture during this test because of the label’s reflectivity.

Once the label test has generated a ‘green’ bullet, an ‘eCheck’ is performed to prove the functionality of the MPC. These tests include turning all lights ‘on’ and allowing the vision system to compare this image with the previous ‘lamps off’ image to prove that lamps are working. The GDO, Intrusion Sensor, microphone, Moonroof, Park Aid and SRX are also tested, by manually activating them. A green ‘bullet’ confirms the correct operation of all items and this allows the operator to proceed to the first full vision check. At this point the cameras switch to a larger aperture so that their color sensitivity is greater, to allow the color of the unit, grab handles and visors to be confirmed, also that grab handles are correctly placed front and rear. Once all green ‘bullets’ are lit, a pass stamp is attached to the B Side and the operator knows that the Head Liner is ready to be shipped to the Jaguar plant.

Camera issues

The entire assembly/test process including the workstations and tables are under PLC control. Once triggered, the four cameras capture a full image of the headliner in less than 5 mS, with each camera ‘responsible’ for one quadrant.

As with all camera-based inspection systems, good illumination is extremely important. In the JCA installation, three fluorescent strips, interspersed by the four cameras, illuminate the work piece from above. These strips are high-frequency fluorescents to give best color sensitivity and to avoid interference ‘flicker’ lines developing in the image (the camera and strips operate at 50Hz and 60Hz respectively), which would affect threshold counts and distort the results.  Further benefits of high-frequency strips are that they reach working temperature much faster and they tend to fail immediately, which avoids slowly deteriorating image captures.

Programming the cameras to look for the hundreds of combinations of product was straightforward because of the simple, spreadsheet approach use in configuring each Cognex Insight vision sensor.   “It’s just a matter of specifying step-by-step what you want each system to do,” says Bradburn. “For position and orientation tests you mark the area you want using the relevant on-screen tool and then you configure the parameters needed to identify that shape or its content. The Cognex approach makes this very easy.  For the color tests, you need to be sure that the system can distinguish that color from any others it may encounter - which requires some experimentation - but after that’s done it’s straightforward to ’see’ the wrong color items and flag them as mistakes.”  Bradburn expects to refine the tests continuously to make this even more effective over time - which is easily done because of the simple programming technique.

As each set of images is captured for analysis, it is transmitted over the factory Ethernet network to a dedicated server, where it is stored for future use.  “This means that we now have 100% traceability,” says Bradburn,” so if any quality concerns arise we can go back to the captured images of the headliner to confirm root cause. Similarly, we can use the archive to double-check on any production issues.”

Configuration issues

Each camera is equipped with Cognex’s full library of image processing and grey-scale analysis tools, including PatFind®, a supertool for locating parts.  Programming is done from a remote operator station using a ’spreadsheet’ approach that enables each step in the vision process to be specified in a simple way.  Combining the flexibility of a programming language with point-and-click simplicity, the vision spreadsheet enables the right tool to be selected for each part of the process. To make life even easier, the vision spreadsheet is transparent, so the image of the part being checked is visible during set up. This allows the user to see vision tools being applied to the image without having to switch between screens.

Parameters are chosen from drop-down menus, and the results of each test are automatically inserted into adjacent ‘cells’ in the spreadsheet. Cells can easily be linked together to perform required tasks, making ‘proof of concept’ prototyping much faster and enabling applications to be modified ‘on the fly’ during product changeovers. The interface also provides context-sensitive help in various languages.

“Machine vision operations are based on data,” says Cognex, “and spreadsheets offer one of the most robust, efficient means of working with large data sets. Also, spreadsheets can include hundreds of specialized functions, options and operations, ranging from advanced mathematics to annotated graphics. Therefore, they have a great deal of built-in capability. Spreadsheets also provide a familiar work environment, which helps minimize the learning curve for inexperienced users and eliminates the need to learn a programming language.”

Quality control and inspection for head-up displays

Cognex ensures long-term customer satisfaction and cost-efficient quality control for BMW in Munich

BMW clients expect the best and demand the most accurate equipment when buying a car from the Munich based manufacturer. Increased demand for a “head-up display”, (HUD), meant that BMW needed to find a quality control system for their HUDs. This system would need to cope with the speed of their production line while maintaining high safety standards.

