Reject rates limited to less than 5% of output with Matrox Design Assistant X-based vision inspection system
Leading global supplier of technology and services, the Bosch Group has been a major player for more than a century. With divisions worldwide, its operations are focused on four distinct business sectors: mobility solutions, industrial technology, consumer goods and energy and building technology. At the Bosch outpost in Curitiba, Brazil, the company’s primary focus is on developing solutions for the diesel engine injection systems for the automotive industry. Its customer base consists of multinational companies working with diesel, as well as off-road and commercial vehicles companies.
When it comes to the manufacturing of Bosch’s diesel injector nozzles, the process involves the operator selecting the specific parts to be produced, then feeding those components into the machine for production; once completed, the operator withdraws the inspected and packaged parts. These injector nozzles are a critical engine component, working to move diesel fuel into the engine’s combustion chamber for vehicle propulsion. The team at Bosch uses vision technology for traceability and verification purposes, as the design and quality of these components is of utmost importance.
At the request of the production line team, Bosch sought out an enhanced vision system, wanting to improve the mark-reading and verification process, as well as the traceability of the injector nozzles. The aim was to reduce the number of machined parts requiring post-production manual inspection. “We had the opportunity to further automate the inspection process,” says Moises Santana, vision system designer with Bosch, “and found that the hardware and software offered by Matrox® Imaging afforded the best option. The new system can handle three independent processes simultaneously using the same computer.”
The newly updated vision system comprises a quad-input Matrox Concord PoE frame grabber and a Matrox Indio I/O card inside an industrial PC with an Intel® i7 core running Matrox Design Assistant X software, which controls the whole system. Three front light bars from LumiVision ensure adequate illumination. An industrial KUKA robot correctly positions the metal components so they can be photographed by the three GigE Vision® cameras from Teledyne Dalsa; after the image capture, the robot repositions the injector nozzles further down the line.
“There are so many good reasons that led us to acquire the Matrox Imaging vision system,” notes Santana. “The software tools are remarkably agile. It is a flexible vision system capable of working with several models of GigE Vision and USB Vision® cameras.”
Putting Pedal to Metal
The three GigE cameras form an integral part of the vision system: two perform optical character recognition (OCR) and optical character verification (OCV) of a code on the nozzles themselves, while the third reads the barcode label affixed to the outside of the packaging tube that encloses the final product. Bosch needed the precision of machine vision technology to read the human-readable codes engraved on the cylindrical metal surface after the shot-peening process.