For cast metal components with complex shapes and geometries a 100 % surface inspection is an inspection taks difficult to realize or only in combination with extremely high maintenance requirements.
Since the surfaces of such components are subject to fluctuations and variations in the production process (due to raw material , storage, transportation , processing , etc.) continuous adjustments by particularly trained staff is needed in the daily practice.
These resources are often not available or only partially available or are not cost-effective for certain products.
An affordable and easy alternative is the documentation station from Ziemann & Urban
The System guarantees a consistent quality of high-resolution images of complex components even under rough production conditions.
With a product-specific insert (eg. by manually sliding table, workpiece carrier or automatically via conveyor, shuttle) a reproducible positioning of the component is guaranteed in the documentation station.
In the station, the relevant views of the parts are imaged by high-resolution commercial single lens reflex cameras (SLRs) (resolutions up to 20 megapixels possible).
The cameras are mounted around the parts to be documented on adjustable holders with integrated lens clamping.
Lighting is provided via switchable component-specific, long-lasting and robust LED flood lamps.
The control of the whole process and the photograph is done by the software „ZU-Control" running on a Windows 7 (64bit) industry computer.
The images can be displayed to the operator and enlarged with a mouse click.
Here a manual quality decision based on the images via touch screen or control box is optionally possible.
If existing on the parts identify features such as DMC, QR or bar codes can be read out and used for the storage of the images obtained.
Using this a folder containing images can be created for every acquired code or part number.
All data can be shared or archived via network .
Communication with higher-level controllers , databases, and production / plant systems or MES is optional.
The documentation station can be realized as a mobile cabin on wheels or fixed integrated into the production processes and automation.
Possible products:
- form complexes castings (engine blocks, carrier assemblies ...)
- complex electro-mechanical assemblies
- (electro) mechanical kinematics
- any sensitive products that require a 100% documentation
