Machine vision is revolutionizing the automation industry by significantly enhancing quality assurance processes. By equipping automated systems with cameras and advanced image processing algorithms, machine vision enables precise and consistent inspection of products in real time. It can detect even the smallest defects, measure exact dimensions, and ensure that products meet stringent quality standards without the variability introduced by human inspectors. This high level of accuracy not only reduces the risk of defective products reaching customers but also streamlines production, minimizing waste and rework. As a result, machine vision is a key driver in achieving superior quality assurance and boosting the overalls efficiency and reliability of automated manufacturing systems.
The Need
The client is a manufacturer of industrial automatic lines for the assembly of various electronic cables. One of the crucial stages in those lines is the station where the wires of the cable need to be gripped by their tip and put in the right place according to schema. To do that we need to use a robot with a gripper and accomplish the accurate placement in less then one second per wire. The minimum wire diameter that the system is required to handle is 0.5 mm.
The Challenge
The Solution
Design and development of a complex optical setup of cameras mirrors and lights for fast spatial localization of the wires’ tips. We extracted from the images the 3D wire position in the real world and set the pre-calibrated robot to grip it and put it in the right slot. While doing it to all wires in the cable, we successfully managed to handle the wires complex geometrics, different colors and many arbitrary wires movements during each step of the process. All the design products of the project are the property of the company that commissioned it.
The Need
The client is a worldwide manufacturer of planar transformers. One of the early stages in assembling the transformers is the printing of each layer separately. After all the layers are ready then there is a process of cutting, gathering and soldering them in a certain order to form the transformer. If one of the layers has defects for some reason, the transformer is disqualified which causes financial losses. Detecting the defects in the early stages will allow the manufacturer to find as soon as possible crucial problems in his PCB design, failures in his machines or maintenance status, and prevent disqualified products from being sent as good products. Since each transformer consists of many layers and many transformers need to be checked, the scanning time of each layer needs to be short as possible.
The Challenge
The Solution
Design and development of a PCB Scanner. The Scanner has a unique optical design to match the 10 microns accuracy requirement and the various light reflections and absorptions of the conductors’ materials. We also designed a smart and adaptive scanning method combined with the software processing to optimize the scanning time to less then one minute per layer. We used cutting-edge algorithms to find defects like short circuits, disconnections, missing parts, coating problems, foreign objects, and damaged soldering. Finally, we developed a custom HMI and integrated the scanner operation with the factory’s ERP system.
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