01 Case Background
Automotive lights are a key component of automotive lighting, usually consisting of a variety of different electrical components such as bulbs, motors, sensors, etc., which need to be connected by connectors such as wiring harnesses and connectors. If the wiring harness or connector fails, it can seriously affect the quality and performance of the lights. Therefore, it is important to inspect connectors such as automotive wiring harnesses and connectors during the production process.
Pain points of manual detection:
The traditional quality inspection of automotive electronic connectors mainly relies on manual visual inspection, which has problems such as low efficiency, inconsistent testing standards, low detection accuracy and high labor costs.
02 Solution
According to the pain points of application scenarios, the card-saving robot has created a standard visual inspection system for lamp connectors. The system is mainly composed of JAKA Zu series/JAKA MiniCobo collaborative robots and JAKA Lens 2D vision cameras, and at the same time connects the customer's PLC, MES system and other information terminals, making the entire detection process more efficient, more accurate and more intelligent, helping customers save costs, improve detection efficiency and accuracy.
Process:
1. Manually place the lamp on the fixed tooling;
2. The JAKA Lens 2D camera is carried by the Jieka robot to detect each connector of the lamp;
3. The vision system judges the assembly status of each connector, and displays the OK/NG result to the main interface;
4. The lamp is manually placed in the next station or defective product placement area, and the detection is completed.
1. Non-contact measurement and detection, rich in functions and wide applications
The JAKA visual inspection system has the functions of size measurement, angle measurement, distance measurement, roundness measurement, area detection, etc., and can be applied to electronic components, auto parts, mobile phone parts, screws and nuts, hardware, magnetic materials, plastics, ceramics, buttons and other composite components, magnesium, aluminum and their alloy parts.
Compared with the traditional manual detection method, it has the characteristics of objectivity, non-contact and high precision.
2. Stable and reliable edge detection algorithm to ensure detection accuracy
The system is equipped with JAKA Lens2D vision camera, which adopts procedural drag-and-drop programming, and users can debug the entire system within 2 hours. In terms of algorithms, JAKA Lens2D is equipped with visual tools such as template matching, edge finding, point-line distance, and point-to-point distance. Through the free combination of tools, the precise distance measurement of the connectors after assembly is realized, ensuring that each connector is assembled in place. The size accuracy of the detection algorithm is as high as 1/20 pixel, the angle accuracy is as high as 0.05°, and the detection cycle of each connector is less than 1 second to meet customer needs.
3. Flexible and flexible card-saving robots, with remarkable results in reducing costs and increasing efficiency
The card-saving robot is small, lightweight, plug-and-play, and can be quickly deployed to the automated production line of automobiles and parts in a short time; Simple operation, low threshold for use, easy follow-up management and use; High repeatability positioning accuracy, to meet the requirements of high-precision production processes such as engine assembly and lamp gluing; High safety, man-machine collaborative production safety is guaranteed. The card-saving robot not only helps enterprises save time and labor costs, but also improves equipment mobility and automated production efficiency and production capacity.
04 Case results
1 1 set of testing equipment can replace 2 workers, save labor costs, reduce tedious and repetitive workload;
2. Compared with manual inspection, the detection accuracy is greatly improved, and the yield rate of finished products is increased to 99.8%;
3. Data docking MES system, which is convenient for customers to trace and manage production information, and helps customers control and optimize the production process.
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