Automatice la producción con SensoPart: Ventajas clave para la fabricación automotriz
Los sensores de visión de SensoPart para el procesamiento de imágenes industriales ofrecen ventajas medibles:
- Flexibilidad: Una de las familias de sensores de visión más completas del mercado, adaptable a los requisitos individuales de la industria
- Mayor eficiencia: Minimiza los tiempos de inactividad y maximiza el uso de recursos
- Mejora en la calidad: Detecta errores a tiempo para reducir desperdicio, retrabajo y costosos retrasos
- Conectividad: Integración perfecta con sistemas existentes a través de PROFINET, Ethernet/IP y más
Facilidad de uso: Herramientas impulsadas por IA que simplifican la configuración y operación
Soluciones personalizadas para aplicaciones automotrices
Cada etapa de la fabricación automotriz exige precisión, eficiencia y alta calidad. Con los sensores de visión de SensoPart, usted obtiene la tecnología adecuada para generar un impacto real en su aplicación específica.
Gracias a un hardware robusto y un software intuitivo y fácil de usar, nuestros sensores son fáciles de instalar y mantener, sin importar el nivel de experiencia. La serie VISOR® se integra sin problemas en los sistemas y protocolos utilizados por los principales fabricantes automotrices. Y cuando necesite apoyo, nuestro equipo está disponible con asesoramiento experto y conocimiento técnico. Con SensoPart, cuenta con un socio confiable enfocado en su éxito a largo plazo.
| The power behind your assembly line | pdf, 2.12 MB | download |
Taller de estampado: calidad que toma forma
La calidad constante de las piezas comienza con una supervisión confiable de las herramientas. En el taller de estampado, nuestros sensores ayudan a detectar el desgaste de las herramientas de forma temprana, lo que garantiza procesos estables y una producción de alta calidad, incluso en condiciones de operación exigentes.
Para tareas de identificación desafiantes, la tecnología de obturador global de SensoPart permite una lectura rápida y confiable de códigos, por ejemplo, al leer la nota de entrega. Ya sea que esté escaneando códigos de barras 1D, códigos Data Matrix 2D o texto simple en cajas de transporte, los lectores de códigos VISOR® ofrecen resultados confiables y trazabilidad completa. También están disponibles accesorios opcionales como focos para un rendimiento optimizado en entornos difíciles.
Carrocería: soluciones personalizadas para máxima precisión y estabilidad
Nuestros sensores de visión respaldan los procesos de automatización en la construcción de carrocerías proporcionando datos de posición precisos, minimizando tolerancias y asegurando una producción eficiente y sin errores. Las rutinas automáticas de calibración y mantenimiento reducen los tiempos de inactividad.
Por ejemplo, al leer códigos Data Matrix en piezas metálicas, el VISOR® Code Reader ofrece un rendimiento excepcional, incluso con contrastes de puntos inconsistentes, superficies inclinadas o distancias variables. Funciones avanzadas como filtros de software, captura de imágenes múltiples y opciones de montaje flexibles garantizan altas tasas de lectura de forma constante. Para la manipulación robótica de materiales, el VISOR® Robotic +Z es ideal para retirar con precisión piezas de chapa apiladas desde portacargas. Fácilmente montado en un efector final del robot, combina visión y medición de distancia para ofrecer datos de posición con una precisión menor a un milímetro. Incluso las piezas grandes, reflectantes y con orientación irregular o con alturas de apilamiento variables pueden ser fácilmente tomadas y colocadas.
Taller de pintura: Precisión que salta a la vista
Automatizar los procesos en el taller de pintura garantiza resultados impecables de forma constante. Los sensores de visión de SensoPart monitorean la aplicación y remoción de materiales, detectando incluso los errores más pequeños desde el principio, reduciendo retrabajos costosos y problemas de calidad.
Por ejemplo, el VISOR® Object (AI) detecta de forma confiable los dispositivos de sujeción durante la supervisión de posición, incluso cuando su orientación cambia o varían en forma y color. Garantiza que los componentes críticos estén correctamente posicionados antes de iniciar la pintura, ayudando a prevenir errores en el proceso que puedan afectar la calidad del acabado. Impulsado por inteligencia artificial, el sensor puede configurarse en solo unos pasos, sin necesidad de conocimientos especializados en visión artificial.
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Manejo de materiales: Logística en su máxima expresión
El movimiento fluido de componentes es esencial para mantener la producción en marcha. Los Vehículos Guiados Automáticamente (AGV) desempeñan un papel clave al garantizar que los componentes se identifiquen de forma fiable y se entreguen en el lugar correcto en el momento adecuado.
Nuestra tecnología Target Mark 3D simplifica el reabastecimiento robotizado de los AGV al localizar con precisión tanto el vehículo como la abertura del tanque, sin necesidad de un procesamiento de imágenes complejo. Con la calibración “hand-eye” totalmente automatizada, el sensor VISOR® entrega coordenadas X/Y y datos angulares exactos, sin necesidad de realizar cálculos adicionales en el controlador del robot. Su diseño compacto también permite una integración sencilla directamente en la pinza del robot.
