ScrappiX

automatic visual inspection machine with double table for O-Ring and generic pieces


LINUX

DATABASE INTEGRATION

STATISTIC REPORTS

COLOR VISION

ARTIFICIAL INTELLIGENCE

ScrappiX is an innovative visual inspection machine for the dimensional and surface control of circular and other shape components. It can be employed for the high precision control of gaskets in rubber, plastic parts and other materials within the limits of the vision field. The pieces are checked through a series of stations responsible for checking defects using digital industrial cameras. The images thus acquired are transferred, without loss or disturbance, to a PC managed by a Real-Time operating system which performs both image processing and interaction with the operator through a simple and intuitive window interface. The Real-Time system allows excellent system stability and extremely high control speeds.

After the elaboration of captured images, the pieces are sorted in different areas of accumulation depending on their pass/fail criteria or they can be reworked. Times are very short for the change of piece to be sorted thanks to the saving of all the configuration parameters and the rapid cleaning of the machine and the loader.


ILLUMINATION

  • Digital regulation of bright intensity for inside and outside surfaces
  • Possibility to control piece with reflecting surface
  • Good precision of dimensional and surface controls
  • No decadence of bright intensity

 

LASER THRUBEAM SENSOR

Laser thrubeam sensor is able to measure with extreme accuracy the planarity of the piece scanning the pieces along all of their dimension. It's possible to measure the height only for pieces perfectly planar. The elevated precision of measuring is achieved using algorithms of elaboration of the signal that allow to eliminate any imperfection of the rotating table during its oscillation.

 

DIMENSIONAL STATION

Independent measurement sensor for dimensional control of circular pieces, with the following characteristics:

  • Progressive scan high resolution B/W camera
  • Nearly zero distortion bi-telecentric lenses
  • Dedicated lighting system

Related control program features

  • Measurement of the inner/outer diameter
  • Measurement of the radial cross section
  • Measurements of general lengths, angles, radii
  • Flash defects inspection
  • Nicks defects inspection
  • Roundness inspection
  • Center distance

 

CONTROL SOFTWARE 

The software for analysis and control of components with complex shape allows the recognition of planar rotation of piece. It also recognizes the top and bottom sides and independently process the image of the piece regardless of load position.

Control program

  • Irregular profiles identification and related control with reference to the sample profile
  • Control of the maximum and minimum height of holes and flash on linear and curvilinear profiles
  • Definition of multiple calibers and control of their dimensions
  • Control of the median and punctual variation of cord sections
  • Simultaneous analysis of surface defectiveness in many inspection areas

OPTIONAL CONTROL DEVICE OF EXTERNAL AND INTERNAL SURFACES

This system consists of two stations (internal side and external side) with each 6 progressive 2 Mpixel color scan cameras, with framing of the outside and inside of the piece every 60°. Each camera has a very low distortion lens. In addition, the system is characterized by 2 levels of colored LED lighting arranged above and below the piece.

The system allows to optimize the illumination of the piece thanks to the independent regulation of the illuminators with pulsed light.

The control program allows you to detect defects on the external and internal edge of a piece and anomalies related to the mold closure and production defects that frequently occur in that area.

TECHNICAL SPECIFICATIONS 35 70 90
Material rubber, plastic, PTFE, metal
Color any color (1)
Min. Outside Diameter 4 mm 4 mm 20 mm
Max. Outside Diameter 35 mm (2) 70 mm (2) 90 mm (2)
Min. thickness 0.9 mm 0.9 mm 0.9 mm
Max. thickness 9 mm 9 mm 9 mm
Productivity Up to 10 pcs/s (36,000 pcs/h) depending on the typology and material of article
Loading system Bulk feeder 300 L

 

PLANARITY STATION 35 70 90
Measuring range 9 mm 9 mm 9 mm
Dimensional resolution 0.001 mm 0.001 mm 0.001 mm
Accuracy of measurement (4) ±0.015 mm ±0.015 mm ±0.015 mm
Repeatability (±2σ) (4) ±0.025 mm ±0.025 mm ±0.025 mm

 

VERTICAL DIMENSIONAL STATION 35 70 90
Camera B/W B/W B/W
Field of View Ø54 mm Ø71 mm Ø102 mm
Maximum height 5 mm 5 mm 5 mm
O-Ring max. height 10 mm 10 mm 10 mm
Dimensional resolution 0.001 mm 0.001 mm 0.001 mm
Optical resolution 0.045 mm/px 0.059 mm/px 0.050 mm/px
MPE (5) inside diameter 9 µm (6) 10 µm + 0.5 x 10-4 x Int/Dia µm (7) 12 µm (6)
MPE (5) outside diameter 9 µm (6) 10 µm + 1.5 x 10-4 x Ext/Dia µm (7) 12 µm (6)

 

SURFACE STATION ON BOTH TABLES 35 70 90
Camera Full color Full color Full color
Number of lenses 4 4 4
Focus adjustment Motorized Motorized Motorized

 

OPTIONALS

 

DIFFERENTIAL THICKNESS LASER STATION 35 70 90
Measuring range 25 mm 25 mm 25 mm
Resolution 0.001 mm 0.001 mm 0.001 mm
Accuracy of measurement (3) ±0.003 mm ±0.003 mm ±0.003 mm
Repeatability (±2σ) (3) ±0.005 mm ±0.005 mm ±0.005 mm
Minimum internal diameter 10 mm 10 mm 10 mm

 

PLANARITY STATION 35 70 90
Measuring range 25 mm 25 mm 25 mm
Dimensional resolution 0.001 mm 0.001 mm 0.001 mm
Accuracy of measurement (4) ±0.018 mm ±0.018 mm ±0.018 mm
Repeatability (±2σ) (4) ±0.030 mm ±0.030 mm ±0.030 mm

 

INTERNAL LATERAL STATION ON BOTH TABLES 35 70 90
Cameras Full color Full color Full color
Width of field of view for each camera 25 mm 44 mm 58 mm
Optical resolution 0.016 mm/px 0.028 mm/px 0.036 mm
Minimum detectable defect size (8) 0.050x0.050 mm 0.085x0.085 mm 0.110x0.110 mm

 

EXTERNAL LATERAL STATION ON BOTH TABLES 35 70 90
Cameras Full color Full color Full color
Width of field of view for each camera 29 mm 48 mm 48 mm
Optical resolution 0.018 mm/px 0.030 mm/px 0.030 mm/px
Minimum detectable defect size (8) 0.055x0.055 mm 0.090x0.090 mm 0.090x0.090 mm

 

DEVICES
Bulk feeder 130 L
ABC Station (Automatic Blowing Checker)
DTC (Dirty Table Checker)
Heater on bulk feeder
Antistatic bars
Laminar flow cabinet
Manual cleaning machine control
Rotating warehouse
Packaging machine
Z conveyor belt

 

NOTES

(1) Transparent to be tested
(2) Not deformed O-Ring, value not referred to all stations
(3) Verified on measurement of Axial Cross Section of black O-Ring NBR at 20°C ± 1°C
(4) Verified at temperature of 20°C ± 1°C
(5) MPE = maximum permissible measurement error according to ISO/IEC Guide 99 - International Vocabulary of Metrology (VIM) - Basic and general concepts ad associated terms, 4.26
(6) Verified on full field of view on average diameters and average cross section of oring at 20°C ± 1°C
(7) Verified on full field of view on average diameters and average cross section of O-Ring at 20°C ± 1°C. (d1 = internal diameter of the measurand, d2 = external diameter of the measurand)
(8) Minimal variation of 20 points of tone difference in adjacency