Application Note | Case Study | Technology Primer | White Paper
Automated Inspection System
Using Teledyne DALSA Software
Ensures Rapid, Accurate
Inspection for Automotive Product
Manufacturer Bosch Limited
The Bosch Group is a leading global supplier of
technology and services, with a focus on automotive
technology, energy and building technology, industrial
technology, and consumer goods. The Bosch Group
encompasses Robert Bosch GmBH and its more
than 350 subsidiaries and regional companies in 60
countries, including Bosch India Limited, which has its
corporate headquarters in Bangalore, India.
In India, Bosch India Limited manufactures diesel and
gasoline fuel injection systems, automotive aftermarket
product, auto electricals, special purpose machines,
packaging machines, electric power tools, and security
systems.
As part of its quality-control efforts, Bosch India Limited
relied on a manual system for manifold absolute
pressure (MAP) sensor inspection through which
it examined automotive components for capacitor
placement and negative temperature coefficient (NTC)
weld quality. To complete these inspections, a random
number of parts were selected at the end of each shift.
Inspectors used a video measurement system to check
each part manually, a process that took as long as seven
minutes per part. Plus, since the process was completed
in three distinct stages, in separate locations, it was
even more time consuming and required that operators
be trained on disparate solutions for each phase of
inspection.
The Need for Speed: Boosting Speed while
Ensuring Accuracy
Bosch India Limited approached Qualitas Technologies,
an industrial automation solutions expert in the region, to
provide an industrial vision-based solution to streamline
the company’s automation efforts, increase inspection
speed, and improve efficiency while still ensuring
accuracy. “We approached Qualitas Technologies as
they are industry experts in machine vision, and we
are very happy with the solution that was delivered,”
says Mr. Harish Babu, senior manager at Bosch India
Limited. “The measurement accuracies we demanded
were very high, so we weren’t sure if they could be
achieved. Qualitas provided sufficient demonstrations
and feasibility reports, which gave us the confidence that
this system will work.”
Recognizing the superiority of vision products from
Teledyne DALSA, specialists from Qualitas designed
a vision system using Teledyne DALSA’s Sherlock
machine vision software configured to a two-camera
solution that included two, five-megapixel cameras with
12 mm telecentric lenses and a blue DOAL light for
illumination.
To complete the inspection, an operator places the
components on one of two rotary indexing tables; one
camera is positioned over each table to capture images
to determine accurate capacitor placement and weld
quality, respectively. Images from the cameras are
streamed to a high-speed, second-generation desktop
PC on which Teledyne DALSA’s Sherlock machine vision
software views each image. The images from the first
camera are checked for the presence and placement of
capacitors and verified for positional accuracy. Images
from the second camera ensure weld quality of leads.
With Sherlock software, the new automated inspection
process is able to ensure an inspection time of less than
300 milliseconds for each component and is accurate
within 10 microns. Once inspection is completed, the
operator unloads the inspected parts, and components
that fail to meet pre-set requirements are discarded.
1
To determine accurate capacitor placement and weld
quality, cameras capture images of components, which
are streamed to a PC operating Teledyne DALSA’s
Sherlock machine vision software.
continued >
Property of Teledyne DALSA. Not for publication or reproduction without permission.
Copyright © 2014. Teledyne DALSA. All Rights Reserved.
Application Note | Case Study | Technology Primer | White Paper
“The solution from Qualitas has enabled us to achieve
unprecedented levels of quality in real-time, which
otherwise would have taken many hours through
manual inspection,” says Mr. Harish Babu. In fact,
Bosch Limited is so satisfied with the improvements
in efficiency and speed the new automated inspection
system provides—a reduction from as many as seven
minutes to just milliseconds per inspection—and the
way this streamlined process has enhanced efforts
to meet stringent quality-control standards, that it is
planning to implement a comparable vision system on
new production lines.
In less than 300 milliseconds per component, Sherlock
software facilitates an automated inspection process that
is accurate to within 10 microns, checking for capacitor
presence and placement and the quality of weld leads.
www.teledynedalsa.com
Americas
Europe
Asia Pacific
Boston, USA
Krailling, Germany
Tokyo, Japan
Shanghai, China
+1 978-670-2000
+49 89 89 54 57 3-80
+81 3-5960-6353
+86 21-3368-0027
sales.americas@teledynedalsa.com
sales.europe@teledynedalsa.com
sales.asia@teledynedalsa.com
sales.asia@teledynedalsa.com
Teledyne DALSA has its corporate offices in Waterloo, Canada
Teledyne DALSA reserves the right to make changes at any time without notice. Teledyne DALSA © 2014.