Quality control for HUDs at the facilities of the automobile manufacturer BMW, is presently installed on the production-lines of the 5- and 6-series, and is an example of the most performing industrial image processing.

A new perspective for BMW drivers

The advantages of a HUD as an option in a car have created a rapid increase in demand. The HUD is a driver information device, developed and produced by Siemens VDO Automotive. The image-producing unit of the head-up display projects a virtual image onto the windscreen by means of an array of optical mirror systems. The displayed image is projected in the viewing field of the driver at a distance of about 2m. The driver can therefore perceive all important information regarding the vehicle and navigation within his normal field of viewing. In this way, the driver has optimal access to information with minimum disruption of concentration.

If the HUD is even slightly misaligned, this will interfere with the driver’s perception of the surrounding environment such street markings, vertical lines of houses, or garage entry.

Image Quality: The decisive criterion

That is why the imaging quality of the projected display in the vehicle is the decisive criterion for acceptance of the HUD by the user. Automobile manufacturer BMW in Munich was concerned with the introduction of a head-up display as an optional equipment feature for the new car types of the 5- and 6-series. For this purpose, the department for Technical Integration at the Research- and Innovation Center of BMW in Munich needed a precise quality control suitable for industrial use. The fact that up to this point there was no appropriate quality control system based on image processing available meant the objective was to develop an absolutely new product within a very tight time frame.

A completely new solution

Measuring methods for the control of imaging quality of HUDs had previously been developed in the laboratory, but there was still a long way to go to reach a solution for the production process. These studies provided important target specifications for the preparation of the system design for this quality assurance project. To add to the technical constraints, this quality control system would have to cope with the interaction of the windscreen and the projection of the HUD installed in the vehicle. Even minor defects in a completely assembled vehicle would not be tolerated at the end of the assembly line.

On the basis of the system design specifications, BMW’s “Technical Integration”-division (hereafter referred to as “TI”) contacted several suppliers of machine vision systems seeking a solution based on image processing which would work with the required quality assurance system of the head-up display. In mid 2002, they decided to work with Gefasoft GmbH, a Partner System Integrator (PSI) of Cognex. Their system solution demonstrated an advanced approach which convinced those responsible  at BMW.

Timing and traceability

Measurement parameters had to be determined and then checked quickly and efficiently without interrupting production.  The timing frequency of the production line determined the time available for testing, and the complete testing system for the head-up display had to, of course, prove financially viable by functioning within a predefined time-frame and coping with the corresponding numbers of vehicles. The testing system had to be suitable for both left-side and right-hand steering.  An additional requirement meant that the testing system of the HUD also would need to be fully traceable and embedded into the information infrastructure of the entire corporate network.

Precise and impartial

Ultimately, the testing system of the HUD has to provide an objective result regarding quality, evaluating and assessing with much greater precision and reliability than the user. It was already clear in the feasibility study and during project planning, that this could only be handled with a PC-based high performance image processing system. Efficient hardware was required, and the algorithms of the vision software would be demanded to function with utmost reliability and precision.

No jams or standstills are tolerated on BMW’s two-shift assembly lines. The complete image acquisition- and- evaluation process of 50 acquired test images must be completed within a time-frame of less than two minutes.

The complete testing-equipment has to be swung into the vehicle as production is in progress, positioned exactly, secured in place, and then needs to be removed from the vehicle again. This means a time-slot of approximately 30 seconds for image acquisition and image processing calculations in the test-cycle.

Cognex PC based vision systems: the highest degree of reliability

The wide range of visual qualities of the projected virtual images make the evaluation of the images considerably more difficult. Image processing cannot however be a cause for error in quality control under changing environmental production conditions. This includes, among other issues, the problem-subject “contrast of displays” under varying conditions of illumination.

Vision-tools from the CVL (Cognex Vision Library) proved to be of great advantage. They provide interactive access to different programming levels, in-depth vision-software, including an option for a more precise detail-optimization. That is enabled the final solution –the selection of the tools, parameterization, linking and detail optimization –to be completed with a higher degree of safety and within a shorter development time.

Reliable detection in difficult conditions

Cognex vision tools perform to the highest of standards without compromising accuracy or safety. The most important individual features in the object image, such as edges, measurements, shapes, angles, bends and shades, are specifically and separately identified. The spatial conditions and relations between these central features of the acquired image are compared with the real-time image. The position of the object is then precisely determined according to this information.

