Projects

The gap between contact surfaces plays a major role in connector assemblies. The distance between the individual contact surfaces is measured to an accuracy of 0.01 mm. For this purpose, the test parts are brought into the VisionUnit. The plug is clamped via a clamping mechanism and light diffusers are simultaneously delivered to the assembly, which display the gap between the contact surfaces in high contrast. A high-resolution camera in conjunction with telecentric optics then measures the gap between the individual contacts.

Manufacturers of connector components are confronted with ever increasing demands on the precision of the plug connections and their compactness. The ZFokus from senswork makes full use of its advantages in the coplanarity inspection of SMD assemblies and in the pin height check.

In order to obtain maximum flexibility with regard to the most varied connector types for manual connector inspection at a manual test station, we use our powerful VisionUnits from senswork with variable focus adjustment. The focus variation is made possible via a 30 mm servo axis, which can be controlled either via a PLC or directly via the camera program.

Enormous quantities of battery cases are produced every day in battery production for e-cars. Our camera system checks the battery case holder for possible damage, breaks and cases that have not been removed in order to be able to secure the subsequent fully automatic refitting.

With the manual mounting of assembly groups in particular, it often happens that individual components are missing or the precision of the assembly does not meet the specifications. An end-of-line test system from senswork checks the correct assembly and alignment of individual components.

In high-frequency technology, the quality of the installed coaxial cables, especially in the connection area of the cables, plays a major role in the subsequent signal quality. The measuring system developed by senswork records the inner conductor tip three-dimensionally, and is thus able to precisely measure the spatial deflection of the tip as well as the protrusion from the outer conductor shield.

Numerous errors can occur in the manufacture of soaps, and while the human eye can recognize that immediately, the way they look can vary widely. A multi-camera system consisting of incident light, transmitted light and 3D inspection reliably detects all defect features.

A robot performs mechanical post-processing on cast parts fully automatically. To do this, the robot must know the rotational position of the component to within a few tenths of a degree before the machining process. Only through a specially developed dark field lighting with a correspondingly large diameter could the relevant features for detection be reliably mapped. A Cognex In-Sight smart camera system then determines the rotational position using an edge-based pattern search and forwards this to the robot controller.

After the painting process of synthetic parts, they are subjected to a fully automatic surface inspection by a shape-from-shading system before further processing. This method allows the smallest surface defects such as paint pimples, scratches, inclusions, lint or other raised or recessed defects to be reliably detected. For this, our system uses eight lighting directions with eight partial images, which are offset by Shape from Shading to form a height map of the surface.

The cables are 10 km long and tow large ships across the ocean to discover new oil deposits. A defective cable can cause millions in damage if it causes a ship to abandon its business. senswork image processing takes care of this. Even during production, a line camera is swiveled radially around the seam, creating a development of the weld seam. In the camera image generated in this way, the smallest defects in the weld seam are visualized and recognized in good time.

The transmitted light assembly designed for this application measures just 2 mm in material thickness on the illuminated surface. This allows the lighting to dip behind the welding spoons to be measured and to capture and measure their position in an extremely stable manner in transmitted light. We use an In-Sight smart camera system from Cognex as the camera system.

This double-head inspection system checks cutting contacts from two directions at the same time by means of cleverly deflected beam paths. The beam path is deflected in such a way that both the interlacing of the contact elements with one another and the gap size can be detected at the same time. A 3D portal system positions this VisionUnit above the contact elements. This VisionUnit saves a complex and wear-prone mechanical test.