Products Machine Vision Image processing ensures precision welding
A fuel tank welding system from BF-Maschinen meets the high- est requirements of the automotive industry, thanks to an optical stereo image processing system from FRAMOS. The image pro- cessing system ensures optimum positioning of the elements to be connected during the welding process. With production quality demands of the automotive industry becoming more stringent, resource efficiency and error reduc- tion rates are key. As a result, opportunities are increasing for new quality assurance systems with a high degree of reliability. A recently created application using a combination of digital cameras and laser technology is now being used in the produc- tion of fuel tank systems for passenger cars - the latest genera- tion of tank welding systems from BF-Maschinen is now being equipped with a system from FRAMOS that provides maximum precision in the fabrication of the tank to the filling pipe. BF-Maschinen has delivered special machines to industrial enterprises around the world since 1994 and is even represent- ed on board the International Space Station (ISS). BF-Maschinen has the latest techniques for the welding of coextruded blow moulded parts - with the corresponding sophisticated tasks on the production line. “The challenge posed by this tank welding procedure results primari- ly from the use of multi-layer plastics,” commented, Dr. Simon Che’Rose, head of Engineering at FRAMOS. “Specific layers (ECOH layer/separating layer) must not be damaged when melting both elements during the welding process.” In order to ensure a reliable seal after making the connection, the accurate meeting of the parts is a prerequisite. Through the calibrated combination of a high grade industrial camera from
SMARTEK Vision and a laser, which projects a cross of light onto the respective flange surface, FRAMOS has developed an active stereo system for the optical tilt check.
Deviations in the parallel position of the surfaces to be welded are measured and communicated to the system control unit. “The optical system measures the position in the area of the relevant flange surfaces. If a part tilts, the deviation of the mea- sured value from a specified set point is communicated to the system control unit,” explained Sebastian Stelting, application engineer at FRAMOS. The tolerance is extremely tight. In theory, both parts and their
respective deviations from the optimum could fall within per- mitted limits, yet the total deviation could still produce an unac- ceptable quality fault. “We’ve packed a large amount of intelli- gence into the system in order to achieve the best possible results and at the same time leaving control of the quality para- meters entirely in the hands of the customer,” said Che’Rose. Additional camera views further reinforce the quality assur- ance. For each welding procedure, their images document both the flange surfaces immediately after being heated as well as the welding bead after joining the parts. Che’Rose added, “In this way we make the production situation visible and recon- structable for each tank.” By also making intelligent use of the test camera for this pur- pose, a total of only three cameras are required for each welding station. At present, several systems are in use by customers and are fulfilling the expectations
of reduced error rate and higher precision production. Che’Rose concluded, “We are working on the assumption that many other applications will follow. The growing requirements for the supply industry, not only in the automotive segment, will further increase the need for optical systems for the purpose of quality assurance. With proven technology available to us, we can quickly and reliably develop and deliver solutions for this application area.” Framos
www.framos.co.uk T: 01276 404 140
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The summer of 2013 was marked by the wide proliferation of industrial USB3 imaging devices
Summer 2013 is noted for being the best in a long time, with long dry spells and very warm days on the beach. However, at Scorpion Vision, summer 2013 will also be known as the summer of USB3. With devices proliferating all summer long, the company can boast a full suite of USB3 imaging prod- ucts - not just cameras but also multi-chan- nel interface boards, fibre extenders for long cable lengths up to 100m, and dedicated USB3 repeaters for attaching multiple devices through one hub. Scorpion Vision supplies the full range of cameras from The Imaging Source which
S14
now includes the six main models that are available across the spectrum of interfaces - from wide VGA CMOS cameras up to 2MP CCD and 5MP CMOS. The latest addition is based on the Aptina MT9M021 1.2 megapixel CMOS sensor with global shutter, offering up to 60 frames per second at maxi- mum resolution.
Of course with faster and larger sensors comes more bandwidth requirement and the USB3 Vision standard meets these demands. Scorpion Vision also exclusively supplies the quad port USB3 industrial interface board from Unibrain - known for it’s exten-
sive range of firewire products, this entry into the world of USB3 is both timely and logical as USB3 seems to be a natural pro- gression from 1394b with similar character- istics and benefits that made firewire a popular interface standard for machine vision. The standard USB3 protocol is enhanced with USB3 Vision, which includes device discovery, device control, event han- dling, and streaming data mechanisms that make USB3 Vision well suited for machine vision applications. Scorpion Vision
www.scorpionvision.co.uk T: 01590 679 333
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