Robotic Press Line Surface Inspection for Changing Part Types
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Solution Overview
Problem
Current methods for inspecting pressed sheet metal parts in vehicle production, such as human visual inspection and static camera systems, are prone to human error, time-consuming, and inefficient, especially when dealing with changes in part types, leading to potential inaccuracies and increased production delays.
Innovation Solution
A press line system equipped with robotic arms and high-speed cameras that follow pre-programmed trajectories to inspect the surface of pressed parts automatically, communicating with the production line and enabling immediate data processing, thus reducing human error and increasing inspection efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If human operators perform visual inspection of pressed parts, then inspection can be conducted, but the risk of human error increases and inspection quality decreases over time due to fatigue
Solution Approach 1:
The patent replaces the mechanical human visual inspection system with an automated optical inspection system consisting of cameras, lighting units, and evaluation units. This substitution eliminates human fatigue and error while maintaining inspection capability, directly resolving the contradiction between inspection reliability and automation extent.
2Productivity
If static cameras are used for inspection, then data can be captured, but the inspection process slows down due to offline data processing
Solution Approach 1:
The patent implements continuous online inspection where cameras capture images and evaluation units process data in real-time as pressed parts move through the production line. This eliminates offline processing delays and maintains continuous production flow, resolving the contradiction between productivity and time loss.
3Adaptability or versatility
If manual repositioning of cameras is performed when changing part types, then inspection can be adapted, but downtime increases and accuracy may be compromised
Solution Approach 1:
The patent employs dynamically adjustable robotic arms with integrated cameras and lighting that can automatically reposition and refocus when part types change. This dynamic adaptability eliminates manual repositioning downtime while maintaining inspection accuracy through automated calibration, resolving the contradiction between adaptability and time loss.
4Extent of automation
If robotic arms with cameras are used for inspection, then automation and speed improve, but the system complexity increases
Solution Approach 1:
The patent integrates cameras, lighting units, and evaluation capabilities directly into the robotic arm system, creating a unified inspection station. This merging reduces the number of separate components and simplifies system architecture while maintaining high automation levels, resolving the contradiction between automation extent and device complexity.
Data Source
Figure 1
AI summary
The invention relates to a press line consisting of a press system (2) with a series of presses, robotic arms for removing parts at the outlet of the press system (2), a discharge conveyor (5) and a device designed for the output of a perceptible signal, wherein the workstation (4) for the robotic inspection of the surface of the pressed parts is arranged in the initial area of the discharge conveyor (5), consisting of the robotic arms equipped with cameras.The invention further relates to the method of inspecting the surface of the pressed part using this device, which comprises the steps of inserting the workpiece into the press (2), pressing in stages, transferring the pressed part onto the discharge conveyor (5), followed by inspection of the surface of the pressed part with cameras, wherein the camera head of the robotic arm follows a movement path at a constant height above the surface of the pressed part, wherein this movement path corresponds to the trajectory stored in the memory of the control unit of the workstation (4) of the robotic inspection, subsequently the evaluation system evaluates the recorded data and determines whether it is a defective or defect-free pressed part.