Certain features can therefore be recognized at a considerably higher level of reliability, precision and speed. The influences of changing conditions of illumination and contrast are eliminated by a simultaneous investigation of the contour and the structure of the object image. These qualities proved to be of advantage in the detection of deformations and distortions of the HUDs. The functional safety of the vision tools also satisfied standards specified by BMW, which required it to be above 99%.

Meeting high standards

The image processing system must fulfill certain standards at BMW, and Cognex has for many years been among the suppliers who meet these requirements. The only real issue of interest is the reliable operation of the complete system. A stand-alone system could not be permitted on a globally parameterized production system. The most important issue for those working at the plant was that the image processing be fully and reliably integrated into the plant diagnosis system.

Long term traceability for customer satisfaction

The cooperation with Gefasoft proved to be of great benefit; the enterprise contributed greatly to the solution thanks to their flexibility and their capacity to react quickly within a limited schedule.  By 2004, the first head-up display testing systems were installed. The positive results of the operation resulted in the head-up display testing systems also being installed in the normal series production in the factory at Dingolfing. Today, approximately a dozen HUD testing systems are in operation for BMW around-the-clock, ensuring the faultless quality of the HUDs. The test results are stored in a database in the central server, thus providing for total traceability. The test-images are archived, and in case of customer requests, the flawless condition of the product at the time of delivery can be proven, even years later.

Inspection of 2D matrix marked codes

Complete traceability ensures long term satisfaction for Siemens automotive clients

Siemens cannot afford any uncertainty when it comes to production for their high profile automobile clients. Safety and quality control has become of the utmost importance in this industry. This means that complete traceability of each individual part is essential. For the production of fuel pumps at the Asnières (France) production plant, Siemens chose Technifor to ensure this traceability using direct part marking (DPM) on the body of each gasoline pump. Siemens is using Cognex In-Sight vision systems all along the production line to read and inspect directly marked codes at each point of production.

Siemens VDO is a leading international automotive supplier of electronics and mechatronics. As a development partner within the automobile industry, they manufacture a comprehensive range of products relating to engine management electronics and fuel injection. For the production of two different kinds of gasoline pumps, Siemens needs to ensure each one is marked with 2 different codes. The position of the codes must be verified and the codes need to be read correctly so that each piece is recorded as having been appropriately marked and checked in a data base as it passes each check point on the production line.

“100% read”
There are two assembly lines. One assembly line uses an alloy material for the body and the second assembly line uses stainless steel. The two bodies are marked with both an alphanumeric and a Datamatix code and must be entirely readable in order to verified before the result is recorded.

Each body needs to be marked using two codes. One alphanumeric and the other Datamatrix so that each piece is identifiable by means of a unique code. Once the codes are marked the pieces undergo a series of checks and controls on the production line. At each stage the code needs to be verified and read. Firstly the codes are verified to ensure their positioning is accurate. Secondly the code is read in order to check that it is legible. This is vital. The code needs to be correctly positioned on the body of the part in question, a part which may be defective or difficult to manipulate. Plus, this same part needs to be correctly read and identified in order to avoid any disruption to the production line. Clients demand a standard of “zero non-read” which means no piece can get through as not having been read. Even one “non-read” piece would necessitate a manual intervention which would not only compromise the “white room” environment but would also slow down the production flow.

Technical constraints
Technifor was entrusted with the mission of marking and reading the codes during the production of each gasoline pump. They decided to use the direct part marking process of “dot peening”. This is an direct impact marking process used to mark codes onto hard or metal surfaces. The surface of the pumps were either stainless steel or aluminum and so these different surface textures increased the challenge. Added to this is the environmental aspect in that production would have to be carried out under “white room” conditions. The reading and verification of codes in these circumstances requires a robust and high performing solution.

Long term traceability
A final need of the client demanded that each production check be recorded so that at each control point an accurate trace is kept on each pump in question. These details are automatically entered into a database which is integrated into the client’s operations. For example the point of inspection which ensures the pump is water-tight. Here the code is verified by the camera, read by the camera and the fact that it has been inspected at this precise point is recorded and the result is fed into the data base.

