Are the products posing challenges due to their various angles, making inspections difficult? To improve product quality, we developed a wire and spring forming visual inspection system.
Probes or photoelectric sensors, which usually focused on "single-point" readings, were used for spring tests in the past. To make the inspection process better, exact measurements will be given by looking at the component. This helps fix the damage that long production runs and uneven feed quality do to equipment. It also means responding quickly to the control unit and checking the equipment's process capabilities and data adjustments all the time.
Improving the number of products made and the general efficiency of processes is crucial in the manufacturing business today. As technology has improved, visual checking systems have become known as an important way to improve the quality of production. Even though these systems help, putting them to use on the production line is still hard considering software and hardware technologies have to work together and be fine-tuned through repeat processes.
Revolutionizing Wire-Forming Inspections with Multi-Camera Technology
With the help of three CCD industrial cameras, it is now possible to check wire-forming processes with different shapes at the same time. With their flexibility, wire-forming tools can make a wide range of products, even distinctive ones. Inspections used to be done with old-fashioned contact probes that could only find a "failure" status at one place on the product. However, before this "failure" point was reached, there were often numerous instances where bending angles, wire dimensions, and form conditions failed to meet the required standards.
Acepillar engineers recommended using CCD cameras for simultaneous multi-angle imaging after performing numerous tests to assure accurate inspection of wire-formed products with complex surfaces and shapes. They additionally integrated the visual inspection system with the MES (Manufacturing Execution System) to collect and analyze relevant data, which allowed for in-line inspection during production and visualization of production quality data. The solution also notifies factory managers in real-time when quality issues develop as a result of consumable usage or equipment breakdowns using a mobile app.
The following are the key inspection points has set for this sample:
Circles' inner and outer diameters:
- Measurement of the inner circle to the left spring.
- Measurement of the outer circle to the left spring.
R-Angles at Different Stages of Spring Folding:
measurements of the angles between the yellow lines and distances between the blue lines.
R-Angles at Different Stages of Spring Folding:
Angles between the yellow lines and distances between the blue lines are also measured.
Comprehensive Approach from Planning to Testing
Acepillar was critical in developing a visual inspection system, leveraging their extensive on-site expertise. We identified the optimum solution for the customer's budget and requirements after considerable discussion and engagement with the customer. This approach not only provides a numerical assessment of the process of production, but it also successfully decreases the development costs connected with the visual system, thereby improving total manufacturing efficiency.
From early layout planning conversations about equipment, system, and camera choices to later-stage testing, we carefully attention to every installation detail. We provide a complete solution to satisfy all of your requirements.
