Cases machine vision
Case: Accurate positioning of large products in a multi-layer cell
The challenge In a multi-layer production cell, three separate product layers had to be positioned with extreme precision relative to one another. The products measured up to 1.5 m × 2.5 m and exhibited dimensional variations due to expansion and shrinkage, depending on their production history. The combination of large dimensions, dimensional variation, and a required positioning accuracy of < 1 mm made this a particularly complex vision challenge.
Our solution JOLT developed and integrated an advanced vision system that detects and accurately localises each product layer individually. Through intelligent image processing, the actual geometry of each product is analysed, regardless of expansion or shrinkage. Based on this data, the layers are perfectly aligned relative to one another using KUKA robots, within the required tolerances.
Results
- Reliable positioning with an accuracy better than 1 mm
- Stable process despite variations in product shape
- Fully automated alignment of large, non-rigid products
Case: Automated and manual quality control with full traceability
The challenge In a production process with 40 parallel machines, a reliable control system was needed that could:
- Automatically verify whether the correct product is being processed
- Check whether the product is correctly oriented
- Register both automatic and manual quality checks
- Store all inspection data centrally and traceably
Not all quality checks could be fully automated, making manual input essential.
Our solution JOLT implemented a camera-based inspection system on each machine for automatic verification of product type and orientation. The system was further extended with a user-friendly interface allowing operators to register manual checks. All data — both automatic and manual — is stored centrally and linked per order and per machine.
Results
- Consistent quality control across all machines
- Automatic inspections of up to 20,000 parts per hour per machine
- One unified system for both automatic and manual inspections
- Full traceability of quality data per order and per machine
- Greatly simplified audit and reporting processes