Customer requirement:
- Continuous 360˚ Laser weld profile Inspection
- Assembly runout inspection at the upper point of welded assembly (Ø0.2 runout to datum A mounting surface – up to 200mm distance)
- Station cycle time: 5 seconds including part load/unload
- Both inspections were processed simultaneously
Design Solution:
- Robotic part load/unload
- Part Fixture:
- Microcentric #4-120-3 high precision air chuck w/.00005” (1.2μm) TIR
- Servo driven fixture rotation for fast, consistent speed
- Weld Inspection:
- Cognex DSMAX 3D Displacement Sensor for 3D weld surface inspection
- Telecentric optics to optimize image formation
- High-speed image acquisition – up to 18kHz at full measurement range
- Max resolution images – 2000 profile points
- Fast dynamic range image – HDR
- Cognex DSMAX 3D Displacement Sensor for 3D weld surface inspection
- Runout Inspection:
- Cognex Area-scan Camera with Gigabit Ethernet (GigE) communications for runout inspection
- Impulse Splitter:
- Input from fixture servo motor encoder
- Input from PLC high-speed counter module
- Above inputs are used to trigger Cognex Quad Pro Vision Controller with VisionPro S/WCFG-8724 PCI Express x4 frame grabber card
- Supports four independent vision device connections
- DSMax
- GigE
- Supports four independent vision device connections