Optimised inspection means complete product confidence
Optimised inspection means complete product confidence
When SAT needed to improve quality control and eliminate defects, they turned to Primeconcept, a Cognex vision partner who helped them to deploy DVT vision sensors on their production lines. With fully automated stamping lines and quality control machines –inspection using vision systems for material and for stamped parts is essential.
SAT, an Italian company based in Sicily and in Morocco, has been producing mechanical parts for the automotive industry since 1983. In 1985 the company diversified into producing lead frames for electronic devices for the electronics and automotive industry and in 2007 founded their specialist tool making department. Their speciality knowledge plus their highly trained staff makes SAT a valued, strategic supplier of global industries and their major players. Important international customers with applications in automotive, consumer and telecommunications rely on SAT to supply lead frames, plates for electronic engines, crimps and lugs (used for electrical connectors) and spare parts for stamping tools for design and construction.
SAT can’t afford to disappoint their customers, who have important applications in the automotive, consumer and telecommunications sectors among others and rely upon SAT products to be in perfect condition.
SAT had tried vision systems before. Having experimented with several suppliers, it was only when Primeconcept, a trusted Cognex partner, recommended DVT vision systems from Cognex that they found the solution they were looking for.
Cognex vision systems provided the necessary range of vision tools for SAT’s varied applications. After testing, they found that the Cognex products guaranteed them reliable inspection and solutions at a lower overall cost even when considering installation, system set-up and maintenance.
A reliable, fast solution
Prior to installing Cognex vision sensors, SAT relied on the press operator to carry out the visual inspection. As well as this a statistical control was performed using a profile projector. This last inspection has two disadvantages when compared with using a vision system. Firstly, being statistical, it is time consuming and secondly it uses up valuable human resources.
Inspect surfaces, dimensions, positions while maintaining a high production turnover
DVT cameras are installed along the automated line that is stamping lead frames at a speed of up to 600 strokes per minute. The DVT range provides different models which are used in this application at various points. The DVT cameras, depending on the type of the defect, can manage the scrap of the defective pieces, or in the worst case, stop the line alerting the operator.
The DVT 540 is used to perform all the feasibility study on new products, as well as for dimensional inspection after the stamping tool and before the packaging line.
The DVT 554C is used for inspection of dimension and the positioning of plated areas and the DVT 552C is deployed to ensure there are no oxidation stains or plating blurs.
They are also now capable of performing complete surface inspection of 64 HiQuad lead frames, a complicated package for applications in the automotive industry.
In this application the vision systems treat up to 700 images per minute with a minimum dimension FOV of 14×10.5mm and a maximum dimension FOV of 60×45 mm allowing SAT to maintain their maintain a fast lead frame production line with high turnover dedicated to mass production.
Benefits and results – satisfied customers, optimised resources
SAT has been able to achieve an almost zero rate of rejected pieces while maintaining fast lead frame production. This has meant improved customer relations, reduced customer support. As well as this they have been able to optimise their use of human resources.
About SAT Group
SAT, an Italian company based in Sicily and in Morocco, has been producing mechanical parts for the automotive industry since 1983. In 1985 the company diversified into producing lead frames for electronic devices for the electronics and automotive industry and in 2007 founded their specialist toll making department. Their speciality knowledge plus their highly trained staff makes SAT a valued, strategic supplier of global industries and their major players. Important international customers with applications in automotive, consumer and telecommunications rely on SAT to supply lead frames, plates for electronic engines, crimps and lugs (used for electrical connectors) and spare parts for stamping tools for design and construction.
About Primeconcept
Primeconcept is specialized in hi-tech solutions for industrial automation. We are partner of global leading manufacturers like Cognex, for whom we work as distributor and automation solution provider. Our main commitment consists of offering reliable products and support services to our customers.
We use to give priority to technological innovation, but we only deal with products which may guarantee long-term robustness and availability. At Primeconcept we cooperate with a qualified network of partners and system integrators to supply our customers with tailored turnkey solutions. We base our job on a deep know-how of factory automation processes and expert personnel, able to support our customers during any step of a project deployment, taking special care to minimize time-to-market. Our staff involves both sales and technical engineers with over 20 years collective machine vision experience, especially on Cognex Vision systems.
