In-Sight 3900 Series
In-Sight 3900 is a high-speed AI machine vision system built for high-throughput production lines, with powerful computing and embedded AI for processing high-resolution images and advanced inspections.
Keeping powertrains production on track, from start to finish
Engines, transmissions, driveshafts, and associated powertrain components are extremely complex assemblies. Hundreds of intricate parts must meet precise tolerances, work together in perfect harmony, and withstand intense amounts of heat and friction.
That complexity, combined with evolving technologies such as dual-clutch continuously variable transmissions, means that powertrains demand high-end quality assurance. Flawed powertrains can have disastrous consequences like loss of power or control, fires, unintended acceleration, emission noncompliance, and vehicle reliability.
Powertrain assembly inspection and defect detection are crucial for preventing failures, reducing recalls, as well as protecting passengers and brand reputation.
Flexible, adaptive inspection for complex powertrain assemblies
There’s no room for errors in powertrain assembly and inspection tasks. Manual inspection is slow, inconsistent, and often misses subtle issues, like a barely visible crack in a weld or a defective gear cog.
Traditional rule-based machine vision systems are not suited for powertrain assembly inspection or defect detection: there are too many types of potential defects and close similarities between defects and acceptable anomalies. It would be impractical to program a rule for every possible defect -- and rule-based solutions struggle to adapt to new challenges.
Changes in lighting, surface color, part curvature, or camera field of view can affect inspection operations, leading to false positives that contribute to scrap rates or introduce flaws. Cognex redefines powertrain assembly with AI-powered vision systems that detect subtle defects and separate them from acceptable anomalies, resulting in flexible systems that minimize scrap rates, downtime, and improve quality.
Every part counts. Cognex covers them all.
Cognex machine vision systems use AI and advanced imaging technology to find subtle flaws in challenging conditions. Cognex AI compares images of defects to acceptable parts, and as the training model is refined, the solution learns and gets better at defect detection. Enhanced imaging tools like high-dynamic range plus (HDR+) maximize contrast on specular, nonuniform, and obscured parts to maximize image contrast, while powerful optics and lighting capture clear pictures during high-speed processes.
For 3D inspections, Cognex solutions use speckle-free lasers, a comprehensive suite of 2D and 3D tools, and a unified software platform to detect powertrain height discrepancies, misalignments, and other defects. And with embedded AI tools, 3D machine vision systems can segment regions and classify parts based on many features or characteristics – without complex programming.
Cognex technology makes it easy for manufacturers to verify quality of key powertrain components, such as:
- Transmission control module: inspect bolts, connector pins, adhesive, and more control module components to ensure quality and streamline inspections.
- Cylinder block: identify faint casting defects like metal pores in rough, reflective cylinder walls – overcoming challenges like glare, surface variation, and image blur.
- Engine block: confirm that all components are present and properly installed across various engine sizes and configurations. Instantly flag missing or misaligned parts and adapt to new types of defects.
- Oil cap: verify O-ring orientation by inspecting sealing beads as O-rings exit the feeder bowl. Inverted parts are automatically rejected and recirculated, reducing waste, preventing downtime, and increasing throughput.
- Cast components: find precise dimensions on cast parts and quickly identify flawed parts.
- Spring band clamps: confirm placement, orientation, and spring engagement of pre-opened, pre-positioned (POPP) clamps across various hose types and angles to prevent leaks of hot, corrosive, or toxic fluids, reduce warranty claims, and ensure long-term reliability.
Examples of Auto POPP Clamps that pass and fail inspections.
Engineered to handle inspections with ease
Cognex vision systems are designed for demanding industrial environments like those where powertrains are assembled. AI-powered systems, advanced imaging technology, and powerful optics ensure rapid, accurate assembly inspection and defect detection throughout powertrain manufacturing lines. Easy to deploy, these systems send results to PCs or PLCs to aid critical decision-making.
Easily integrated into plant automation and IT systems, AI-powered Cognex vision systems ensure real-time data, image archiving, and dependable powertrain performance. And when you need help, get more done with access to the Cognex support network of global experts and on-demand, self-service resources.