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10.12.2018

Automated quality inspection and manual reworking in the foundry 3D Quality Control and Process Optimization for Foundries

Precise, reliable quality inspection for castings
Data obtained enable process optimization

Optical quality inspection is a particular challenge for cast parts with complex geometries or rough surfaces. With VINSPEC 3D INLINE, the Wiesbaden-based image processing specialist VITRONIC offers a fully automatic inspection system that scans the surfaces of complex components such as crankcases or cylinder heads. The system inspects integrated in the production line and enables short cycle times. Even the smallest surface defects and geometric deviations are detected with 100% reliability: independent of the material, simultaneously and from all sides. NIO parts are sorted out for reworking or as rejects. The system supports manual reworking with networked data and clear visualization for the operator. The result: safety and function-critical components are produced with consistently high quality and deviations in the process can be corrected at an early stage.


Industry 4.0: Data optimize processes

VINSPEC 3D INLINE inspects all surfaces contact-free - up to six different side surfaces simultaneously. All side surfaces of the component are scanned simultaneously and each scanned as a 3D point cloud. This point cloud is compared with the 3D model stored for each side; the smallest local deviations can thus be precisely determined. The test regions can be configured individually for each side of a component and different tolerance limits can be defined for width, length, depth and volume.

VINSPEC 3D INLINE checks within these predefined tolerance limits:

  •  External geometries: Complete, error-free and without damage (e.g. cast-on slugs damaged or broken off)
  • Component openings: Complete, flawless and without closure (e.g. closed by sand/pouring/core fracture)
  • Surfaces: Error-free and without damage (e.g. notches due to mechanical impact, cold running, drawing points, burrs, sand spots)


All test information flows directly into the live log and is stored in an integrated database for later tracking, evaluation and statistics, component-related and by test region. In addition, the software provides live hotspot analyses in order to detect accumulations of defects in good time and to support any need for adjustment in production. All inspection results are recorded, visualised, archived and analysed - for the sustainable optimisation of processes, costs and quality in casting production.


Visualization accelerates manual reworking

Effective cooperation between man and machine: VINSPEC 3D INLINE transmits the recorded test data to visualization stations for manual reworking. Here, the operator sees all identified defects in different views; even data from external inspections (e.g. X-ray, CT) can be integrated into the visualization and used for optimal reworking.


This facilitates manual reworking for the operator and accelerates the process considerably - an important cost factor. The operator confirms the rework directly at the terminal and the data is fed back into the system.


Rapid familiarization of skilled workers

The operator must have the necessary know-how so that tests and reworking such as welding, plaster grinding or tapping can be carried out correctly. Here, too, VINSPEC reworking stations offer great advantages: Once the operator has been authenticated, the system recognises his level of knowledge and indicates any missing training, e.g. if he does not receive any instruction on a new type of component. Test plans or changes made to all components are also stored. All this information helps to avoid errors and save time and money.

 VINSPEC 3D INLINE at a glance:

  •  Automated 100% inspection of complex cast parts
  • Integrated into the production line, with minimum cycle time
  • Very flexible: component geometries, surface properties, defect types
  • Robust and low-maintenance even in harsh environments
  • Early detection and determination of error causes (hotspot analyses)
  • Effective manual reworking
  • Connection to robot possible

 Advantages

  • Reduction of rejects
  • Avoidance of complaints
  • Proof of quality for every cast part
  • Reduction of production costs
  • Efficiency/productivity increase


Test data for the Smart Factory

On the way to an intelligent factory, industrial image processing proves to be a real all-rounder. Thanks to it, machines can not only "see", but also "understand". This enables efficiency, flexibility and intelligence in production and will provide valuable services in more and more applications in the future. In the near future, the VINSPEC 3D INLINE inspection system could automatically transfer the data to robots for deburring. Inspection data could be made available across multiple locations via cloud, so that all inspection information for a component could be retrieved at any time. Optimizing processes and reducing costs while maintaining consistently high quality - these are essential prerequisites for remaining internationally competitive.



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