When fully automated precision machining and precision Prüfhandling of brake discs per robot integrated in the process image processing detects exact position, plain text and characters.
The braking distance of cars is less attention than the acceleration values. His time was a VW Beetle when braking from 100 km / h to 0 after 60 m to a halt. Today-ton luxury limousines, not more than 35 m. Two reasons for the shorter stopping distance are modern ABS and precision brake discs.
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An organizational unit of the medium Drehereibetriebs Alber Cast editing GmbH has specialized in the manufacture of precision components for the car superclass. However, car manufacturers no longer exist today only satisfied with the best quality. The traceability of the production must be ensured. For this to take place a hundred percent reliable and complete sets of brake specialist recently on image processing technology. Two intelligent vision systems from Cognex In-Sight 7050 and In-Sight 5604, read real writing codes on rotating discs.
The image processing systems increase process reliability and relieve in combination with a handling robot, the employee: brake discs for the automotive luxury class weigh 12 to 20 kg.
So far, one employee had to manually lift the slices out of a grid and pick up and deposit on the changing work stations and over again. Since the beginning of 2013 the turning and milling downstream Feinbearbeitungs- and inspection works fully automated. For the automation specialist CNC Automation GmbH cube has a Yaskawa Motoman robot-integrated MH50-35 in cooperation with the image processing experts at i-mation GmbH in the solution.
At the top of the grab an In-Sight 7050 vision system from Cognex has been installed. With its autofocus, rapid image acquisition and own lighting the smart camera detects the exact location of the supplied brake discs on the conveyor belt. The image processing based on the inner diameter of the discs. Transmitted in fractions of a second to the robot controller, the image data enable fast gripping the brake discs by means of high performance magnets.
After recording the first step follows: the reading of plain text characters (OCR). For this purpose the robot places the brake disc onto a turntable. Well contrasted with red LED lighting, the characters are ready to use the second vision system. The In-Sight 5604 line scan camera with 1K-high-speed line scan detects the needled embossed printing during two revolutions of the rotor.
The reliable reading of the character was one of the more challenging tasks for image processing experts at i-mation. More specifically, the reading of different embossed character sets. Because of product batch to batch of the product itself, the type and design of the embossing change. The task was achieved by gradually learning all the possible variants. This facilitated the software tools from Cognex for OCR applications such as In-Sight Explorer.
On the plain reading of Scripture follow Feinbearbeitungs- and test steps, which include balancing and the sound test count. Finally, the robot places the discs in layers of six pieces in a grid on and covered it after an automatic gripper change with a sturdy wooden board, the BV-camera of the robot recognizes their exact position using a black marker cross.