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.

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.

Quality control and assembly verification for automotive lines using Vision Sensors

Cognex vision standard solution on automotive assembly lines

For ThyssenKrupp Krause GmbH based in Bremen, Germany , a company competing on a global scale, using vision to optimise quality control throughout the production line creates key advantages in terms of quality and cost-efficiency.

The company has a successful track record as a supplier of complex automation technology developing and manufacturing assembly lines for the automotive industry. Thyssen knew they would have to create an added value on their production lines in order to satisfy their customers and maintain global success. They decided to turn to vision technology. Why did they choose Cognex as their supplier?

Quality comes first: a chain is only as strong as its weakest link
The automotive industry and its suppliers have strict requirements with respect to the reliability, cost-efficiency and quality of production facilities. If recommending the integration of technologies such as vision to the production line from the start, ThyssenKrupp needs to be sure that the quality control they are deploying down the line is 100% reliable. The result is an optimised quality assurance system throughout the assembly line (Integrated Quality Assurance, IQA) which integrates relevant company communication and database management. Based on the idea that “a chain is only as strong as its weakest link”, the IQA requirements are very strict.

Vision technology has become a central element of the quality assurance system and an important factor in the optimisation of different production steps.
When choosing a vision supplier ThyssenKrupp Krause wanted to satisfy 3 major criteria:
-100% reliable vision tools and algorithms
-User-friendly operation and installation
-Quality, global technical support

Cognex vision: the global solution
When they chose Cognex, the company found a globally-oriented partner who was able to meet these requirements far more effectively than any competitors. “This company has already installed hundreds of thousands of systems throughout the world, is extremely experienced and offers an highly efficient international support program”, notes Dr. Trittin, who was involved in the decision to select Cognex as a supplier.

Six years of successful vision solutions and more to come
Between 2001 and the end of 2006, more than 320 vision sensors from the In-Sight product family and around 24 PC-based systems with VisionPro were integrated at the Bremen site. In 2007 alone, the Bremen site will have installed a total of 120 In-Sight sensors. For example, several in-Sight vision sensors are placed on robotic arms on the assembly line in order to verify engine motor assembly.

Why does this company place so much trust in one single supplier of vision sensors?

A vision solution for any application in challenging industrial environments
Complex production lines demand a wide range of vision tasks to be reliably carried out. These tasks are largely concerned with quality control. The working environment can prove challenging and so robust vision systems that could withstand variable lighting conditions or a dusty atmosphere were required. Cognex can supply a reliable vision solution for almost any task based on their library of vision tools including powerful software such as PatMax™. PatMax is integrated into both the new In-Sight vision sensors and PC-based VisionPro systems. PatMax uses the basic geometric structures of objects such as edges, dimensions, shapes, angles, curves and shading to localise them. By analysing the geometrical data of features and their spatial relationship to each other Patmax can define the position of an object while coping with changes in the position, orientation or scale. Other Cognex vision tools are based on this technology including PatInspect™ , PatFlex™ and OCVMax™ - a system for advanced character verification. This base of proven, precision tools are part of a range of Cognex products guaranteeing advantages that are easy for the customers of ThyssenKrupp Krause to understand.

Product-focused flexibility
ThyssenKrupp needs be able to accommodate the wide variety of different product models manufactured by their customers. Therefore the vision system must also be flexible. The company maintains an in-house vision laboratory where staff produce feasibility studies and develop solutions for difficult tasks that require advanced vision applications. Throughout the process chain, all vision applications are connected as part of the quality assurance system allowing requirements for complete traceability to be met. Product traceability is, however, only one part of the quality management system. 2D code readers are used on a production line to trace which part was installed while other readers are used to determine the correct part for assembly. For example, injection pumps of a particular kind are matched to the corresponding injection nozzle control module. This prevents production errors further down the production line.

Ease-of use
Staff at the plant are not machine vision experts. The vision systems must therefore be easy to operate. Cognex applications and their parameters can be easily adapted by means of simple set-up. The development environment is intuitive and the vision tools are integrated with the production controllers. The In-Sight Explorer development environment is a reliable, convenient solution for programming networks of vision sensors and integrating them into the automation process and into company communications. The fact that they communicate via an integrated Ethernet interface makes them easy to use and is familiar ground for users.

A global network
Customers of ThyssenKrupp Krause are based all over the world and may also have subsidiaries in different countries. It is not uncommon to have a system integrator working on site. As a result, the global aspect and easy integration of the vision system supplier is critical. Cognex has a diverse network of system integrators based all around the world adding security to a customer investment and ensuring the same vision hardware and software products are used everywhere. Components can be replaced at any time improving flexibility and cost-efficiency.

