Case Study · Manufacturing

Single-Camera Inspection of Child Parts and Crimping in a Terminal Box

One 12 MP camera inspects the presence or absence of child parts in a terminal box and measures the crimping part — delivering the required output on two variants.
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Industry

Manufacturing

Application

Vision system for terminal box — child-part presence/absence and crimp measurement

The Application

Optimised quality inspection for a high-accuracy production line

Manufacturing industries require an optimised solution for the quality inspection of their products. Vision inspection provides an efficient, high-accuracy solution that increases overall productivity and the flexibility of the manufacturing unit.

The requirement was to inspect child-part presence / absence in the terminal box and to measure the crimping part. The project was completed as per the customer’s requirement, with the desired output achieved on two variants.

Key Factors

  • Single camera used to inspect all the parameters
  • Accuracy achieved up to 500 microns
  • Communication through Modbus TCP/IP
  • User-friendly HMI with all controls
  • Extensive support after installation

Performance at a Glance

One camera, every parameter

1

Camera inspecting all the required parameters.

500 µm

Accuracy achieved on the measurements.

2

Product variants delivering the desired output.

Project Summary

From requirement to result

A single-camera vision system built around the customer’s inspection requirement.

01

Requirement

Inspect the presence or absence of child parts in the terminal box and measure the crimping part.

02

Single-camera inspection

A 12 MP Basler camera with a 25 mm lens inspects all parameters, running on Aurora Vision Runtime.

03

Modbus TCP/IP & HMI

Results are communicated over Modbus TCP/IP and controlled from a user-friendly HMI.

04

Two variants, full support

The desired output is achieved on two variants, backed by extensive support after installation.

Final Result

Vision components and live inspection results

Vision components — camera, lens and lighting over the rotary fixture
Results screen — pass / fail for capacitor, welding, lancing, coil and crimping checks

Technology Used

Hardware behind the inspection

12 MP Basler Camera

Captures every terminal box so all parameters are inspected with a single camera.

25 mm Lens

Matched to the field of view of the terminal box inspection area.

Aurora Vision Runtime

Runs the inspection and measurement program on the line.

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