INSPECT.assembly: ADVANCED VISION SYSTEM FOR IN ......2017/11/17 · EXAMPLE: CABLE ROUTING Pass Fail System checks for appropriate channels. Routing over guides or too close to other

Radiant Vision Systems | A Konica Minolta CompanyRadiant Vision Systems | A Konica Minolta CompanyPresented By Davis Bowling | November 17, 2017

INSPECT.assembly: ADVANCED VISION SYSTEM FOR IN-LINE ASSEMBLY VERIFICATION

Global SupportAutomated Visual InspectionLight & Color

3Radiant Vision Systems | A Konica Minolta Company

© Radiant Vision Systems, LLC.

TODAY’S TOPICS

• Assembly Verification Challenges

• The Trouble with Current Methods

• The Solution: INSPECT.assembly

• Fully-Integrated Solution

• Production Line-Ready

• Advanced Imaging Capability

• Specially-Configured Software

• Application Examples

• System Specifications

• Summary



ASSEMBLY VERIFICATION CHALLENGESTHE TOUGHEST INSPECTION PROBLEMS



THE TROUBLE WITH CURRENT METHODS



CURRENT INSPECTION METHODS



HUMAN VISION IS REQUIRED

EXAMPLES:

Display appearance

Surface cosmetics for consumer products

Particulates in parenteral preparations



HUMAN VISION IS MORE ACUTE

EXAMPLES:

Electronic assembly inspection

Surface cosmetics for consumer products

Glass quality inspection



MACHINES ARE MORE REPEATABLE

EXAMPLES:

Multi-part manufacturing processes

Operational standards across branches

Testing consistency from supplier to OEM



MACHINE DATA IS QUANTIFIABLE

EXAMPLES:

Process control

Vendor management

“Big data”



CAMERAS NEED TO SEE MORE DETAIL

• Resolution – The number of pixels in an image translates into spatial resolution, which determines the ability to distinguish fine detail within an image.

1MP Resolution 29MP Resolution



THE IMPACT OF RESOLUTION

• Higher-resolution CCD imaging enables:

• Easier detection of contrast variations

• Pixel-level defect detection and correction (displays)

• Detection of subtle defects



CAMERAS NEED TO SEE MORE CONTRAST

• Dynamic range:

The ratio between the

maximum possible signal and

the “noise” level at the

minimum signal of one

measurement

• Measured in dB (decibels)

• Calculates a signal-to-noise ratio

(SNR)

WHAT WE SEE:SIGNAL

NOISE



THE IMPACT OF DYNAMIC RANGE

• Dynamic range - Larger dynamic range yields greater

measurement precision and enables higher contrast ratio

measurement.

Low Dynamic Range High Dynamic Range



CAMERAS NEED TO BE CALIBRATED TO THE IMAGING ENVIRONMENT



A CAMERA DOESN’T CUT IT



SOLUTION COMPONENTS

Imaging System Analysis Software Automated Test Stations



THE SOLUTION: INSPECT.assembly



INSPECT.assembly

Lighting

Fixture

Computer

AdvancedImaging System

Inspection ResultSystem Components



FULLY-INTEGRATED SOLUTION

INSPECT.assembly is a turnkey Assembly Verification

product, that can be installed over a moving conveyor belt

or a non-moving test station

Components

• ProMetric® Y29 Imaging System

• INSPECT Software

• Fixture (including lighting)

These components combined make up the INSPECT.assembly.



PRODUCTION LINE-READY



WHAT DOES INSPECT.assembly DO?

Engineered for Assembly Verification

INSPECT.assembly inspects for the following:

• Component presence• Connectors• Cable routing• Screws

And it does all of this on a moving conveyor.

• Batteries• Labels & their location• Fasteners• Missing components



ADVANCED IMAGING CAPABILITY

Radiant’s advanced imaging systems provide the visual sensitivity to replicate and quantify human

perception of and color



INSPECTION METHOD COMPARISON

Typical machine vision struggles to distinguish black screw from hole

Advanced imaging system with high-resolution and dynamic range detects the missing screw




• Measures relative contrast/color

• Speed favored over resolution (limited detail

inspection); small CCD pixels, noisy images

• Low repeatability for applications that

normally require human inspection

• Poor contextual evaluation

• Measures absolute luminance/chromaticity

• Extremely high resolution, low noise, and

broad dynamic range imaging system

• Detect minute visual differences in a way that

replicates human visual perception

• Detect and classify defects by severity

Machine Vision Camera Advanced Imager




• When Human Visual Judgement is the evaluation

standard, INSPECT.assembly…

• Improves Consistency

• Captures

Quantifiable Data

• Reduces Labor Cost

• Reduces Latent

Failures



SPECIALLY-CONFIGURED SOFTWARE

http://www.szxmsck.com/




• Multiple software functions are

combined to perform the exact

inspection needed.

