Visual Inspection Machines Quality Control

Machine vision is a manufacturing sector that is growing very rapidly. Growth drivers feel that there is a need for the integration of industry intent and vision. It is because of this that new vision techniques have emerged and this has led to the creation of incredible opportunities for all types of businesses.

It’s never easy to explain machine vision, especially to people who have never heard of it before, sometimes it takes a professional to clarify it. Some things that need to be understood include embedded vision, hyper-spectral imaging, and artificial intelligence. This is an aspect that can help us better understand machine vision.

Industries Covered

Visual inspection machines are required for different industries. This includes:

Military tools
automotive industry
Printing
Pharmacy and medical
Machine
Precision hardware
plastic industry
Electronics and semiconductors
Packaging
Mining and metal
Silicone or rubber components
Products Covered
Visual inspection system manufacturers handle different parts and they include smart cameras, smart sensors, machine vision cameras, compact vision cameras, lighting, frame grips, software systems, lenses, accessories and services.

Application of Visual Inspection Engine

The visual inspection system is able to combine high preliminary vision processing with the best technology to solve various types of quality control, identification and automatic inspection problems. They include:

Measuring Inspection

There are several good visual systems to offer dimensionally and measurement-accurate examination results.

Color Match

There are vision systems capable of providing enhanced color and image processing offerings. This kind of system provides precision in terms of quality.

Pattern recognition

The system is perfect for arbitrary logo, feature, shape and pattern recognition.

Types of Pre-Processing Inspection

This is a very important aspect of the visual inspection engine. This is the capacity to preprocess the image. This means that the system can actually manipulate the captured image to produce better enhancement and contrast before the image is processed.

Attendance Verification

This type of system provides reliable and high-speed options for checking the shape, completeness, position, size and presence of different features. This is important in verifying packaged goods, assemblies and spare parts.

Surface Inspection

The integrated visual inspection engine must be able to pinpoint inclusions, discoloration, cracks, scratches, and contamination at very high speeds. For this reason, quality control is in order and in the end; You can achieve the most superior product.

Manufacturers need these systems to maintain the highest standards in terms of the quality of their finished products, sub-assemblies and components. It is always important to use advanced and automated machines and quality control systems. There are so many new generation leading options in the market today and they are better in many ways. It’s always a good thing to find something that’s efficient, faster, and something that the experts integrate.

Industrial Robotics

Industrial robots complete tasks such as painting, welding, assembly and product inspection with speed and precision. They don’t tire like humans and perform repetitive actions reliably without getting bored, which leads to high productivity at low costs. These attributes make industrial robots invaluable to manufacturers in many industries.

Some industrial robots perform repetitive actions without variation, as in typical ‘pick and place’ applications. These actions are determined by programmed routines that determine the direction, speed, acceleration, deceleration, and distance of a coordinated series of movements.

Other robots use machine vision systems to perform complex tasks, such as weld inspection and optimization in the automotive industry. This usually involves complex actions and sequences of movements, which the robot itself may even have to identify.

Machine vision systems comprise high-resolution cameras linked to powerful image processing software. They make for efficient handling and control, and work without wear and tear even under demanding manufacturing conditions. Machine vision systems achieve high success rates, and ensure smooth production without manual intervention or supervision, even in unpleasant environmental conditions.

Machine vision has a wide range of applications in industrial automation:

2D Robot Vision

2D vision systems use line-scan or area-scan cameras to capture photographic images that contain width and length, but no depth. By processing these images, they measure the visible characteristics of an object, and feed robotic handling systems data on its position, rotational orientation, and type.

The automotive industry uses 2D vision systems to pick heavy gearboxes from cages, unload cylinder heads from wire mesh boxes, identify axle castings, and detect the position of slide bearing shells.

Automated 3D Position Detection

3D vision systems detect the position and shape of an object in three dimensions using specialised cameras and lasers. They determine the starting point, overall length and rotation of a component, and transmit this data to industrial robots for fast and efficient handling. 3D vision systems enable the automated, reliable handling of different sized objects.

A common application for 3D vision systems is the production of crankshaft castings in the automotive industry, where they instruct robots to position castings ready for the next stage of assembly.

