By Evan Wollak and Brian King
Industrial vision systems are versatile; so versatile, in fact, Borg Warner Automotive Systems in Bellwood, Ill., uses vision systems to detect visual defects, define parts for a robotic pickup, confirm unique identification markings, and, most importantly, stop assembly lines when defects are present.
If there is not an easy way to mechanically or electrically detect the defect or process variation, consider a vision system. There are many products targeted toward specific applications (low-cost simple cameras, high-resolution cameras, or cameras with serious processing power). Using the right camera for the job will help bring the solution to the plant floor quickly and under budget.
Most of the best candidates for vision inspection are those presented with a random orientation. The cost of engineering a mechanical system to orient parts and present them to a mechanical poka-yoke (mistake-proof) device is high; however, the time needed to develop and implement such a system is usually the largest constraint. You can mount a camera system with an off-the-shelf lens or light to a machine and wire it into an existing electrical system within a day or so. Complete the camera programming in an hour for simple applications. This quick deployment makes the system ideal for responses to customer complaints or product launches with tight timelines.
Vision systems are also useful to reduce changeover times. Machines that have mechanical inspections and run multiple part types often need part-specific tools. A camera system can change the inspection parameters automatically and drastically reduce setup times.
