IPD Technical Conference February 19 th 2008 Industry: Automotive – Circuit Board Mounting Screw...
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Transcript of IPD Technical Conference February 19 th 2008 Industry: Automotive – Circuit Board Mounting Screw...
![Page 1: IPD Technical Conference February 19 th 2008 Industry: Automotive – Circuit Board Mounting Screw Application: Screw with Silicon Rubber Collar Assembly.](https://reader035.fdocuments.in/reader035/viewer/2022062806/56649c8a5503460f9494414b/html5/thumbnails/1.jpg)
IPD Technical ConferenceFebruary 19th 2008
Industry: Automotive – Circuit Board Mounting Screw
Application: Screw with Silicon Rubber Collar Assembly Inspection
Presented by: Scott Montgomery / DALSA - IPD
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Metal Screw with Green Silicon Rubber Collar
Assembly and Measurement Inspection
Thread
Silicon Rubber Collar
Automotive part – used to bolt mini circuit board to center console inside a JeepWrangler. Silicon collar used to keep water from penetrating. i.e. four-wheeling
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Inspection Requirements
Measure Silicon Rubber Collar Rib Diameter:
12.05 mm + / - 0.13 mm
Check Silicon Collar for Following Surface Flaws (or defects):
Yellow Pigment Stains
Foreign Material, i.e. fibers, thread, etc.
Gas Pockets in the silicon mold
Flash and Short Shots
Missing, Rotated, Misplaced or Reversed Collars
Check for Following Thread Defects: Foreign or Extra Material in Shoulder
Missing Threads
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Critical Measure: Rib Diameter
Rib Diameter
+ / - 0.13 mm
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Surface Flaws in Collar
Yellow Pigment Stains Foreign Material Gas Pockets
Flash Short Shots
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Misplaced and Reversed Collar
Reversed CollarCollar Properly Placed Misplaced Collar (pushed downward)
Head Diameter LargerHead Diameter Smaller
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Thread Defects
Missing ThreadsForeign Material in Shoulder
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Vision System Overview
Vision System : VA-41 w/ Sherlock
2 Cameras, TM2 640 H x 480 V Camera 1: Lighting and Optics:
TML 56676 Telecentric Lens
24v. White LED Pad Light, size 75mm x 75mm
Aluminum Polished Block
Camera 2: Lighting and Optics Fujinon 35 mm Lens w / 5mm ext. ring
24v. White LED Ring Ling ( 45 deg. angled LEDs )
Initial trigger pulse sent from PLC, then custom DALSA IPD I/O trigger module – generates a trigger pulse train
User Interface – Visual Basic front end
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Camera 1: Collar and Thread Inspection
Aluminum Block( simulates a backlight )
Front Pad Light( white LED )
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Camera 2: Insertion Inspection(misplaced collars)
Ring Light( 45 deg., white LED )
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Machine Overview
Screws and green silicon collars are “bowl fed” independently to pick-and-place grippers
Screws are dropped into a pocket on an indexing rotary table
As the table indexes, a gripper inserts a silicon collar over the screw head
At the next station, a motorized drive engages, lifts, and presents the screw assembly to the vision system – CAMERA (1)
The completed assembly is spun 360 degrees to perform 100% surface flaw and thread inspection, and rib diameter measurement The vision system snaps a picture every 18 deg. of rotation – 20
triggers total for one completed revolution
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Machine Overview (continued)
The table indexes the assembly to the next station to check for proper collar insertion – CAMERA 2
The vision system outputs a separate “PASS” signal at each inspection station to the PLC
If the assembly failed either inspection, a pick-and-place gripper will discard the part at the next indexed station
Otherwise, the part moves to the final station and is placed onto a conveyor that drops the completed assembly into a shipping carton
Once the desired lot quantity is reached the carton is sealed and ready for delivery.
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Application Challenges
Achieving Full 360 degree, 100% Surface Inspection Using a pulse train of input triggers from DALSA IPD trigger
module ‘matched’ to the desired speed of rotation – 1 sec.
Finding a “One Light Fits All” Solution Green collar absorbs standard ‘RED’ LED wavelength of light Motion blur and minimal background contrast Lighting on a cylindrical surface produces centerline hotspot
Detecting Subtle Surface Flaws and True Flash Defects Discriminating between real defects and acceptable surface
imperfections – TEXTURE TOOL Discriminating between true flash and acceptable flash
Keeping Within Rib Diameter Tolerances Minimizing drive wobble and slippage Detecting drive slippage Minimizing perspective distortion
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Capturing a Full 360 degree Field of View(using a pulse train of input triggers)
PLC VA-41DALSA IPD
CustomI/O Module
1 Trigger Pulse 20 Trigger Pulses **
1 2 3 20
** Input triggers are fed to the trigger input on VA-41 I/O breakout board( PIN 2 )
Begins Inspection Cycle
Begin to Capture and Process Images
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Finding a “One Light Fits All” Solution
Aluminum Block( simulates a backlight )
Front Pad Light( white LED )
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Lighting Challenges( creating a well-contrasted background with diffuse foreground )
Center line hotspots ( skunk stripe )
Polished aluminum block reflects light, providing a bright background
Green silicon rubber absorbs most
LED light
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White LED Pad Lighting Suits All Inspections Requirements
Edge ProfilingSurface Inspection
Flash
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TEXTURE TOOL ( Detecting Subtle Surface Flaws )
Gas Pockets
TEXTURE tool is effective for measuring texture based on edge density wherethe edge sensitivity can be ‘tuned’ to discriminate between true defects and natural surface variations - TOTAL EDGE COUNT is primary measure
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Other Surface Flaws
Foreign Material
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True Flash vs. Acceptable Flash
Acceptable Flash True Flash
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Tracking Independent Reference Points
Left side Reference Point Right side Reference Point
Flash Tools( tracks laterally )
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Minimizing Drive Wobble ( critical for rib diameter measurements )
Measuring Rib DiameterTracking Spin Motion
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Detecting Drive Slippage
Tracking thread motion to detect drive slippage
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Minimizing Perspective Distortion
Conventional Lens Telecentric Lens
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Conventional vs. Telecentric Lens
Conventional Lens
Perspective Distortion
Telecentric Lens
Flat - No Distortion
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User Interface
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Summary
Overall cycle time per part : 2.0 seconds
Inspection time – 800 msec.
Shuttling part in and out – 1.2 seconds
Machine runs at less than 1.0% percent scrap rate
Produces about 40,000+ parts per week
Customer Quote :
“ Thanks to IPD, now I can sleep at night “
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O.K. Guys, It’s a Wrap ! ! !
Tom “ the builder ”
“Vision Guy”
“ Dr. V.B. ”