Cognex In-Sight smart vision system targets automotive applications

 To ensure complete reliability of automotive parts, automotive parts manufacturers need components to be traceable throughout the entire production process; to meet this challenge, Alber Gussbearbeitungs-GmbH uses two In-Sight smart vision systems from Cognex , used to read the alphanumeric code on rotating disc brakes. In addition, automotive transmission manufacturer Hanwha Tech also uses In-Sight code readers to use its wide viewing angle and high resolution to overcome these difficulties on the assembly line.

Hanwha Tech produces transmissions for Ford Motor Company. Ford needed a more accurate barcode reading solution to increase productivity and achieve zero-defect production at its manufacturing facility in Chongqing, China. The solution was needed to ensure precise assembly and detect missing transmission carrier elements. To meet this challenge, Hanwha TechM has deployed In-Sight barcode readers to successfully achieve the highest read rates, improve productivity and deploy a comprehensive history management system to meet Ford's requirements.
The manufacturing of automotive disc brakes is a challenging process requiring advanced tracking requirements. Alber has developed a fully automated brake disc surface smoothing and testing process that ensures a high-quality product and relieves employees of heavy labor loads. Integrated machine vision uses modern vision systems to provide process vision and reliable alphanumeric character reading (optical character recognition).
Automotive disc brakes weigh approximately 12 to 20 kg (26.5 to 44 lbs). Before Alber adopted Cognex machine vision technology, employees had to repeatedly lift heavy trays from steel boxes and place them on various inspection tables. Performing this strenuous work creates health risks for workers on the production line. This is no longer an issue as the turning and cutting processes and inspection work for downstream surface smoothing operations are fully automated.
To automate this process, automation experts from CNC Automation Wurfel GmbH teamed up with image processing experts from i-mation GmbH to teach the Yaskawa Motom an MH50-35 robot how to view. In addition, an In-Sight vision system is mounted directly on the head of the pliers. With its automated focus, fast image acquisition, and built-in lighting, the fully integrated smart camera identifies the position of a disc brake traveling on a conveyor belt. The camera aligns it with the inner diameter and sends the image data to the robot for control in a fraction of a second, allowing high-performance magnets to quickly clamp the disc.
After clamping the disc brake, the first step is to read the alphanumeric characters. To perform this step, the robot places a disc brake on a rotating disc. Another In-Sight system reads alphanumeric characters and brings them into focus using its integrated red LED light. The high-speed 1K In-Sight line scan imager captures graphical embossed characters during two rotations of the disc brake.
In-Sight vision systems are critical to the successful handling and character reading of rotating parts, not only enhancing the safety of the process but also relieving the labor load on employees performing difficult tasks.
In addition, i-mation uses step-by-step tutorials for all possible variations, making it easier for OCR applications with Cognex's high-performance OCRMax graphics processing tools and user-friendly In-Sight Explorer software.
After reading the alphanumeric characters, surface smoothing and inspection steps are performed, including balance and sound testing. Finally, the robot builds the stacks of individual disks in six stainless steel boxes and then places wooden lids on top. The robot's In-Sight camera locates the exact position with the help of a simple black cross.
The visual inspection system based on the code reader is indispensable for collecting accurate assembly information of each component and managing historical records on the automobile assembly line. The system must be powerful enough to overcome adverse conditions such as oil, dust, humidity, vibration, etc. to obtain accurate code reading. Because these factors have a direct impact on inspection results, they must be considered when implementing a vision system.
In addition, since the automotive transmission carrier includes input, output, and reaction carrier components, direct part marking (DPM) two-dimensional data matrix codes are laser-marked on these components. The QR code contains important information, including batch number, serial number, factory information, production time and date. This code is read by a code reader to check whether the correct components were used during the assembly process and whether history recording and process management were performed. These components can then be managed throughout production, assembly and distribution. Accurate code reading is directly proportional to production efficiency, product quality and a complete history record management system.