Inspection (AI)

Pad printing is considered one of the main methods for printing on parts. However, during this printing process, various defects can occur...

In an industrial bakery, rolls, pancakes, donuts, and bagels are produced on an automated production line. After coming out of the oven, these baked goods must be removed from the conveyor belt and placed in boxes by a robot. At the same time, the degree of browning of each item must be assessed to ensure quality.

The quantity of screws required for battery pack assembly is stored in a bunker feed system  and fed from there to the screwing systems accordingly. For smooth production, it is important that misaligned screws are detected by the sensor and only those in the correct position are fed to the screwing system.

In automated automobile production, it is important to check whether the correct fuel hoses and clamps have been installed. The components are to be checked with the aid of a vision sensor.

In automobile manufacturing, the switches on the dashboard vary depending on the vehicle model.
To ensure that the correct switches have been installed in the correct vehicle, a vision sensor should carry out a type check.

In many applications, connector harnesses with colour-coded pin positions are used to make electrical connections between different components.

During the assembly and production of electronic parts, connectors must be attached to printed circuit boards, and wires or cables are inserted in the connectors. The aim of the application is to check whether a connector has been fully inserted into the socket.

During final product control, it is to be checked that the products have a uniform appearance. The aim of the application is to guarantee the correct position of adhesive labels on packaging so that the products appear identical on the sales shelf.

During final product control it is checked that the products are correctly sealed. The aim of this application is to check that closures are fully sealed so that products cannot leak during transport. 

Test tubes must never be mixed up in laboratory automation. The aim of the application is to check the color of test tube lids in a carrier and send the results to the control system to avoid mix ups. 

After harvest, oranges and other citrus fruits go through several processing steps before reaching the market or end consumers. One important step is the precise control of spray nozzles for chemical treatment. This protective coating is essential for extending the shelf life of the oranges and preventing premature spoilage. To ensure the preservation agent is applied in exactly the right amount, the oranges must be counted and their surface distribution measured on the conveyor. A vision sensor is required to reliably perform both tasks.

The labeling of the battery pack requires the manual application of safety and identification stickers. Incorrect or inaccurately positioned labels could lead to misinterpretation or misuse of the battery pack, necessitating label verification.

In wire harness production, new cables are attached to existing ones using adhesive tape. These connection points must be consistently detected by sensors throughout the cable manufacturing process.

On many PCBs, thermal paste ensures optimal heat transfer between electronic components and a heat sink. Incorrect application of thermal paste can lead to damage to the components. To prevent this risk, a camera should check the thermal paste for presence, position and correct geometry.

When manufacturing ball bearings, it is vital to know that the bearing has the full number of balls. The aim of the application is to inspect a ball bearing after assembly to ensure it is complete.

Regardless of whether the wiring is automated or manual, it is necessary to check the connector latches. Improperly latched connectors can trigger a subsequent defect and cannot be corrected due to the battery pack design.

During assembly, it is frequently necessary to align two metal sheets as close as possible in the joining process in order to guarantee a good weld seam. The aim of the application is to determine the gap between two metal sheets and to transfer the measured value to the control system. 

Punched, milled or cut holes in metal sheets are checked for dimensional accuracy during assembly. 

High precision is of utmost importance during the application of lubricant. However slight irregularities may occasionally occur, which can compromise the production process. It is therefore important to detect potential errors at an early stage.

Pad printing is considered one of the main methods for printing on parts. However, during this printing process, various defects can occur...

Inside the battery pack there are wiring harnesses which need to be fixed with fastening clips. Failure to engage the clamps correctly can result in damage to the cables or rattling noises during subsequent driving operation.

During the assembly, packaging and production processes in different sectors, parts must be collected from trays for individual work steps. 

In automotive manufacturing, small fasteners secure components, such as attaching the door side trim to a car door. Missing fasteners can cause parts to loosen, so it’s essential to confirm that all are present and in place before assembly.

The protection of external electrical connections and coolant lines requires the manual application of protective caps. Without protective caps, accidental contact with high-voltage connections or damage as well as contamination may occur, so their presence must be monitored.

When assembling vehicles, sheet metal parts and / or plastic parts must be connected to one another. These are often assembled with clips which the parts are screwed or plugged together.

The importance of quality assurance in plastic processing is continually increasing. Industries such as medical technology and the automotive sector require 100% product inspection. Defects including over/underfills or burrs not only affect the aesthetics and functionality of the end products but can also lead to increased costs due to waste/scrap or rework. Inspecting parts using a vision sensor allows for the early and reliable detection of these defects, ensuring product quality.

Almost every electrical component has plug connections with pins. During production, these pins can be bent or incorrectly positioned due to various influences, such as mechanical stress. This can lead to damage to the component. Therefore, careful inspection of the pins for early detection of possible damage is important.

The necessity of quality control in plastics processing is increasing. Defects like overmolding/underfilling or burrs not only impact the appearance and performance of end products but can also escalate costs due to waste or rework. Utilizing a vision sensor for part inspection enables early and dependable detection of such flaws, ensuring product quality. 
Displaying inspection results, defect classifications, and part numbers in real time optimizes production.

Throughout the production process, a large quantity of data is generated that has to be monitored and checked. The operator must be able to consult, manage and evaluate this data easily in order to identify and implement any necessary modifications to the process.