Automated AI inspection of aluminum casting parts
Task
Quality assurance in the foundry requires reliable inspection of aluminum castings for casting defects and machining quality. Manual inspection is time-consuming and prone to errors.
Solution
An automated inspection system with AI-supported image processing captures the components with high-resolution cameras in several inspection stations. A six-axis robot guides the parts through the inspection process, while a specially trained AI evaluates and marks defect images. Our “ZU Control” software assigns the inspection results to the corresponding components and makes them available for subsequent processes.
Benefits
- Increased inspection accuracy: Consistent, objective quality assurance thanks to AI-supported image processing.
- Increased efficiency: Reduction in personnel costs through automation of inspection processes.
- Seamless integration: Integration of the system into the ongoing production process without interruption.
Technical realization
The inspection process takes place in several stations:
- A six-axis robot positions the aluminum castings in front of high-resolution industrial cameras.
- Images are captured in several inspection stations with 16-megapixel cameras.
- Specially developed lighting creates a bright component image with high contrast and great depth of field for the fine cast structures
- The captured data is analyzed by AI-based software that automatically detects and classifies defects.
- The “ZU Control” software saves the inspection results and transmits them to the downstream production processes.
- This automated inspection ensures a high level of quality assurance and minimizes rejects.
- Audit reliability thanks to master part sequence with stored validation set
You can find more details in the technical article published by Wiley Verlag