Solution
The nature of the technical constraints and the challenging circumstances of the application meant that machine vision was the only solution. Cognex In-Sight cameras proved the only reliable means for code verification and reading as well as being capable of cooperating with the data collection process. In-Sight vision systems are high performing even in difficult environments. The constraints of this application required robust vision sensors. The marking process involved is extremely effective and chosen for its durability. The nature of marking by peening requires a high performing vision solution capable of reading 100% of the codes while coping with low contrast and surface reflection difficulties.

Traceability and verification in production of automotive parts

Cabi, Italy: Identification and quality control, Cognex has all the answers

Identification and quality control, Cognex has all the answers

For the production of engine motors, Italian automotive manufacturer Cabi cannot take any chances when it comes to part safety and quality control for their high profile automobile clients. These criteria have become of the utmost importance in this industry meaning that complete traceability of each part is essential. Cabi chose Technifor to ensure this traceability using direct part marking (DPM) on the surface of each product. Cabi is using Cognex Checker and In-Sight vision systems to eliminate the risk of errors in the production process as well as to read and inspect directly marked codes at each point of production.

High profile: high standards

Cabi’s production site has different work areas. Each work area is dedicated to a different client. Each piece has a specific graphical symbol identifying the client. This means the production process is error-proofed from the word go. In addition to client identification, a 2D code ensures traceability of each single part.

This 2 tier identification is initially performed by Checker™ for symbol detection and then by In-Sight® for code verification and reading. Checker, the innovative vision sensor is used to detect the presence of each symbol before the part is marked using laser with a 2D code. Cabi had never used vision sensors before. Previous systems proved incapable of verifying the code or even checking for its presence and thus, the company sought the advice of Technifor and Cognex.

Technifor was entrusted with the mission of marking and reading the codes during the production of each motor. They used a laser marking process to mark 2D codes onto the surface of each part. The reading and verification of these kinds of codes in high speed, industrial circumstances requires a robust and high-performing solution. Cognex In-Sight vision sensors are deployed at the point where each code needs to be read, verified and recorded. Each production inspection is recorded so that at each control point, an accurate trace is kept on each part. These details are automatically entered into a database which is integrated into the client’s operations. The fact that the code has been read, verified and inspected at this point is recorded with the result being fed into the database.

Multi-tasking: Cognex vision solutions handle all kinds of constraints

The nature of the manufacturing environment and the challenging circumstances of the application meant that machine vision was the only solution. Checker is used to check for the presence of the symbol on each part thus ensuring that the correct part is marked with the correct code. Checker is an innovative and cost efficient new sensor from Cognex providing a new approach to error detection in production. This application required robust vision systems owing to the technical constraints of marking by laser. This process is extremely effective and chosen for its durability yet requires a high performing vision solution capable of reading 100% of the codes while coping with low contrast and surface reflection difficulties.

Cognex In-Sight cameras with ID Max software proved the only reliable means for code verification and reading as well as being capable of cooperating with the data collection process. In-Sight vision sensors are high performing even in the most difficult environments. Advanced software tools are capable of reading 1D,2D,RSS, CS and DataMatrix codes regardless of print quality or surface characteristics. ID Max, the code reading feature on in-Sight ID readers can handle low and poorly formed codes as well as read, track and verify.

Competitive technology: machine vision error-proofs Cabi’s production process

Cabi is able to respond to the demands of their clients thanks to the capabilities of Cognex vision sensors. Each part leaving Cabi is traceable from « cradle to grave » ensured by Technifor « mark and read » relying on Cognex vision systems. Cabi can now assure their clients that the entire process of production is controlled, inspected and recorded from start to finish. They can also prove that each piece is completely traceable and has been correctly inspected. By taking advantage of the best of advanced technology Cabi is ensuring they maintain a competitive edge and pass the benefits onto their clients.

Production inspection upgrade for defect elimination

Vision system solutions boost flexibility for robotic “pick and place” application

Engelhard Technologie, Germany, a global manufacturer of soot particle filters for the automotive industry use In-Sight vision sensors for greater efficiency on their production lines.

Engelhard Technologie GmbH use robots to handle materials during production at their Nienburg plant. To optimise the manufacturing of soot particle filters for the automotive industry, they followed the advice of their robot supplier; Staübli ,to consider vision systems from global specialist Cognex. By December the vision system was in place. Thanks to the efficient development environment of the In-Sight Explorer, the ‘pick-and-place’ vision guided robotic solution was up and running in less than four weeks.

