Spark Plug Inspection System

Automated Spark Plug Inspection System enables End of Line Quality Control of Automobile or Aircraft Spark plugs.

The Spark Plug Inspection system seamlessly integrates into the production line. The inspection begins with the operator loading the spark plugs onto the conveyor. As each plug advances, our comprehensive dual-camera inspection station captures images from both top and side views. This dual-camera approach, utilizing a 4MP area scan camera (for the top view) and a 2MP camera (for the side view), ensures complete coverage for detailed analysis.

The system requires an approximate 75-millisecond window. This brief static period allows the cameras to capture clear, undistorted images. These images are then processed using custom image processing algorithms, specially designed to discern between acceptable (OK) and defective (Not OK) parts. Any identified defects trigger the system to redirect the flawed spark plug to a designated rejection bin. Meanwhile, the accepted parts seamlessly proceed to the end of the line, accumulating in a designated good bin.

S.NoSpecific parameterTypical Value or RangeComments
1Inspection speed (Parts Per Minute)180 PPMThe inspection speed can be adjusted based on accuracy requirements and inspection criteria.
2No. of Area Scan Cameras2Cameras will be selected based on the requirement (4MP, 2MP Monochrome Camera)
3Height of Spark Plug 40-60 mm-
4Outer Diameter of Spark Plug10-20 mm-
5Top View Linear Dimensions Resolution19 umBased on a 4 MP area scan camera & 20 mm FOV.
6Top View Linear Dimensions +/- Repeatability+/- 9.5 umBased on a 4 MP area scan camera & 20 mm FOV.
7Top View Linear Dimensions Accuracy19 um (+/-)Based on a 4 MP area scan camera & 20 mm FOV.
8Side View Linear Dimensions Resolution13.8 um (+/-)Based on a 2 MP area scan camera & 10 mm FOV.
9Side View Linear Dimensions +/- Repeatability6.9 +/- umBased on a 2 MP area scan camera & 10 mm FOV.
10Side View Linear Dimensions Accuracy+/- 13.8 umBased on a 2 MP area scan camera & 10 mm FOV.
11Camera Top Working Distance (Lens tip to Plug top surface) ~170mm Tunable with consequence on resolution, accuracy, repeatability
12Camera Lateral Working Distance (Lens tip to Plug lateral surface) ~100mmTunable with consequence on resolution, accuracy, repeatability

Benefits

  • The machine is capable of accommodating different models.
  • Single-Person Operation: The machine is designed to be operated by a single person, enabling automated inspection compared to the manual process
  • Multi-Level Access: The machine includes a multi-level login feature that provides authorized personnel with access to machine settings and all inspection batch reports.
  • Automatic Report Generation and Logging: The machine automates the generation of inspection reports, allowing users to review the results

Features

  • Software-Configurable for eccentricity, offset and gap limits.
  • Configurable Image Processing Functions & Parameters: Users can customize the inspection parameters to optimize 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.

Types of defects identified

  • Eccentricity between the outer housing profile and the inner electrode.
  • Offset between the earth electrode and the center of the inner electrode
  • Spark Plug gap between inner electrode and inner housing profile.