High Speed Flange Inspection System
The Flange Inspection System streamlines and automates the inspection of automotive flanges, eliminating human error and significantly increasing throughput. With a capability to inspect up to 150 flanges per minute, the system offers high-speed, non-contact inspection using a combination of 3D profilers and area scan cameras. This fully automated solution improves the quality and reliability of the flange inspection process.
Problem Statement:
Manual inspection of flanges is time-consuming and prone to human error, especially at high production volumes. Variations in part orientation, inconsistent lighting, and subjective judgements often result in unreliable quality checks. The client required an automated system capable of inspecting multiple parameters, including surface defects, foreign material, dimensional accuracy, and flatness— all at high speed and with traceable results.
Solution:
Unilogic developed a high-speed Flange Inspection System that uses a combination of 3D line profilers and area scan camera to capture detailed images from the top and bottom of each flange.
- Flange Loading: An automated mechanism will feed the flanges in a properly aligned manner to the inspection station.
- Image Acquisition: Images are captured at different angles using one area scan camera and two 3D profilers.
- Image Processing: Custom-developed image processing algorithms analyse surface and dimensional features to classify parts as OK or Not OK.
- Sorting Mechanism: Rejected parts are separated using a pneumatic ejector, while good parts are collected in the output bin/conveyor.
- Data Logging & Reports: The system automatically logs inspection results and generates batch-wise inspection reports.
| S.No | Specification Parameter | Typical Value or Range | Comments |
|---|---|---|---|
| 1 | Machine Inspection Speed | 60 PPM to 150 PPM | - |
| 2 | Surface Defects | Minimum 0.5 mm² | 3D Profiler View |
| 3 | Foreign Material Detection | Minimum 0.5 mm² | Top Camera / 3D Profiler View |
| 4 | Thickness | 2 mm to 12 mm | 3D Profiler View |
| 5 | Maximum Length | 10 mm to 65 mm | Top Camera View |
| 6 | No. of Area Scan Cameras | 1 | 5 MP, USB3, mono, Global shutter |
| 7 | No. of Line Profilers | 2 | High definition 3D line profile sensor |
| 8 | Machine Dimensions (L × W × H) | 4039 mm × 1925 mm × 1886.3 mm | - |
Key Features:
- Inspection Speed: The machine is designed to inspect and process 60 to 150 parts per minute, with the actual speed varying based on the size of the flanges
- Easy Accessibility: The machine can be operated with push buttons, reducing the need for operators to access the PC.
- Configurable Image Processing Functions & Parameters: Users can customise the inspection parameters to optimise the machine's image processing capabilities according to their specific requirements.
- Report Generation: The machine offers report generation capabilities in various formats, including Excel and PDF.
Benefits:
- Single-Person Operation: The machine is designed to be operated by a single person, enabling automated inspection compared to the manual.
- Energy-Efficient Components: The machine incorporates electric and pneumatic components that are designed to consume less power.
- Multiple Setups for Different Flange Models: The machine supports the configuration of multiple setups, allowing for seamless changeover to different models of flanges.
- Multi-Level Access: The machine includes a multi-level login feature that provides authorised personnel with access to machine settings and all inspection batch reports.
- Automatic Report Generation and Logging: The machine automates the generation of inspection reports and is able to log the reports.