Vision = accuracy = an efficient robot application
Immediately after firing, the ceramic filters are automatically forwarded to a conveyor and then to the robot cell. The soot filter product variants differ only very slightly from each other, but still need to be handled reliably by the vision system.

The In-Sight 5100 vision sensor used in the robot cell must recognise each individual shape amongst the 25 different filter variants and also determine their exact position. These angles are provided to the robot as precise data and must be accurate as the reading of the 2D codes takes place at the same point. A great advantage for this application was were the vision tools integrated into In-Sight as part of the PatMax software. These tools operate using geometry-oriented object recognition. This allowed a target of 99.9 % accuracy to be set.

The accuracy of the position data as supplied by the In-Sight vision sensor guides the robot. The selected ceramic filters are then placed by the robot onto the conveyor belt and they are forwarded to packaging.

Fast, flexible configuration
Thomas Wente of Engelhard Technologie GmbH, responsible for project execution, said: “We considered it to be very important to be able to execute projects quickly and reliably, yet we wanted to be able to perform any necessary changes to the process ourselves.”

Easy configuration, installation and organisation of the In-Sight vision system helps to speed up project realisation and brings a greater flexibility to project work, as well as bringing about a faster response capability in any process adaptation.

Color detection using vision
It was also possible to master additional control tasks such as packing the soot filters. By using an In-Sight 5100C colour vision sensor it is possible to verify the presence of a green quality label on each filter and whether the cardboard box contains the prescribed number of parts. By continuously checking the number of packed parts and by comparing the number actually produced it is possible to determine the amount of rejects/loss. The support of Cognex experts at the production line itself made it possible to implement the control task in only two days demonstrating once again the benefit of a simple operator interface.

A scalable development environment
From the beginning, additional applications of the vision system had been planned for the production lines. The user-friendly working platform based on the Windows environment enabled a time-saving, application-specific solution for the vision tasks to be completed. Work was begun straight away using the In-Sight Explorer development environment which saved initial set-up time and costs. The staff learnt very quickly how to use the In-Sight Explorer thus reducing vision development time while providing a basis for functional system flexibility and integration into the company’s production network. Another In-Sight has been integrated into the existing robot cell and two further vision sensors control the second and latest robot cell to be installed

Cognex ID Readers – the right mix for complete part traceability

By deploying the DataMan 7500, DataMan 100 ID Readers as well as the In-Sight 5110 vision systems from Cognex, Borg Warner Turbo Systems in Germany took the quality control of their turbocharger production in a new direction. When they implemented a traceability project with a principal objective of using Cognex ID Readers – the DataMan 7500 and the DataMan 100 - to identify the individual code on a component they were able to create seamless traceability through the production process and beyond.

Tracking 3.5 million products…
Some 3.5 million turbochargers a year leave the BorgWarner Turbo Systems production plant every year. More than 2,000 staff look after products, markets and development. In early 2006, an innovative team of specialists first launched their data traceability project with the aim of tracking data using core assembly coding. The core assembly is the first production state of the turbocharger and it is to this that all remaining components are fitted.  Turbochargers are the small power stations which have advanced the diesel engine more than almost any other technology, especially in cars. Being exposed to temperatures of up to 1050 °C and pressures of up to three bar, perfect production quality is essential.  One of the project objectives was to use Cognex ID Readers – the DataMan 7500 and the DataMan 100 - to identify the individual code on a component. After several test runs, it was decided to use an adhesive label with a 2D matrix code printed on it so components could be coded quickly and easily. Also - the code can easily be read, even when dirty.

Cost saving traceability
From the first steps of assembling parts to the final inspection, all important production parameters are detected, inspected and the results stored in the central database at BorgWarner for further processing. This not only minimizes errors in production, but if defects were subsequently detected, the data biography of the turbocharger reconstructs the production conditions preventing any future disputes arising from claims by automotive manufacturers and limiting the investigation to a minimal number of items. The constant validation of these steps using data already collected from prior steps likewise contributes to error prevention, making the data traceability system a proactive tool. This represents an enormous cost saving to the automotive supplier.

