For large quantities or large product variety, a highly accurate or automatic 100% measurement is often not feasible or viable. For such products, Ziemann & Urban offers flexible manual test stations for the testing of samples. The solution described measures punched dipping caps for lighting the automotive industry. The dipping caps are installed in H4 or H7 car bulbs. The user guidance is completely realized with the vision system. The sample size is adjustable. Devices to be tested are manually clamped in a component-specific fixture and placed in multiple views (top view and up to two side views) under the camera. The Windows7 (64-bit) based image processing system measures the dimensions and displays the results. Order data (batch number, lot number, inspector, job number, etc.) can be read by a barcode scanner from a SAP generated document. The result of the sample is visualized on the 23 "TFT monitor. It is also transmitted via a text-file-based interface in the customer`s own SAP system, where records of the samples are created and archived. The system is declared as a measuring system in the production enviroment. It has been proven the capability to measure the necessary tolerances with measuring system analysis (MSA). The MSA is done with a separate calibration part.
