The challenge
Ensuring defect-free parts in tight
spaces
In the automotive industry, even the smallest defect can lead to serious issues. That’s why manufacturers and suppliers rely on machine vision systems for 100% quality inspection. A Tier 1 supplier of automotive exhaust components faced this issue when a customer reported that some parts – specifically butterfly valves – arrived with flaws. The supplier needed a way to detect defects before shipping and turned to Neff Group Distributors for help.
The solution
Compact machine vision system with linear lights
To meet the supplier’s needs, Neff designed a compact machine vision system that fit perfectly in a tight workspace. The solution included a Cognex In-Sight 7200 smart camera with PatMax® pattern detection and two LM45 linear lights from Smart Vision Lights’ Mini-Lini series. These linear lights provided the right amount of illumination for the detailed quality inspection required in the space-constrained workstation.
Inspecting the butterfly valve
The critical point of the inspection was the butterfly valve’s pivot point, where the rotating closure plate (or vane) moves. A damaged or misshapen pivot could cause the valve to malfunction. At the automotive inspection station, the valve is placed in a fixture, and the camera and linear lights are triggered to inspect the internal pivot.
The camera and machine vision lights are positioned above the valve, focusing on the critical pivot. The two LM45 linear lights are strategically placed on either side to ensure full coverage of the part during the quality inspection.
Application images
How the machine vision system works
The vision system uses two Cognex PatMax® tools, one for each side of the valve. Neff trained the system using a perfect, undamaged valve and set the matching percentage high enough to catch any defects. Valves that pass inspection are welded and continue through the production line, while defective parts are removed and set aside for rework.
Why Smart Vision Lights’ linear lights were the right choice
Smart Vision Lights’ LM45 mini linear lights proved to be an ideal solution for this automotive application. Kerry Whitt, Field Application Engineer at Neff Group Distributors, explained, “They are rugged enough for the metalworking environment in which they were installed. Being able to control them both with one output from the camera made the application much simpler.”
The results: reliable quality inspection for automotive parts
With the right combination of machine vision lighting and a camera system, the supplier can now reliably detect defects in butterfly valves and ensure proper assembly. This high-precision quality inspection process helps ensure only defect-free parts are shipped to customers.