Machine Vision Inspection for Relay Assembly
Yangning
High-Speed Image Acquisition: Telecentric lenses and coaxial polarized lighting setup
- Telecentric lenses eliminate perspective distortion for micro-component dimension measurement. Coaxial polarized lighting suppresses copper surface reflection, delivering stable edge contour extraction for rivets, contact springs and stamped terminals. Camera exposure window is locked within 22 μs to avoid motion blur under continuous rotary indexing movement.
- Request vision test report for relay samples.
Defect Classification Algorithms: Detecting stamped edge burrs, rivet tilt, and missing springs
- Pixel-level threshold segmentation and template matching run parallel for feature validation. Defect library covers stamped edge burrs ≥0.03 mm, rivet angular tilt >1.2°, missing contact springs and offset terminal placement. System output: defect coordinate, severity grade and pass/fail tag, with detection accuracy ≥99.7%.
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Vision System Type Repeatability Max Takt Maintenance Interval Relative CAPEX Telecentric coaxial polarized vision ±0.008 mm 0.8 s 12,000 hrs High Standard ring-light machine vision ±0.025 mm 0.4 s 8,000 hrs Medium Manual visual inspection ±0.12 mm 1.8 s N/A Low
Mechanical Shutter Timing: Synchronizing high-speed strobes with rotary indexing plates (< 0.8s takt)
Strobe trigger signal interlocks with cam indexing dial position encoder. Image capture occurs during dwell phase of rotary plate, when fixture position variation ≤0.01 mm. PLC synchronizes camera, lighting and PPU material handling without extra waiting time.
Real-time Reject Sorting and Defect Heatmaps for Upstream Stamping Tooling
- Failed parts are diverted via Poka-Yoke mechanical interlock reject chute. Defect data streams to MES, generating heatmaps showing spatial distribution of recurring burrs and dimensional drift. Tooling engineers use these trends to adjust stamping die clearance before batch non-conformance occurs.
- Relay In-line Quality Inspection and Preventive Maintenance Specification provides full criteria for vision station routine calibration.
