High-energy video system for fine inspection
In the automated production line at Inter Control in Nürnberg, approximately 80 components are added to the machine every minute, allowing them to pass through the checkpoint while the conveyor is in motion. Each thermostat undergoes a detailed inspection for various defects—such as ceramic cracks, surface flaws, and misalignment of contact points—using advanced image processing techniques. This ensures that even the smallest imperfections are detected with high accuracy.
At Inter Control, 100% high-quality image processing technology is employed to maintain product excellence and support the overall production base. The system is built on a structure that includes a high-energy video system, along with software and program management modules, enabling it to meet the complex requirements of inspecting labels for around 150 different products. This approach not only enhances quality control but also streamlines the production process.
To address growing competitive pressures and improve product quality, Inter Control implemented image processing technology at its Nürnberg facility. Components from the household appliance industry, HVAC systems, and automation devices must all be 100% inspected. The thermostat manufacturing process involves a ceramic base with a bimetallic mechanism, connectors, and multiple assembly options. Ensuring that these components remain intact on the ceramic base is the primary goal.
The company gathered ideas and explored various system solutions to tackle this challenge. As a result, the production process and quality control system were designed to be as efficient as possible, with requirements continuously expanding. Ceramic suppliers had already raised concerns about potential issues, such as crack formation, and actively participated in discussions about image processing solutions.
Inter Control processes about 50 million ceramic parts annually, and only a completely safe and reliable system can handle such volume. Additionally, there are around 200 different product varieties due to variations in ceramic bases and assembled components.
The Firth Bildverarbeitungs-Systemhaus 3D Motion solution was chosen for its efficiency and cost-effectiveness. It consists of a high-energy video system combined with software and program management modules, meeting the complex testing needs for 150 products. The system was quickly installed and has proven reliable for two or three shifts of fully automated production, handling 80 components per minute.
Object-oriented thinking plays a key role in simplifying operations. The Fürth-based video specialist analyzed the product range and developed an effective image processing system. When the machine runs automatically, the same base plate can be fitted with different ceramic bases and contacts. With many joint types and configurations, managing a wide variety of models becomes complex. However, the object-oriented approach allows for flexible programming and inspection, reducing the need to develop separate test procedures for each model. Only the base plate needs to be scanned, and all inspection tasks adjust accordingly, making the system more efficient, cost-effective, and safer.
The In-Sight 5400 vision sensor, equipped with Ethernet and IP67 protection, serves as a standalone image processing unit. It stores inspection procedures for about 150 product categories and offers an easy-to-use interface. Operators can program and read data for new varieties without deep image processing knowledge. Key inspection tasks include checking part placement, joint geometry, angular position, hole diameter, flange type, and color marks on ceramic components.
The compact image processing system, consisting of the In-Sight 5400 and lighting device, is directly integrated into the fully automatic mounting equipment (Figure 1). This setup reduces space usage and improves efficiency.
Crack detection is particularly challenging due to factors like dirt and oil contamination. To address this, the system uses multi-faceted observation techniques to enhance accuracy. Inter Control's team has developed a robust authority system, and the company plans to expand these solutions to subsidiaries and specialized machines.
As fault detection becomes more refined, the system is getting closer to precise licensed parameters. Previously, small batches could lead to occasional errors, but now, faulty parts can be identified and sorted out immediately. Oil pollution problems are also being addressed effectively, ensuring no false alarms occur. The In-Sight 5400’s advanced tools have proven valuable in fault detection.
The built-in image processing device minimizes the need for manual visual inspections. If three consecutive faulty parts are detected, the machine automatically stops. Only fully inspected products are placed on the distribution pallet and leave the automated line (Figure 2). Fault sources are analyzed statistically, leading to process improvements and better quality control.
In the competitive home appliance industry, quality is becoming increasingly important. Thanks to strict image processing monitoring, failure rates have dropped to 25–50 ppm, eliminating complaints and returns. For global spare parts suppliers, this achievement brings significant benefits by reducing recall costs and protecting brand reputation.
The success of the current system has led to the expansion of three other automatic machines with image processing equipment. Technical knowledge gained will also be applied to Inter Control’s subsidiary in Bad Kissingen and special machine manufacturing. New equipment will also feature built-in image processing capabilities, further enhancing efficiency and reliability.
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