Cognex DataMan Reader for Comprehensive Tracking of Vacuum Pumps

Detection Content

Difficult-to-read Data Matrix codes on laser-etched direct part marking (DPM) data for tracking parts.



Solution

Cognex DataMan readers achieve 100% tracking of laser-etched DPM codes.

Cognex DataMan Reader Features

 Provides top-notch reading rates, including for the most challenging two-dimensional DPM codes.

 

In most automobiles and light vehicles, the vacuum brake servo (brake booster) provides assistance to the driver by reducing the effort required for braking. The vacuum pump is a critical component of this system, and even minor defects can result in non-compliance with the strict quality requirements of manufacturing these systems. Zeltwanger Automation GmbH, near Tubingen, Germany, assembles and tests 400,000 pumps each year, distributing measurement data to each pump. This data is provided by a laser-etched Data Matrix code on each product, which is read by a Cognex DataMan reader. The reader decodes the information and transmits the data to the factory network, enabling full tracking of the parts.

Ensuring Brake Performance

Each vacuum pump takes 40 seconds to complete a full rotation on Zeltwanger's assembly and testing unit's rotary step table. The testing unit automatically screws on the cover and tests the pump's sealing properties. Once it confirms that all seals are properly installed and intact, the pump is connected to a servo-controlled drive unit for testing. The vacuum pump undergoes torque and pressure measurements in various speed ranges, oil pressure tests, and oil flow velocity tests at operating temperatures. If all testing steps pass, a laser marking system applies a plain text Data Matrix code containing measurement values, a serial number, and manufacturing date.

Data Adds Convincing Proof

In the next step, the DataMan reader scans the newly laser-etched Data Matrix code and ensures that it is read reliably and accurately at a 100% success rate, outputting all test values. This step ensures that the measurement values can be accurately associated with each product and its lifecycle.

The DataMan reader guarantees that all necessary data from the previous testing steps is present in the code and readable. If all information is identifiable and the part passes, the vacuum pump proceeds to the next stage. If the information is inaccurate, the part is rejected, and an operator pastes a label indicating that it requires further correction.

Standard Performance

Adding test values to the Data Matrix and ensuring their readability and storage for tracking purposes not only enhances Zeltwanger Automation GmbH's confidence but also improves process reliability. The DataMan reader, in a compact housing, features lighting equipment, an imaging device, and a processor with industrial connectivity. Even in harsh and limited space environments, the DataMan reader provides a high and accurate read rate for two-dimensional DPM (direct part marking) Data Matrix codes.

In subsequent process steps, Zeltwanger's new assembly and testing unit sends the data contained in the Data Matrix code to a gateway computer with two network cards. This allows the unit's operation to be separated from the customer's network. In the event of error messages, Zeltwanger's service personnel can intervene directly through a remote server, bypassing the customer's system and reducing downtime.