SICK solution for flexible plastic parts inspection for Automotive Suppliers

In an automatic testing unit, a 3D smart camera combined with an encoder enables flexible quality checking of a wide range of different plastic parts.

Challenge

Industry:
Automotive Suppliers

The Czech company Provys specializes in the construction of specialist machines for the automobile and electro-technical industries. The customer AKT requested the development of an inspection system which could check a variety of plastic parts, such as lock covers for cars, for a wide range of different characteristics. Due to the complex nature and variety of inspection tasks – eight part types, each with more than 20 inspection characteristics – the solution needed to be flexible and adaptable. The contrast conditions – black parts against a black background – provided a further challenge for the inspection process. The final aim was to create a solution which could write the measurement values and records of the parts inspections in LOG files so that the production and inspection data for individual parts could be accessed at any time.

Application Solution
For this task, Provys developed an inspection system in which a SICK 3D smart camera (IVC-3D) is moved over the test objects by a linear motor. The smart camera scans the test objects with its integrated laser-optic system and generates a profile section. Connected to the camera is an encoder (DRS60) which adds the exact position for each profile section, so that the camera can generate a complete, high-precision 3D image of the test object. The 3D camera uses the recorded data to determine – unaffected by surface colors and contrast – which of the part-specific inspection characteristics programmed into the system are present and which are absent. Both the smart camera and the encoder can be parameterized, meaning that Provys can adapt this entire highly-flexible system to new inspection characteristics at any time.

Benefits
The 3D smart camera solution inspects parts with high precision and availability. It is ideal for Provys, as it requires only one camera and no extra lighting, due to the built-in laser sensor. The user-friendly camera is also efficient and flexible, and can be independently adapted to new parts or characteristics. Provys procured the 3D smart camera and programmable encoder from a single source, so they are perfectly tuned to each other. The inspection measurements and records are documented, so production and inspection data can be retrieved for the end customer at any time.

This is an application from SICK.
Tri-Phase Automation is a SICK distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote

Quality check of bottle caps

Avoid unplanned production stops by inspection every cap after capping

Caps of containers with liquid detergents have to be verified on correct capping. A cap that is not correctly placed on a container can lead to production issues downstream in the production. More over bad capping can lead to quality problems. A SICK vision sensor verifies the capping process.

Application Solution
The Inspector is an intelligent vision solution in an easy-to-use sensor package.

This is an application from SICK.
Tri-Phase Automation is a SICK distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote

Checking contents of boxes using IVC-3D

At a chocolate manufacturer, the shape, height, number and position of packaged chocolates must be verified. Three-dimensional inspection is required to check all of these features simultaneously.

Application Solution
The SICK IVC-3D Smart Camera is a reliable solution for the type of product verification involved in this application. It is the first system in the world that combines the flexibility of intelligent cameras and the performance of high-speed 3D verification in a robust industrial application. The IVC-3D, which requires only a PC or a laptop for setup, operates either autonomously or as part of a production network. Once an object is checked, the information can be sent directly to a PLC or a handling device and monitored over Ethernet.

Benefit
The IVC-3D provides fast, reliable inspection of the chocolates. It can read 5,000 profiles per second at a height resolution of 0.4 mm and inspects 3 boxes per second. It is easy to program and integrate, and provides a contrast-independent check. As a result, complaints and expensive returns can be drastically reduced.

This is an application from SICK.
Tri-Phase Automation is a SICK distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote

 

Cookie shape verification and quality control

Customers expect to find properly shaped, whole cookies in the package!

Customers expect to find properly shaped, whole cookies in the package. Wrong size cookies can cause packaging problems in production. This makes it important to verify the cookies during the production process. A cost-efficient way to ensure a high and consistent quality is to automatically measure each cookie, and automatically reject faulty ones.

As the cookies enter the packaging line, they pass by the IVC-3D camera. It records the 3D shape (correct diameter, height and volume) at high speed and that the cookies have no dents as the baked cookies pass by on the conveyor. Faulty cookies are rejected and the measured values are communicated to a control system for fine tuning the process and to save statistics.

Benefit
Satisfied customers – only top quality cookies delivered.

This is an application from SICK. Tri-Phase Automation is a SICK distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote

Blister package and chamber inspection

Vacuum-leak testing and machine vision merge using Cognex In-Sight® vision system.

cognex-pti_screen

The purpose of the system designed by Packaging Technologies & Inspection is to test the integrity of blister packs. Prior to the configuration of the system, they were required to use one of two destructive test methods: dye penetration or strictly vacuum-leak.

By combining vacuum-leak testing with In-Sight 5400, they have achieved a single nondestructive-test method. The system is designed so that the vacuum-leak test will locate any flawed blister packs. Once they are selected, the In-sight system captures an image of the package.

From this one image, In-Sight is able to identify which specific blister chamber is flawed and evaluate the quality of the rest of the package.

Read the full story: Blister package and chamber inspection