Assembly Inspection

Proper part assembly is essential to any manufacturing process. Poorly assembled parts lead to malfunctioning, unsafe products. Machine vision systems equipped with fast, fixed focus cameras and LED illumination continuously inspect parts during assembly to verify the presence of characteristic features, and instruct robots to remove defect items from the production line.

Characteristic features include screws, pins, fuses, and other electrical components. Machine vision systems also check for missing slots or holes, which can prevent proper assembly. Inspection takes just seconds, even with a huge variety of different parts, allowing manufacturers to maintain high levels of efficiency and productivity.

Machine vision systems for assembly inspection have a wide range of applications. These include checking vehicle components in the automotive industry, verifying fill levels in blisters, chocolate trays, and powder compacts, and ensuring correct label positioning on boxes.

Contour Inspection

Machine vision systems for contour inspection examine the profile of an object using high-resolution cameras and 3D sensors to ensure it is free from deviations (e.g. chips), which affect the shape and thus the function of the product. They also check measurements such as length, width, and radius to ensure they are within set parameters.

Pharmaceutical companies use machine vision systems in automated production lines to inspect injection needles, which are unusable if blunt or bent. Multiple cameras photograph needles as they flow through the system on powered conveyors. Sophisticated computer software analyses the captured images to determine needle sharpness and check the contour of the tube. Industrial robots use this information to separate and discard defect needles.

Injection needles’ size makes them almost impossible to inspect with a naked eye. Machine vision systems can inspect 40 needles per minute with 100% accuracy, speeding up production and reducing costs. Other contour inspection applications include concentricity checks of spark plugs for petrol engines, the measurement of coating structures on capacitor foils, and tooth inspection of saw blades.

3D Seam Inspection

Poorly welded components break, causing products to fail. In the case of automobiles and aeroplanes, this often has disastrous consequences and costs lives. Robotic weld seam inspection and optimization is now the standard in many industries.

Machine vision systems for weld inspection comprise a sensor mounted on a robotic arm. A laser in the sensor projects a line of light across the surface of a component joint, a technique known as laser triangulation. At the same time, a high-speed camera, also housed in the sensor, captures an image of the line as an elevation profile. Through the relative motion of the component and the sensor, the system builds a 3D image of the welded seam surface.

Using this image, a computer checks the seam’s consistency along its length. It accurately detects imperfections like profile variations and pores, which weaken the joint, and instructs a robotic burner to rework or repair seams if necessary.

Machine vision systems store inspection results in a database along with serial numbers, which makes components easy to trace. They work on multiple seams of different types, shapes and sizes, and operate at high speed. The automotive industry uses automated weld inspection and optimization systems extensively to ensure vehicles are of high quality and safe to drive.

 

Balancing Machine

A balancing machine is a device used to establish and maintain the proper tension of a rotating machine. It is capable of performing tasks through rotation of individual parts as well as sensor detection.

Most balancing machines have a set of solid bases along with bearings and suspension. Most of these machines are also capable of balancing different parts such as rotors for electric motors, turbines, disc drives, fans, pumps, and also propellers.

The use of a balancing machine is quite simple. You should place items that need to be straightened directly onto the bearing either mechanically or manually. Then the unit is rotated using air-drive, end-drive, and also belt-drive. The item then vibrates during rotation. The vibration will make the sensors installed in the machine know the condition of the unbalanced unit. In addition, it can determine the number of shifts required to establish balance. In addition, it can also pinpoint where the load is needed to balance or where the load should be placed.

There are many types of balancing machines available. Two common types are soft bearing and hard bearing machines. Both differ in terms of suspension. Generally, hard-bearing balance machines require the use of lower frequencies to be more durable and flexible. This type of machine is ideal for use with objects of various weights.

On the other hand, soft-bearing machines require higher frequencies so they are less flexible. They require a new calibration for each use. Generally, they are used to balance items with the right properties. Although more time consuming, they are ideal for use for high production jobs.

You can also find vertical balancing machines. They are used primarily to calculate the balance of how far an item can move away from a geometric center in a standing position. Blade balancing machine is also available. It is mainly used to prevent additional correction for some items such as fans, turbines and propellers.

Furthermore, for instruments that are not easily disassembled, a portable balance machine would be ideal for use. Through displacement sensors mounted on the part, they can measure vibrations during operation. Then, they will identify the parts that need to be balanced.