Vizuální kontrola:
Stanice pro montáž krytů výrobku s velmi přesným měřením profilometrem a kamerou
Jedná se o samostatně stojící pracoviště vizuální kontroly, které slouží k přesnému složení dvou částí výrobku s minimální šířkou mezery pod 1 mm.
Pro realizaci tohoto úkolu jsme zvolili řešení zaměřené na vizuální kontrolu s vysokou opakovatelností a minimální chybovostí. Hlavní součástí stanice je kamera s telecentrickým objektivem, která díky svému paralelnímu zobrazení umožňuje přesné měření volného prostoru. Telecentrický objektiv eliminuje zkreslení hran a zajišťuje konzistentní velikosti pixelů napříč celým snímkem, což je u mezer menších než 1 mm klíčové.
Další nezbytnou komponentou je profilometr, který doplňuje kamerové měření o 3D analýzu povrchu a montážního spoje. Profilometr snímá výšku a tvar jednotlivých dílů s rozlišením až ± 0,02 mm a porovnává je se zvoleným referenčním modelem. Kombinací dat z kamery a profilometru dochází k vizuální kontrole složení dílů v reálném čase, čímž se garantuje správné zapadnutí bez vůlí či přetlaků.
Software ELVAC Vision vyvinutý in-house propojuje oba senzory do jednoho uživatelského rozhraní. Operátor definuje kontrolní zóny a tolerantní mezery prostřednictvím grafického editoru. V režimu provozu systém automaticky vyhodnocuje výsledky a při zjištění odchylky upozorní obsluhu nebo přeruší výrobní linku. Díky pokročilým algoritmům a možnosti využití neuronových sítí lze navíc provádět adaptivní kalibraci parametrů pro různé povrchové úpravy či materiály.
Modulární konstrukce pracoviště umožňuje snadnou integraci do stávajících linek a flexibilní rozšíření o další kamery pro víceúhlové snímání. Celé řešení vizuální kontroly splňuje požadavky Industry 4.0 na digitální sledovatelnost a sběr dat pro statistickou analýzu procesních parametrů.
Klíčové přednosti v tomto projektu:
Vizuální kontrola s ultra-přesným telecentrickým objektivem
Profilometr pro 3D měření s odchylkou ± 0,02 mm
Real-time vyhodnocení složení dílů v jediném pracovním kroku
Grafické rozhraní pro rychlé definování kontrolních zón
Modulární integrace a podpora Industry 4.0 standardů
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