IPD Technical ConferenceFebruary 19th 2008

Automotive Fuse Box Inspection

Braas Company Info Founded in 1961 by Jim Braas

ESOP Company

4 physical branches – MN, WI, IL, FL (+ IA,SD,MX)

Fluid Power and Motion Control/Automation focus

105 employees

Over 15 years in Machine Vision

Industries Served: Medical, Electronics, Pharma, Automotive Tier, Packaging

Primary Product Lines

Denso didn’t get the memo about blue logos

Application Data Part is automotive fuse block assembly.

Goal: Identify bent & missing pins inside of connector sockets.

Pin locations must be relative to each other within +/- .005”

3 sockets per assembly. Each required Hi-Res camera to achieve required resolution (1376 x 1035).

Different lighting required for each socket due to shape and depth differences.

Hardware selected: VA41 w/ 3, Mpixel cameras.

Target Part (Sockets shown in red)

Socket 1 Details

Multiple pin heights

Reflective particles in socket housing

Different sized pin tips

Red LED Dome light selected.

Socket 1 Lighting Results Pin tips

much more distinct.

Dust particles not as noticeable

Socket 2 Details

Consistent heights

Reflective particles in socket housing

Pins high in Socket

Red LED Low Angle Ring Light selected.

Socket 2 Lighting Results

Pin tips much more distinct.

Match Tool used for presence and location

Socket 3 Details

Consistent heights

Reflective particles in socket housing

Pins LOW in Socket

Array too wide for Dome.

Red LED Low Angle Linear arrays

Socket 3 Lighting Results

Pin tips much more distinct.

Match Tool used for presence and location

INspect Solution (Locator & Pin Tips) Housing

Socket used as Locator

Match Tool used to find pin tips

Inspect Solution (Location of Pin Tips)

Match Tool Used to find pin tips

Model drawn around entire perimeter of pin to minimize errors from background (dust). Search widow enlarged to capture pin movement

Point tool enabled to track pin movement from nominal part model

Detail of Pin Tip Match Tool

Inspect Solution (Distance between pins)

Length Tools attached to center point of pin tip Match tools

Length tools used to check distance from one pin to another for interface with plug

Inspect Solution (Pin Array to Socket Edge)

Mid Point calculated between pin tips 2 point tools and pencil tool used to generate line on socket edge Distance from mid point to socket edged calculated (to account for interface with mating

plug) One Distance Tool used for each set of pin tips (all reference same socket edge). One tool

shown for clarity).

Additional application info

Additional VA21 also used to detect placement and orientation of mounting feet, and to read bar code under fuse box.

Wrap Up

Items sold for application 1 VA41 w/ 3 Mpixel cameras 1 VA21 w/ 2 low res cameras 1 LED Dome, 1 LED Low Angle, 2 LED Linear Arrays, 2 High Freq florescent

(VA21) 5 lenses and extension tubes of various sizes 2 power supplies 1 Industrial Switch

Additional Notes 2 additional systems have been sold for similar applications to this customer. Currently customer has 9 Dalsa/IPD systems in house. Former DVT/Cognex user. Customer now looking at Sherlock for future applications. They have grown

more comfortable in vision programming, and are enjoying the flexibility of Sherlock

Than You!

Questions?