Defect Detection on Cast Metal Bars

Defect Detection on Cast Metal Bars

Customer Problem:

A manufacturer of cast metal bars was looking for an economical way to inspect post-cast, machined bar surfaces for tears, waves, finger grooves, dragmarks and other surface defects. The metallic bars' reflectivity was the biggest challenge to overcome, because it caused inconsistent contrast over the entire surface of the shiny cylinders. These cylinders, from which a variety of items are produced including stamped automotive parts, must also meet customer quality requirements for decreased flash (waste) and increased production speeds.

Manufactured in various lengths and handled at rates of up to 20 ft/minute, the bars had been inspected by hand for manufacturing defects. The cost of manual inspection and its variability, however, prompted the company to look for a better solution.

Certified System Integrator Program

Set Yourself at the Forefront of the Global Vision Market

Vision system integrators certified by A3 are acknowledged globally throughout the industry as an elite group of accomplished, highly skilled and trusted professionals. You’ll be able to leverage your certification to enhance your competitiveness and expand your opportunities.

GET CERTIFIED

Cognex Solution:

The Cognex system integrator developed a specialized illumination, inspection, and reject handling solution for the customer. Proteus's solution was based on a Cognex Checkpoint 900 machine vision system using three cameras to perform 360 degree inspection of the surface of each bar as it is processed. The vision system first locates, then inspects each bar over its entire length. The inspection process is designed to detect surface defects and then send a signal to handling equipment down-stream to remove the rejected piece.

Additionally, Proteus implemented an easy-to-use interface for its customer and provided the capability for flaw-type tracking and analysis, enabling the customer to identify the position, size, type, and frequency of flaws.