Projects

Camera systems with telecentric lenses and the corresponding working distance are often too long to be integrated into a machine without space problems. No problem with the Cognex In-Sight based VisionUnit from senswork.

Classic image processing quickly reaches its limits, especially in the area of ​​surface inspection. With the help of the Neuralzye® software from senswork, an AI inspection of transparent strip material has now been implemented, with which the detection of bubbles and inclusions can be detected.

In an automatic circuit board assembly process, a wide variety of circuit board connectors are automatically pressed with the circuit board. In order to ensure that the circuit board connector can be plugged in in advance, our camera system checks the pin geometries of the plug in advance and uses the pin positions to determine whether it can be plugged into the circuit board image.

For the high-volume production of touch displays, current trends are clearly pointing in the direction of hybrid bonding. This combines the advantages of solid and liquid bonding to permanently connect glass and display. To ensure that the alignment of the individual components is precise, senswork offers high-precision camera systems for determining the correct position and rotation.

This project is the first time senswork has implemented the new test equipment concept for highly integrated manual test stations. A high-resolution camera system measures pin positions of an MTD connector assembly, records connector coding and verifies housing dimensions within a tolerance range of 0.1 mm. A color dot spray system marks well-tested components.

Quality assurance is the top priority in the automotive industry. The error tolerances are low. With the ZScan 3D multi-sensor system from senswork, large assemblies made of aluminum or other sheet metal, e.g. oil pans, can be measured three-dimensionally and compared against CAD data.

Fakra connectors are used in automotive electronics for the transmission of signal data such as GSM, GPS or camera data. In order to meet the high quality requirements even in the fully automated production of high volumes, a leading supplier of these products relies on senswork‘s inspection technologies.

Plug connections are essential in electrical engineering. Whether in the smartphone, in the car or in production facilities, they ensure that data or electricity flow from A to B. For this to work flawlessly, the connector pins must fit perfectly on the circuit board. With the virtual connector gauge from senswork, the smallest deviations can be detected before damage occurs.

Today, die-pressed carbons and graphites are used in large quantities to manufacture a wide variety of subcomponents for the automotive industry, such as fuel and water pumps. To ensure that the products leave the production line free of defects, senswork has developed a fully automated system for the quality assurance of such components together with a mechanical engineering company from Rosenheim.

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.

The testing device, which is 100% manufactured by senswork, enables the measurement of Fakra plug assemblies with an accuracy range of ± 0.02 mm. Both the Fakra interface side and the PCB side with press fits are tested with this device. An automatic focusing device ensures that the pins relate to the reference feature with constant image quality. The system is calibrated by a checkerboard calibration with high-precision calibration targets.

For the automatic joining process of display assemblies with a so-called metal carrier, a total of 6 camera units from senswork support the robot in aligning the components with one another. This is made possible by a unique prism module, which guarantees a precise view in two directions for each camera. This makes it possible to compare the reference point of a display with that of the metal carrier in a camera image.

Our semi-automatic test system measures different Fakra connector assemblies for correct coding, wobble circuit as well as pluggability of the PCB side. To check the pluggability, we use our virtual plug gauge, which recognizes the pluggability in a virtual board image based on the given pin positions.

A dual camera system with mirror deflection enables the reading of part numbers on so-called turbocharger guide vanes by means of OCR. For this purpose, two Cognex In-Sight 8000 smart camera systems were integrated into a senswork VisionUnit with mirror deflection.

The turnkey test system consisting of a camera for the PCB side and a camera for the interface side tests a wide variety of Fakra plug assemblies. This is made possible by an adjustable viewing direction of the camera on the interface side and a well thought-out interchangeable set of partial exposures. Good parts are marked with a needle head that is integrated directly into the part receptacles.

For a French automotive supplier, senswork developed and implemented optical control modules for the quality inspection of automotive reversing sensors. Different sensor types are processed in one machine, then packed and stacked in different trays. The modular machine consists of four assembled modules connected by a common control system. A total of seven camera systems are used for optical inspection and defect detection.

In this application, plastic injection molded parts fed by a vibratory conveyor are transferred to a rotating glass plate, where they are inspected by two camera systems. The first of the two systems checks all parts for type accuracy, while system 2 subsequently detects the smallest burrs on the diameter.

With 18 images in different positions and focal planes on the component, our camera system checks a connector assembly on the front and back. With a resolution of 8 µm / pixel and the specially developed stitching tool, the images are joined together and combined into one overall image.

Our camera system inspects automotive labels in a robot cell from a distance of more than 1 m. With a powerful spot lighting, the label can also be illuminated intensively and still homogeneously from this distance. The test program checks texts via OCV, the quality of data matrix codes using AIM-DPM and the quality of printed symbols 100 percent.

With another VisionUnit from senswork with mirror deflection and manual focus adjustment, hundreds of connector assemblies are fully tested every day in an automatic testing machine from Adaptronic. The additional lighting ensures the best lighting conditions for the high-contrast representation of the test features.

An automotive supplier manufactures connector strips for the specialty "autonomous driving". These strips must be extremely precise and should be tested using an inline process. The ZFokus from senswork enables pin heights to be determined with an accuracy of ± 0.01 millimeters.

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.

For a follow-up process in the production of airbag assemblies, it is important to fully automatically recognize bore features on a wide variety of component types and to pass the positions on to a robot. Through an intelligent combination of dark field lighting and senswork circle detection algorithms, this process is 100% supported in production.

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.

Before individual components of an automotive assembly are assembled, they are charged with grease in an automated production line. Here it is important to ensure that the amount of lubricant is applied sufficiently and precisely.

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.

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.

A 360 ° panorama endoscope is used to examine the inside of an aluminum body for processing marks and surface defects such as cavities and pores. Our system checks cylindrical internal surfaces in several height sections using deep learning tools for irregularities in the surface.

Before spark plugs are packed, they are inspected for completeness per layer. The space situation only permits the use of wide-angle optics, which leads to a strong distortion of the perspective. In this case, classic pattern searches can already reach their recognition limits. Using Deep Learning, however, the the inspection works very reliably.

Defects in air filters must be detected on a complex structured surface. Fluctuations in the light reflection make the use of rule-based image processing impossible. ViDi Detect accurately detects errors in the structured area - despite a high natural variance of the air filters.

Stamped metal at different angles of reflection presents a challenge for rule-based image processing: No two features look exactly alike,especially on curved surfaces. ViDi Read can accurately read letters under a wide range of lighting conditions.