Projects

Plug connections have to be manufactured precisely so that the pins fit on the board during assembly. With the virtual connector gauge from senswork, the smallest deviations can be recorded before damage occurs. 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. In order for this to work perfectly, the connector pins must fit perfectly on the circuit board or in the socket.

When producing clay bricks, it is critical to ensure the dimensional accuracy of all the bricks being made. This prevents bricks from leaving the factory beyond the manufacturing tolerances and, under certain circumstances, costly return transport from the construction site. For the reliable detection of defects, senswork has developed the BrickChecker, which can be seamlessly integrated into an existing production line.

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

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.

In order to check the quality of screw caps on filled soup glasses after filling, senswork now offers a 360 ° camera inspection system, which allows a view of the surface of the cap in a picture through a specially developed mirror deflection. With up to 6 glasses per second, the quality of the lid surface is ensured and checked for damage and freedom from scratches.

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.

With 18 images at different positions and focal planes on the component, our camera system checks a connector assembly on the front and back at the same time. With a resolution of only 8 µm / pixel and the stitching tool specially developed by senswork for this purpose, the images are joined together before the actual evaluation and combined into an extremely high-resolution overall image.

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.

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 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.

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.

In a labeling machine, the product labels are applied with up to 20 applications per second. An incorrectly inserted type of label or incorrectly applied labels can mean recalling entire batches or laborious re-labeling as long as the error is noticed in good time. senswork barcode scanning systems provide a remedy here: Our barcode technology based on Cognex Dataman reads up to 20 barcodes per second effortlessly and with absolute reliability.

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.

As part of a fully automated production, one and the same system should have various connector geometries such as connector strips, Fakra plugs or other HF plugs 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.

Manufacturers of connector components are confronted with ever increasing demands on the precision of the connectors and their compactness in order to meet the functional requirements for high-frequency, digital data. The quality of connector components must be 100 percent guaranteed. The coplanarity test of SMD assemblies or the pin height test are two applications that are exemplarily solved with the ZFokus.

Using the example of the soldering point inspection, ZFokus allows the determination of the soldering volume, the detection of gaps in the soldering point and the evaluation of the shape of a soldering point. ZFokus shows its strengths wherever 2D systems today when evaluating soldered joints, due to fluctuating contrast variances, produce excessive pseudo rejects or cannot reliably detect defect features.

In order to obtain maximum flexibility with regard to the most varied of connector types for manual connector testing at a manual test station, senswork offers correspondingly powerful VisionUnits 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 subsequent process in the manufacture of airbag assemblies, it is important to fully automatically recognize bore features in a wide variety of component types and to pass the positions on to a robot based on a reference coordinate system. An intelligent combination of dark field lighting and senswork circle detection algorithms supports this process in production to 100%.

In the battery production for e-cars, enormous quantities of battery cases are produced every day. 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. A mirror system enables the best possible perspective of the trays as the trays pass through. Sections of the trays are recorded and evaluated at 10 images per second.

Before the individual components of an automotive assembly are assembled later, they are charged with lubricating grease in an automated production line. Here it is important to ensure that the amount of lubricant is applied sufficiently and precisely. With a smart combination of lighting and filters, senswork was able to create an unbeatable contrast between the lubricant and the background, thus guaranteeing a very stable evaluation.

With the manual assembly of assemblies 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 inspection system from senswork uses a high-resolution color camera to check the correct assembly and alignment of individual components, thus ensuring 100% product quality for delivery.

So that assembly elements can be precisely joined in switching elements of electric cookers, the position and rotation of an assembly must be known very precisely. In an automated production line with several robots, our cameras recognize the position and angular position of the elements with an accuracy of 0.01 mm or 0.2 degrees and transmit the measured data to the robot system.

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

In the production of soaps, especially in large quantities, numerous errors can occur which the human eye can recognize immediately, but which can be very different in their representation. Only a well thought-out multi-camera configuration from senswork consisting of incident light, transmitted light and 3D inspection recognizes all defect features that influence the product quality. A total of 6 cameras with 18 images per second check 100% for all types of errors in a fully automatic handling system.

In a fully automated handling system with a 6-axis robot, a 3D laser scanner from senswork captures components almost in flight. The robot presents 3 components per second to the scanner. This records the component geometry in 3D and measures a recess on the component at several positions. With an accuracy of <0.1 mm, the product quality can be ensured in large quantities.

A robot carries out 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.

Using a 4-fold laser scanner setup, metal rods are checked for correct surface and geometric tolerances. With a 3D calibration, the laser scanners deliver 3D data sets in the same calibrated coordinate system. This method can also be applied to continuous materials. The measuring system is used to measure metal rods and to check the surface for flaws. It is moved over the rod at a speed of up to 100 mm / second.

After the painting process of plastic parts, they are subjected to a fully automatic surface inspection by a shape from shading system before further processing. This method enables even the smallest surface defects such as paint pimples, scratches, bullet holes, lint or other raised or recessed defects to be reliably detected. For this, our system uses a total of 8 lighting directions with correspondingly 8 partial images, which are offset by shape from shading to form a height map of the surface.

In this system, Euro pallets are fed via a roller conveyor belt to a robot system, which automatically removes the sack layers and places them on a longitudinal conveyor belt. Using a time of flight camera from senswork, the positions of the plastic bags are recognized fully automatically and transferred to the robot coordinate system. The recognition accuracy of the system is +/- 10 mm, and thus allows precise pick-up by the suction gripper mounted on the robot.

These 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 parts fed in by a vibrating conveyor bowl are removed from the feed line by a Scara robot and placed in a moving tray. Our camera technology controls the rotational position of the parts in the feeder, the position of the moving tray and the correct placement of the products in the tray. Three tasks - one camera - made by senswork.

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 extremely stable in transmitted light. We use an In-Sight smart camera system from Cognex as the camera system.

100% inline testing of seven-segment modules in production. After the injection molding process, the parts to be tested 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.

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 interlocking 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 by senswork above the contact elements. This VisionUnit saves a complex and wear-prone mechanical test.

A 360° panoramic endoscope is used to examine the inside of an aluminum body for processing marks and surface defects such as cavities and pores. Our system uses Deep Learning tools to check cylindrical inner surfaces in several height sections for irregularities in the surface.

Chocolate is difficult to describe completely with a rule-based algorithm, since no two chocolates are identical. The individual chocolates have a high natural range of variation.

The individual elements of a first aid kit must be identified through a transparent packaging. Since the packaging reflects light, the individual components of the packaging are difficult to recognize.

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.

Varying opacity and bubbles in the liquid create a very inconsistent background in the bottle. The imprinted date and batch codes are difficult to recognize for ordinary image processing. ViDi Read can read letters accurately under a wide range of light and background conditions.

Different liquids create inconsistent backgrounds under the transparent bottle. Plastic seams and difficult reflection angles pose another challenge. ViDi Read can accurately read letters under diverse light and background conditions.

An inhomogeneous topology, different shades and the changing shape of the tortilla make the detection of cracks or wrinkles extremely difficult. ViDi Detect can distinguish between tolerable deviations and defects by training on a reference set of approximately 100 different tortilla samples.

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.

The transparency of glass vials makes it difficult to distinguish breakage from dirt along the front or back. Rule-based image processing reaches its limits here. ViDi Detect can accurately distinguish the variation of natural parts from anomalies by performing a reference set of good parts under varying light conditions and amounts of dirt.

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.

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.
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