Montaje: Precisión en cada movimento
En entornos de montaje de alta velocidad, incluso pequeños errores pueden provocar retrasos costosos. Nuestros sensores de visión ayudan a evitar confusiones y errores de ensamblaje, garantizando la máxima fiabilidad del proceso. Por ejemplo, en la fijación automatizada de tornillos: en lugar de depender de procesos manuales que consumen mucho tiempo, requieren muchos recursos y son propensos a errores, nuestro sensor VISOR® detecta con precisión la posición de los orificios para tornillos en la carrocería del vehículo y proporciona datos exactos al robot guiado por visión. Diseñado específicamente para la integración robótica, el hardware compacto del VISOR® se adapta directamente a las pinzas del robot. Y gracias a su software intuitivo y fácil de usar, puede integrarse sin problemas con sistemas de robots líderes como KUKA y Universal Robots.
Para el control de bloqueo de conectores durante el montaje, VISOR® Object ofrece una solución potente, automatizando tareas de inspección para evitar fallos eléctricos o mecánicos. Ya sea de forma estacionaria o montado en un robot, proporciona una evaluación de imágenes rápida y fiable en milisegundos, lo que lo convierte en una herramienta flexible y de alto rendimiento para un control e inspección de calidad eficientes.
Proveedores: Calidad confiable desde el inicio
La calidad constante en la cadena de suministro es fundamental; los errores detectados tarde en el proceso pueden aumentar significativamente los costos durante el montaje final. Nuestros sensores de visión ayudan a prevenir estos problemas antes de que ocurran.
Un ejemplo práctico es la verificación de presencia de clips en tableros: nuestros sensores basados en inteligencia artificial detectan de manera confiable incluso clips brillantes o negros y garantizan resultados precisos incluso en condiciones difíciles.
Tren motriz: Innovación para la movilidad del mañana
Automatice la producción de baterías y motores eléctricos para maximizar la eficiencia y la calidad. Nuestros sensores de visión proporcionan datos precisos que elevan su proceso de aseguramiento de calidad.
Cuando se trata de leer códigos Data Matrix en celdas de batería, el VISOR® Code Reader se destaca en condiciones reales de producción. Gracias a múltiples variantes ópticas e interfaces integradas, se adapta fácilmente y lee los códigos con precisión, incluso en superficies cilíndricas, brillantes o de bajo contraste. También maneja grandes volúmenes de códigos de forma rápida y confiable, lo que garantiza una trazabilidad completa, calidad constante y un flujo de producción sin interrupciones en la fabricación de baterías.
Elija el sensor de visión adecuado para sus necesidades de aplicación
Nuestras soluciones de automatización confiables y de vanguardia se integran perfectamente con sus sistemas existentes. Confíe en nuestra experiencia para preparar sus líneas de producción para el futuro y mantenerse por delante de las demandas del mañana.
Explore aplicaciones reales en la industria automotriz
Los siguientes ejemplos de aplicación demuestran los usos prácticos de nuestros productos.
Filter application examples
41 Application examples match your search criteria
Automated assembly of electrical plug connections
The modules installed in the high-voltage battery must be electrically connected to each other, and the connectors must be applied accurately to avoid damage.
Automated bolting of the upper housing part
The upper part of the housing must be screwed to the lower part of the housing. To do this, the sensor must detect the position of the screw holes in the housing top.
Check of the correct feeding of screws in the right position
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.
Check the right type of fuel filler necks
In automobile production, different vehicle variants are manufactured on one and the same production line. In order to ensure that the correct type of
tank nozzle has been installed in the correct vehicle, a vision sensor should carry out a type check.
Check the right type of fuel hoses and clips
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.
Check the right type of switches on the dashboard
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.
Comparing Plain Text and DMC-Codes
In modern production facilities, where traceability and quality control are essential, reading OCR and DMC codes on components plays a key role. These codes are used not only for identification, but also to ensure complete traceability of products and components throughout complex manufacturing processes. A reliable vision system must not only recognize OCR and DMC codes, but also compare them against each other.
Control of safety and identification labels
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.
Detection and Control of Thermal Paste on Printed Circuit Boards
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.
Detection of the screws in the feeder
The quantity of screws required for battery pack assembly is stored in a bunker feed system and fed from there to the screwing systems individually. For subsequent control of the correct position of the screws , they must be detected at a specific position in the feed system in order to provide a trigger signal.
Determining the stacking height of housing parts
For further processing, stacked housing parts must be removed from a material container and placed in the correct position. This requires determining the current stack height in order to use it to align the robot gripper, including the cameras mounted on it, at the correct working distance for determining the position.
Effortless Traceability: Displaying code contents, texts,
In modern manufacturing, the need for seamless component traceability (Track-and-Trace) continues to grow. Data Matrix Codes (DMCs) have emerged as one of the most reliable methods for identification and traceability. The goal is to scan the Data Matrix Code on each component, guaranteeing precise product processing and flawless serial number management.
