视力传感器消除了故障拒绝
Maclean车辆系统的许多奥特曼(MVS)otive fastener products is stainless steel capped wheel nuts. The nuts are assembled on an index machine that processes two parts simultaneously at each station. The fasteners must be inspected to verify the nuts are properly threaded. MVS previously performed this fastener inspection with an eddy current sensor whose accuracy was less than desired, at times resulting in expensive over-sort.
“We looked at a number of different vision sensors,” said TJ Konieczke, Manufacturing Controls Engineer for MVS. “Some were sensitive, intimidating and had a high learning curve like the vision systems that we have used in the past. We selected Cognex Checker® vision sensors because they are very easy to program and operate. We simply put them in place, connect a PC to the USB port, train them on the part to be inspected, and pick tools off a menu that inspect the critical features of the part.”
Konieczke安装了两个Cognex Checker 101视觉传感器，俯视着45度角，距离装配机的检查站的两个部分约5英寸。将零件放在固定装置中的检查站，并由弹簧饲养员固定在适当的位置，因此将其定位的高度有一些可变性。Konieczke通过拖动检查工具并将其放置在他想检查的功能上来建立视觉传感器。首先，他通过使用边缘查找器工具定位零件的边缘来解决零件的可变放置。然后，他选择了一个亮度工具来寻找反射螺纹的光。
然后，他将视觉传感器设置为与操作装配机的可编程逻辑控制器（PLC）接口。PLC提供了一个静态输出，该输出指示何时使用两个新零件处于适当位置。当视觉传感器收到此信号时，它会捕获图像并检查零件。然后，视觉传感器将输出发送到PLC，表明该零件是好是坏。根据检查结果，PLC确定是将零件发送到通行证还是失败箱。
最近，MVS已在Cognex检查器232视觉传感器上标准化了新应用程序，该应用程序提供了高分辨率和广泛的视野，可以检查每分钟高达1,600个零件的小功能。
视力传感器确定零件位置并评估螺母整个开口的亮度而不是由传统传感器评估的单个点的亮度，已经消除了错误/失败的决策。消除排序成本迅速为新视觉传感器支付。视觉传感器还增加了信心，即不会将单个不良零件运送到客户。Konieczke总结说：“最新一代视觉传感器更加可靠，更准确，同样容易设置和操作，并且比传统传感器贵得多。”
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