VISION & GEOMETRICS SOLUTIONS FOR MANUFACTURING
Technical Capabilities of Vision and Geometrics Systems
High Precision Measurement & Gauging of Laser Cut Features
Our customer required 100% 'in-line' inspection of 10 laser cut features (position, diameter, and shape) on octagonal tubes with tight tolerances.
BOS tested and selected a high resolution Cognex camera with specialty optics and lighting for the application The camera was mounted on a high precision single-axis motion system to allow for the inspection of multiple features along the length of the part. To allow for features to be inspected on all eight sides of the octagonal part, the part was fixtured on a rotary axis.
As part of a turnkey system integration, a material handling robot loaded and unloaded the inspection station to ensure every part that came out of the BOS L-MS laser cell was immediately validated as 'good' before being passed downstream. All 'bad' parts were rejected from the system.
The inspection system was successfully integrated into this production line with a 20 second part to part cycle time. The system achieved a Gage R’n’R result of <10% and it demonstrated a static repeatability of 0.006mm.
3D Vision Guided Robotic Fastening and Torquing
Our customer required rivnuts to be robotically fastened into holes on parts that were hollow rails. The incoming rails were all bent to some degree (the parts were either "smiling" or "frowning"), which caused variability in hole position between like parts.
To make things a little more challenging, there were 5 rail variants in total, each with multiple holes requiring rivnuts.
FANUC 3D-L vision was utilized on the rivnut robot(s) to integrate a robust process that allowed for the variability in hole position to exist and accommodated for it within the required cycle time for the system.
Repeatable location of critical features (holes) to achieve the required cycle time of 29 or 34 seconds, depending on part variant.
The cost of 3D vision hardware was offset by the ability to utilize a more cost-effective part fixturing design as a result of the vision guidance.
3D Vision Guided Robotic Grommet Insertion
Disclaimer: This photo is a concept demonstration for marketing purposes of the integrated production system (cannot be shown).
Our customer required rubber grommets to be installed in vehicles passing overhead.
Each vehicle required multiple grommets to be installed in the vehicle underbody in less than 60 seconds; there were two grommet variations in total.
Variation in overhead vehicle position and contact deflection needed to be considered in the design.
A robot with a revolver-style vacuum EOAT was used to pick grommets from a pallet. FANUC 3D-L vision was utilized to guide the robot to position prior to insertion, accommodating for position variability.
A second robot was utilized to refill the pallet with grommets for the next vehicle. It picked grommets from the escapement of a feeder system and placed them in the pallet while the first robot completed its insertion sequence.
Additive manufacturing (FDM 3D printing) was utilized effectively to rapidly prototype multiple iterations of the vacuum gripper fingers for the EOAT to identify the best design alternative.
The automated solution has been successfully integrated into the production line and is achieving cycle time, quality, and technical availability requirements for our customer.
Additive manufacturing demonstrated its value as part of the design process to facilitate quicker innovation for our customer.
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