High Speed Metal Ring Inspection System
The Ring Inspection System is designed to automate the quality inspection of metal (SS) rings used in sealing and mechanical applications. With a throughput of up to 120 parts per minute, this system ensures reliable, high-speed inspection while eliminating manual errors. The integration of top, and bottom imaging—powered by 3D profilers and area scan camera—allows for comprehensive defect detection and dimensional checks.
Problem Statement:
Manual inspection of rings is labor-intensive, inconsistent, and prone to oversight—particularly in high-volume production lines. Ensuring dimensional accuracy, and defect-free surfaces requires a robust solution that can handle a wide range of ring sizes while maintaining high throughput and accuracy.
Solution:
Unilogic developed a fully automated Ring Inspection System that uses a combination of 3D line profilers and high-resolution area scan camera to perform rapid inspection.
- Feeding Mechanism: An automated mechanism will feed the rings in a properly aligned manner to the inspection station.
- Image Acquisition: The system captures images from top and bottom perspectives using multiple 3D profilers and a camera.
- Defect Detection: Using special image processing algorithms, the software identifies surface defects, foreign material, and dimensional deviations, classifying parts as OK or Not OK.
- Sorting Mechanism: Defective rings are removed via a pneumatic ejector, while accepted parts continue to the good bin/conveyor.
- Report & Traceability: The machine logs all inspection data and generates automatic inspection reports.
| S.No | Specification Parameter | Typical Value or Range | Comments |
|---|---|---|---|
| 1 | Machine Inspection Speed | 60 PPM to 120 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 8 mm | 3D Profiler View |
| 5 | Outer Diameter (OD) | 10 mm to 60 mm | Top Camera View |
| 6 | Flatness | 1 mm | 3D Profiler View |
| 7 | Circularity | 0.5 mm | Top Camera View |
| 8 | No. of Area Scan Cameras | 1 | 5 MP, USB3, mono, Global shutter |
| 9 | No. of Line Profilers | 2 | High definition 3D line profile sensor |
| 10 | Machine Dimensions (L × W × H) | 4039 mm × 1925 mm × 1886.3 mm | - |
Key Features:
- High-Speed Inspection: Designed to inspect 60–120 rings per minute, depending on ring dimensions.
- User-Friendly Operation: Operable through push buttons, minimizing direct PC interaction.
- Advanced Image Processing: Supports customizable inspection parameters for different ring types and defect thresholds.
- Report Generation: Generates inspection reports in formats such as Excel and PDF for easy documentation and analysis.
Benefits:
- Single-Person Operation: Reduces manpower while improving consistency and reliability.
- Power Efficiency: Integrates low-power electric and pneumatic components for energy-conscious operation.
- Supports Multiple Models: Allows quick setup changes for inspecting different ring sizes and types.
- Secure Multi-Level Access: Offers tiered access for operators, engineers, and supervisors with report and setting control.
- Automatic Report Generation and Logging: The machine automates the generation of inspection reports and is able to log the reports.