Read every code at any stage…
A PC is installed at every workstation and at each one, operators use the DataMan 7500 to scan the code. The data created can then be accurately assigned to the current core assembly.  The data system specifies working steps and inspection criteria and once work is complete, decides whether to approve the component.  At another point, the DataMan 100 inspects the operational balance to ensure that the turbocharger is guaranteed to run concentrically.

… even in tough production conditions
Finally the turbo charger rating plates are marked with a Data Matrix code in accordance with the customer classification.  Within a fraction of a second, a Cognex In-Sight 5110 tests the Data Matrix code for code quality so that even after the adhesive labels have been destroyed by thermal action during production, the setting and assembly values detected can still be linked to the turbo charger number via the database years after it was manufactured.

Reading and verification of codes

Automotive parts : signed, sealed and delivered with 100% traceability

Being one of the biggest constructers and suppliers of automotive parts, Borg Warner cannot afford to make mistakes. They needed to guarantee the quality of a new high added value component and to be able to trace the product from cradle to grave.

They decided to turn to Cognex whose vision sensors already figure on many of their production lines and machines. The resulting project was directed by Alema Automation, a Cognex Partner System Integrator (PSI) for the south west of France.

The challenge: Each piece needs to be marked, the precision and quality of the marking needs to be verified. Finally, it needs to be confirmed that each piece has gone through the necessary quality and safety controls before being delivered.
The solution: VisionPro from Cognex along with the In-Sight 5110, Cognex Partner Product ESO’CR from Esox, another Cognex PSI as well as micro percussion marking machines from Technifor, another trusted partner of Cognex.

Marked for Life
Once off the production line each piece is marked with micro percussion: 2 lines of alphanumerical characters indicating the product reference, the batch number, the team identity and the manufacturing date.

Following this a first vision station consisting of an 8500 card and VisionPro (the library of vision tools from Cognex), reads the characters thanks to the software ESO’CR. The information is then transferred to a Technifor engraver who converts them to Datamatrix and this code is marked on the other side of the piece. The ESO’CR software has proved to be of added value to the automobile industry. It has allowed us to stay within our budget and our time frame.” Explained Olivier Skalinski, project leader at Alema.

In order to avoid any error and to guarantee the staying power of the marking, an In-Sight 5110, installed beside the micro percussion machine, verifies the content and the quality of the marking.

How can you be sure that each piece has been inspected?
Once marked, the piece then undergoes a series of hydraulic testing with 8 points of inspection. Once out of the testing phase, the piece then passes to a second In-Sight 5110 vision station where it needs to be established that the piece has successfully undergone all the necessary tests. Not an easy task.

Reliable reading regardless of the environment
The pieces that arrive at the second vision post may be dry and clean or they may still be oily from the testing process. Despite the fact that the lighting and legibility conditions are completely different to those of the first reading station, the In-Sight 5110 is perfectly capable of reading the code on each piece without any extra configuration.

Alema was also obliged to take up another challenge: ensure that the In-Sight can communicate with the factory data base containing the results of the testing phase. Alema developed a unique interface with this in mind enabling In-Sight to deliver a verdict for each piece: suitable (or not) for delivery.

Faulty pieces which are reparable are sent back to be fixed while the pieces that have been successfully checked and verified are directed to the packaging zone. For maximum security, Alema has installed a third In-Sight 5110 system at the entrance to the packaging area, which performs a final check and verification of the piece.

Record timing
The application has been developed and installed by Alema in record time: 2 days to confirm that the system worked correctly on prototype pieces, then one week to install at the factory site, including personnel training in use and maintenance.

A winning combination
The robustness of the In-Sight vision sensors, their ability to cope with environmental changes in lighting and position allowed for the same material to be used on different work posts and also allowed Borg Warner to greatly reduce the amount of spare part stock kept at hand.

Another benefit, was the commitment of Alema Automation to the project in its entirety, (reading, marking and verification) thus avoiding any conflicts of interest between different suppliers.

“Thanks to the comprehensive nature of the Cognex solution and to their partner network, we have a high performance, cost-effective solution at our disposal” concluded Stéphane Laval at Borg Warner..

Following the success of this solution, Borg Warner aims to adapt other production lines and deploy the same solution in order to optimise this traceability throughout their production processes.