Type Recognition and Inspection of Injection Molded Parts

The Challenge

An automotive manufacturer needed an inspection system for polymer injection molded parts to ensure that the correct part types were being processed while also identifying defects. In this application, the client needed a system that could accurately distinguish between part types and detect small burrs on the diameter. The inspection process also had to keep pace with production demands, requiring a repeatable solution that could eliminate the inconsistencies associated with manual inspection.

The Solution

Senswork created a solution by feeding the polymer die-cast parts from a vibratory conveyor to a rotating glass plate for inspection. Once the parts are on the rotating plate, they are analyzed by two separate camera systems. The first camera system performs type recognition, verifying that each component matches the required part specification and ensuring that incorrect or mixed parts are immediately identified. Once the type verification is complete, the parts proceed to the second camera system, which inspects the diameter for the smallest burrs and other surface defects. Both inspection stages are evaluated in real time using senswork’s VisionCommander® image processing software, enabling precise and rapid pass/fail decisions.

The Results

By combining type recognition and defect inspection into one application, the manufacturer was able to streamline quality control and reduce the need for multiple inspection stations. The system achieves inspection cycles of up to two parts per second, allowing it to support the high-volume production environment while maintaining consistent inspection performance. The use of the VisionCommander® image processing software provides fast and accurate evaluations, ensuring reliable detection of part variations and defects. As a result, the manufacturer benefits from improved product quality, increased inspection efficiency, and greater confidence that only compliant parts move forward in production.

Would you like to learn more about machine vision applications for plastic injections and packaging? See more examples here.