Projects

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.

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.

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.

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.

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.

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.

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.

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.

The image documentation system records products in resolutions of up to 25 megapixels and allows products to be identified with an optionally available barcode scanner. An automatic exposure time control ensures that the image quality is always constant. A scripting plug-in also enables user-specific actions to be carried out after the image has been taken.