• The “Screw Tool” combines a

number of tools to meet precise

tolerances of the component

features.

http://www.szxmsck.com/




• Each software recipe is configured

exactly to the requirements for a

given part.

• Multiple recipes are supported by a

single system, to accommodate

multiple products on the line.



APPLICATION EXAMPLESINSPECT.assembly IMAGES AND ANALYSIS



LET’S TAKE A CLOSER LOOK…



EXAMPLE: CABLE ROUTING

Pass

Fail

System checks for appropriate channels. Routing over guides or too close to other components will be flagged as a failure.

Improper cable routing can lead to electrical failures due to shorts or breaks.



EXAMPLE: CONNECTOR ALIGNMENT

Pass

Fail

System checks for connector alignment and gaps for various connector types. Misalignment or an out-of-spec gap will be flagged as a failure.

Connector misalignment can cause failures because of poor or lost connections once the system is in regular use (e.g., due to vibrations).



EXAMPLE: SCREW PRESENCE

Pass

Fail

System checks for screw presence. Missing screws will be flagged as a failure.

Missing screws can cause failures because of sub-assembly / component movement when in use.



EXAMPLE: LABEL PLACEMENT

System checks for label placement and position. Labels and logos that fall outside of tolerances are flagged as a failure.

Skewed or missing labels and logos can have obvious negative impact for a manufacturer’s image.

SOFTWARE EXAMPLE



SYSTEM SPECIFICATIONS



INSPECT.assembly SPECIFICATIONS

• Computer: Typical workstation w/ Intel Core i7, 32GB RAM, 1 TB Hard Drive, Windows 10.

• Monitor: Full HD, 1920x1080, Touch Screen.

• Camera: ProMetric® Y Imaging System, 29MP

• Illumination: Super bright, white LED lamps (x4, adjustable location and brightness)

• Part-in-Place Sensor: 1 operator-driven trigger device, and 1 smart camera-based

trigger device.

• Software: Radiant INSPECT Software with INSPECT.assembly configuration

• Test Housing: Fixture size 1200mm height x 890mm depth

• Installation time required: 2 Days of onsite installation time will be required for

software and hardware configuration.

• Delivery Schedule: 4 weeks from receipt of PO.




Inspect components




Auto Registration




Results/Data Reporting




Accommodating 2nd Sourced Components




Model Selection via Image



WHAT ARE THE SYSTEM OPTIONS?

Shop Floor Communications




Barcode Reading




2nd Monitor for Operator Station




Typical Field of View Options (560mm working distance):

• 35mm lens – 550mm x 370mm• 50mm lens – 370mm x 245mm

Working distance has some adjustment, so FOV can be increased/decreased approx. 15%. This version supports single part only.



WHAT WE NEED FROM YOU:

• Part Samples

• Set Line Speed

• Minimum Indexing Time

• Space on the Line

• Barcode (if required)

• Product Model Mix

• Component Mix per Part (2nd Sources)



SUMMARY

✓ Human inspectors and machine vision systems have unique advantages and disadvantages for visual inspection. Neither offers the ideal solution.

✓ Advanced imaging systems from Radiant combine human visual acuity with consistent, quantifiable data acquired by machines for true automation.

✓ INSPECT.assembly integrates this advanced imaging with specially-configured software and fixturing into an inspection station that easily rolls up to existing lines.

Radiant Vision Systems | A Konica Minolta CompanyRadiant Vision Systems | A Konica Minolta CompanyQuestions? Contact [email protected]

THANK YOU!
mailto:[email protected]

INSPECT.assembly: ADVANCED VISION SYSTEM FOR IN ......2017/11/17 · EXAMPLE: CABLE ROUTING Pass Fail System checks for appropriate channels. Routing over guides or too close to other

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