With the growth of China's per capita income, the improvement of living standards and the maturity of the market, people have more and more diversified demand for cars. In recent years, new models have emerged in an endless stream, and single-line and multi-variety production methods have been widely promoted and applied in the production of cars. In order to adapt to this kind of production mode with high mechanization and automation level, effectively avoiding various defects and errors, inspection, measurement and part identification technology can be said to be indispensable.
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In the increasingly competitive global automotive industry, improving product quality, reducing processing waste, and reducing manufacturing costs have become an important part of current corporate competition. In the automobile manufacturing process, reasonable use of various error-proof detection technical measures can effectively improve product quality.
Sensors and accessories from Bonner Engineering International, Inc. (referred to as Bonner) provide cost-effective, error-proof detection solutions for automotive customers, ensuring product quality, increasing reliability, increasing throughput, and saving production costs. For many years, Bonner has been providing its customers with innovative, sensor-based technologies from easy-to-use to high-performance optoelectronic sensors, workpiece sorting light curtains, laser sensors, ultrasonic sensors, vision sensors and security products to help customers in the automotive industry. Solve practical application problems in production.
Error proofing solution
Figure 1 Thread hole detection scheme 1
Figure 2 Threaded hole detection scheme 2
1, the detection of threaded holes
The processing of threaded holes and optical holes can be seen everywhere in the manufacturing process of automobiles, but different designs have different requirements for the process. Therefore, it is necessary to distinguish between the threaded holes and the light holes in the production process.
Solution 1: Multi-functional vision sensor detection (as shown in Figure 1)
The area light source is used to illuminate at a specific angle, and the threaded holes and the light holes have significant differences in light reflection. Therefore, in the images captured by the Presence PLUS Pro vision system, the light and dark generated by the apertures and the threaded holes are very easy to identify and the detection accuracy is high.
Option 2: Small spot laser sensor detection (as shown in Figure 2)
The QS30LD/LDL series of laser sensors have a 1mm spot and excellent detection performance for static, dynamic, single point setting and manual adjustment of sensitivity. The reflection of the small spot on the threaded hole and the inner wall of the light hole is obviously different, and the intensity of the reflected light received by the sensor is greatly different, and the sensor distinguishes the light hole and the thread hole accordingly.
2, the presence or absence of the hole detection
In the process of automobile manufacturing, there are often many holes involved. In order to improve production efficiency and reduce the occurrence of waste, it is necessary to confirm the presence or absence of holes on the workpiece before many processes are carried out to prevent rework. For example, before the door is mounted to the body, it must be confirmed that there are no holes in the door beam to ensure that the correct door is installed on the body. The Presence PLUS Pro vision sensor captures the appropriate size of the image with the ring light source and uses the Block Detection tool or the Pattern Lookup tool to determine the presence or absence of a hole (see Figure 3).
Figure 3 Detection of the presence or absence of the hole
3, hole ID identification
The increasing variety of car models has made collinear production a new trend. In the collinear production process of automobiles, it is especially important to distinguish between types of vehicles and parts. For example, on the welding line, the type of the body-in-white is identified to determine the corresponding welding procedure; the door is determined according to the size of the hole in the door. The types of different types of doors are assembled to the corresponding body. The Presence PIUS Pro vision system identifies the hole ID as shown in Figure 4.
Figure 4 Identification of the ID of the hole
4, multiple workpiece positioning
In the actual production process, the positioning and positioning of multi-workpiece assembly is very common, and accurate inspection can help production enterprises to effectively improve production efficiency. In the detection system consisting of Presence PLUS Pro vision system, LCF16LT lens, high-frequency fluorescent light source and trigger signal provided by PLC, Presence PLUS Pro is used to detect instrument panel accessories, and high-frequency fluorescent lamps illuminate the measured object from top to bottom. The use of a variety of testing tools (such as pixel detection tools, target tools, edge tools) to detect the placement, orientation and positioning of foam gaskets and plastic workpieces. The position and positioning of the foam sheet and plastic nut on the car dashboard assembly are shown in Figure 5.
Figure 5 Multiple workpiece positioning
5, the sorting of parts
Figure 6 Sorting of parts
In the external/internal components (such as seats, electronic equipment, equipment) assembly lines, other sequential operations, and warehouse order processing, the operation must be performed according to the established operating procedures. Therefore, it is necessary to ensure the correctness of the operation sequence.
Bonner's PVA light curtain is the key to solving automotive application lines, electronics assembly lines and materials handling applications. The application of the PVA light curtain can effectively prevent errors during the assembly process. Its transmitting and receiving devices are placed on both sides of the bin, and its high-resolution work indicator light indicates the operator to select a specific bin. When the operator selects the correct workpiece, the PVA light curtain is blocked, and the output signal enters the PLC or computer to confirm the correct operation. The PLC or computer will start the PVA indicator of the next operation bin, and the wrong operation or out of order operation will be able to Was discovered in time.
The advantages of applying a PVA light curtain are:
(1) Ensure that the workpiece is inspected in order to prevent repeated operations and improve assembly quality;
(2) It is easy for novice or temporary assemblers to quickly master the operation process;
(3) It is convenient to continue operation after working gaps or after replacing components;
(4) It is flexible and easy to assemble different products on the same assembly line, and the training workload is greatly reduced.
Conclusion
In the mass industrial production process, especially in some dangerous working environments that are not suitable for manual work or where the human eye is difficult to meet the requirements, the advanced error-proof detection method can greatly improve the production efficiency and the automation degree of production. Moreover, the digital signal transformed by the sensor is easy to realize information integration, and is the basic technology for realizing computer integrated manufacturing.
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