Projects

senwork develops AI-based technology that enables 100% quality assurance of LabDisks or Lab-on-a-Chip designs in the production cycle. High precision manufactured, transparent plastic cartridges can now be recorded in the production cycle with this inspection station and reliably evaluated.

VisionUnit allows Variable Focus Adjustment in the Tightest of Spaces

Cognex In-Sight based VisionUnits by senswork

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.

Virtual Connector Gauge checks Circuit Board Connectors for Pluggability

Reeling Circle Test of Circuit Board

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.

Camera system ensures precise joining process of glass and display

Quality Assurance in Hybrid Bonding

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.

VisionModule from senswork checks correct feeding of microchips in fully automatic system

Ensuring the correct feeding of microchips

Applications in the semiconductor industry require both high-precision, leading-edge technologies and reliable performance characteristics in cleanroom and control test environments. One of the largest manufacturers of semiconductor device handling systems relies on a specially developed VisionUnit from senswork to ensure chip positioning for very small chip sizes with extremely small dimensions.

Triple camera system measures connector assembly from three sides

High precision Measurement of MTD Connector

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.

Fakra connector quality assurance

Fakra Connector Inspection in fully automated Production

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.

High-precision pin inspection of connector assemblies

The Virtual Connector Gauge

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.

The VisionUnit from senswork enables a semi-automatic measurement of connector assemblies

2D-Measuring System for Connector Assemblies

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.

Turnkey inspection device with an automatic focusing device

Pin Inspection of Fakra Connector Assemblies with Press Fits

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.

The prism module from senswork enables a simultaneous view in two directions

High-Precision Joining of Vehicle Displays

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.

Manual Inspection Station withAaxis focusing system for inspection of Fakra connector

Fakra Connector Inspection System

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.

Camera system with variable camera adjustment insepcts the Fakra connector assembly

Turnkey Manual Testing Station

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.

When the resolution alone is no longer enough ...

Manual Test Station with 3-Axis System for Connector Assemblies

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.

VisionUnit with automatic focus adjustment checks USB plugs

USB Connector Inspection on Multiple Focal Planes

With USB connectors there are different contact surfaces on different Z-planes. In order to ensure a sharp view of the contact quality even at high resolution, this VisionUnit records several images on different focal planes in the shortest possible time. The characteristics are calculated across screens in the test program.

VisionUnit inspects connector assemblies in a test machine

Smart Camera with Mirror Deflection

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.

ZFokus - Inspektion von Pressfits an Steckerleisten

Height check with ZFokus

Inspection of Press Fits on Connector Strips

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.

Pluggability Check, Coding and Label Inspection

Inspection of Electronic Assemblies

As part of a fully automated production, one and the same system should test various connector geometries such as connector strips, Fakra connectors or other HF connectors and their labels. Features such as pin positions, wobble circles and coding features are to be checked. As part of the label inspection, textual content is automatically read and compared using OCV, and symbols and graphics are checked for completeness and print quality / legibility.

Contactless Measurement

High Resolution 3D Inline Inspection

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.

Maximum image sharpness for a wide variety of component types

VisionUnit with Manual or Automatic Focus Adjustment

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.

Measurement of the inner conductor tip deflection of coaxial cables

New 3D Method for Inspecting Coaxial Cables

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.

Transmitted light illumination enables reliable testing of component positions

Inspection of Welding Spoons for Position Accuracy

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.

Detecting the smallest defects in injection molding

Surface Inspection of Seven-Segment Displays

100 percent inline testing of seven-segment modules in production. After the injection molding process, the test parts are checked for the smallest inclusions and inhomogeneities in a double nest in transmitted and reflected light. The senswork inspection tool compensates for nest and shape variances fully automatically and thus ensures an extremely reliable inspection.

Connector Inspection with a Mirror and Prism System

Inspection of Cut Contacts on a Connector Assembly

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.

Robust Reading of the Label using Deep Learning based OCR

Reading a Raised Inscription on Smartphone Cases

Varying the font and character size on a non-homogeneous background is very difficult for conventional OCR. With a robust training set, ViDi Read can accurately read letters in a variety of lighting and background conditions.

Error detection with the help of Deep Learning

Quality assurance for LED curcuit boards

A curciut board for LEDs is very complex and can contain a large number of errors. This makes it difficult to describe all the required features of a good part with rule-based image processing. ViDi Detect uses an example-based approach to model the full range of required circuit board features.

Component Placement Inspection using Deep Learning

PCB assembly verification of smartphone boards

Badly positioned, incorrect or bent components on a populated circuit board are difficult to detect with conventional image processing. Using Deep learning, classification and defect detection is much more reliable, even with a low even with a small amount of training data.