Projects

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.

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.

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 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.

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.

When individual components of a multitool cutting tool are fed in, the senswork camera system detects the position and rotation in a flexfeeder feed. Pick candidates are automatically recognized on the Flexfeeder surface on the basis of differently illuminated individual images and the position data is transmitted to the robot. The standard system has been expanded to include additional dark field lighting for reliable detection of the flipped position of all components.

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.

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.

There are many dimensional data on saw blades that ultimately determine the cutting quality and service life. For the inspection of diamond saw blades, senswork, together with the company Plattner, has equipped a measuring station with a double-head laser scanner system, which measures and records all tooth geometries, blade width, cutting width, angularity, and diameter during the run.

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.

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.

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.

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.

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.

Our cameras precisely detect the position and angular position of the elements so that assembly elements can be precisely joined in switching elements of electric stoves. The measured data is transferred to a production line with several robots.

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.

In a fully automated handling system with a 6-axis robot, a 3D laser scanner captures components in flight. The robot presents three components per second to the scanner. This records the component geometry in 3D and measures a recess on the component at several positions.

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.