Building on vision success: next stop – aircraft assembly
Cognex vision products are now standard offerings on all assembly lines delivered to customers. Thanks to their experience in developing complete production lines with IQA for the automotive industry ThyssenKrupp Krause now intends to use its expertise and technical capabilities in other industries. For a year, the company has been working on projects for the aviation industry with the aim of developing production lines for the complete assembly of aircraft segments. The integration of a quality management system and the corresponding organisational structures are also important factors. The company has also developed and produced complete systems for logistics companies which are able to carry out fully automated unloading of containers.

Defect-free parts in 360 degrees

A demanding market place needs the right vision systems for quality inspection
Meccancotecnica Umbra manufactures seals for pumps for the circulation of the anti-freeze liquid in combustion motors. The production cycle runs at about 3 turns per every 8 hours. The automotive sector is a demanding one. Parts destined for the marketplace need to be 100% without defect and capable of standing up to difficult working environments. Meccanotecnica Umbra realised that they needed a reliable and confirmed quality control solution for the inspection of their parts while in the production phase. After trying various vision suppliers they finally found the solution they needed in the In-Sight 5000 range from Cognex.

The search for the right vision solution
In the automotive sector every component must be capable of withstanding difficult environmental conditions (vibrations, variations in temperature, wind, rain, etc.) Generally different types of pump are used which need to support about 3 bars worth of pressure in order to guarantee the perfect workings of the entire vehicle.  So, it makes sense that manufacturers would seek a top of the range quality inspection before the pieces leave the factory floor.  Meccancotecnica Umbra decided to use a vision sensor in order to satisfy the demanding standards of quality required by the market.

Having chosen a particular vision company they started testing vision sensors. After an initial testing phase it was necessary to admit that for various reasons including system limitations and a lack of support from the supplier led to it never getting past the testing phase. The quality inspection of the production cycle was thus continued manually by personnel with all of the limitations this kind of manual inspection can imply.

In-Sight 5400 for the inspection of automotive components
Luckily, soon after, technical experts at Meccancotecnica participated in a Cognex vision seminar and afterward explained their requirements to Cognex asking for a feasibility study for a potential project for quality inspection to check each product passing through their production lines. The solution was developed by TEC, a partner system integrator (PSI) of Cognex for central Italy. The PSI network is specially selected and trained by Cognex to deliver turnkey solutions for vision and identification applications. They proposed they use the In-Sight 5400 from Cognex as well as 2 Cognex In-Sight 5401 readers.

Every seal; depending on the type and the dimension, is made up of 9 components of a different nature such as carbon, steel springs, silicon, etc. which are then mechanically assembled on an automated line.  After the assembly phase, before the pieces are sent to be stacked for distribution, they are sent to 3 different inspection stations.

A 360° inspection in just a few seconds
At the first inspection station, an In-Sight 5400, takes 24 snapshots of each fully rotating piece in only 2 seconds in order to verify the external profile of the seal in a complete 360° inspection.

The second inspection post continues the inspection of the still rotating piece using ten snapshots learned by the camera checking the surfaces of the various parts that make up the seal and verifying their functional aspects.

The third station performs 2 inspections on the seal which is no longer rotating. In the first, the internal part of the same seal is inspected in about 250 milliseconds and in the second, it is checked whether the product is properly stamped with the model number, the lot number, the company logo and the production date. This is done in less then 600 milliseconds.

Quickly installed and easy to use
The application was developed and installed by TEC in record time; in only 20 days it had been confirmed that the system was capable of working correctly on the prototypes. The installation in the factory was done within a week plus the time it took for the training of the personnel in the use and maintenance of the entire system.

In-Sight readers for optimal production inspection
The reliability of the In-Sight vision systems, their capacity to adapt to the varying environmental conditions as well as the powerful vision tools available for Cognex vision sensors allowed TEC to establish a long lasting relationship with the client.  Considering the advantages, Meccanotecnica has already shown their intention to adopt similar solutions to optimise the quality of other productive processes.
About Meccanotecnica
Meccanotecnica Umbra was founded in 1966 and in October 1992 took the legal form of a joint stock company.  Since its conception, its production has been based almost exclusively on the manufacture of mechanical face seals for electro-pumps, initially for home appliances and for diverse and light industrial appliances. A few years later, MTU entered into the automotive field, manufacturing seals for pumps for the circulation of the anti-freeze liquid in combustion motors. The development of the company over time has been characterised by the continuous growth of its production and exports. For several years, the percentage of exports has been around 40% of total revenues, distributed throughout 50 countries, where high-level competitive recognition was attained for the products in an increasingly global market.