Fast, Easy Code Reading in Just a Few Clicks - No Expertise Needed
Every day, countless packages are shipped around the world. To ensure each one can be tracked reliably, shipping labels must be read accurately, often containing barcodes, QR codes, or DataMatrix codes. A vision sensor is used to automatically identify and decode these labels. However, proper setup is required before the sensor can perform this task effectively, and this setup process is often the first obstacle.
Filling quantity monitoring of the screw supply
A large number of screws are processed during the assembly of a battery pack. Bunker feed systems are used to stock these screws. In order to avoid an interruption in production, it is important to be informed in good time that screws need to be replenished.
Handling Door Seals in Automotive Manufacturing
In car door seal production seals of various lengths must be handled with precision. To ensure correct placement, each seal is guided along a conveyor belt. During transport, the end of the seal must be detected so the conveyor can stop at the exact position for the next step. An optical sensor is required to identify the end of the seal in continuous operation and send a signal to the conveyor belt to stop at the correct position. Once the seal is correctly positioned, it can move on to the next production step.
Identification by means of directly marked codes
Each component installed in a battery pack usually has a directly marked code on it. Before the components are installed in the housing bottom part, this code must be read out and transmitted to the higher-level control system for subsequent tracking.
Inserting battery modules into the housing bottom part
In order for the robot gripper to be able to insert the components into the lower part of the housing, contactless position detection of the housing bottom part is necessary.
Locking check of the connections
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.
Measuring a gap between two metal sheets
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.
Position control of car body parts
Painting is an important step in automobile production, which not only fulfills aesthetic but also functional aspects. In this step, the body of the vehicle is coated with paint. An important part of the overall process is the position control of the various body parts after drying with the help of an optical sensor. To do this, all car body components such as the bonnet, trunk lid, and doors must be closed in order to move on to the next step, the assembly.
Position control of the fastening clips of cable harnesses
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.
Position detection for automated bolting
The battery modules must be screwed into the lower part of the housing. The screw holes are usually located under mechanical devices, which in turn have an opening. The sensor is to be used to detect the position of the screw holes underneath.
Position detection for removal of the upper housing part
In order to close the battery pack, the housing top must be removed from a material container using a gantry or articulated-arm robot. To do this, it is first necessary to determine the position of the component in the container without contact.
Position detection of the lower housing part in the material container
The base of a battery pack is the housing bottom part, which is first removed from a material container by a gantry or articulated-arm robot. For his purpose, it is necessary to determine the position of the component without contact.
Position determination for the removal of battery modules
Several components, such as battery modules, are installed in a battery pack. To remove the individual battery modules, their position in the material container must be determined without contact.
Positioning of sniffer lances for leak testing
Leak testing is one of the last production steps of a battery pack. So-called sniffer lances must be precisely guided to specific positions for the gas check.
Precise handling of large components with robots and VISOR®
In the automotive industry, it is often necessary to automate the movement of large objects, such as sheet metal, for car body construction. The precise detection of the X and Y position of the component using a vision sensor is critical to ensure a precise gripping process for the robot.
Presence Check of Clips on Automotive Body Parts
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.
Presence check of protective caps
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.
Presence of clips on sheet metal parts
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.
Reading DOT codes on vehicle windows
Vehicle windows must be identified during production and mounting processes to avoid mix-ups with similar windows. The aim of the application is that a window is clearly identified by means of a DOT code.
Reading dot-peened data matrix codes on sheet metal parts
In production, components, e.g. sheet metal parts, must be identified. During assembly processes, there is a risk of mixing up similar components. The identification of an incorrect part after installation can have costly consequences
Reading of lasered datamatrix codes on sheet metal parts
In production, components must be identified. There is a risk of confusion between similar components during assembly. High costs can be incurred if the wrong component is identified after installation.
Reading the delivery note
In order to guarantee the traceability of the components installed in a battery pack, the codes on the delivery notes attached to the transport boxes are read with a sensor. The contents can consist of one-dimensional barcodes, two-dimensional data matrix codes or plain text.
Reliable Pin Position Control of Electrical Connectors
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.
Robot-assisted refueling of AGVs (with Target Mark 3D)
Utilizing robotic assistance, AGVs can be automatically refueled or recharged. The robot will dock the charging system or fuel port to the AGV, streamlining the process.
Robotic assembly on AGVs (with Target Mark 3D)
A robot is tasked with performing various processing steps on a battery pack, which is transported into the processing cell by an AGV
Setting down the housing top for final assembly
After determining the position of the housing top in the material carrier, the component is placed on the housing bottom part.
VISOR® Makes Component Positions Visible
A robot is tasked with picking components from a flexible feeding platform. The position of the objects may vary. A vision sensor can identify and relay the exact position of the part to the robot.
VISOR® Robotic +Z: 2D vision-guided robotics with integrated distance measurement
2D vision-guided robotics with integrated distance measurement for removing body parts from load carriers.
Visualisation of entire process with SensoWeb
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.
