Problems faced:

-  The current process is a manual process where the bottom of the machine wash has been manually checked for the presence/absence of screws on the 4 surfaces of the object.

-  This process is done to ensure that the screws are present on the part as they play a role in the structural integrity of the machine.

-  Since screws are a small object, to manually check each one on 7 different locations on the object is a cumbersome task and leaves a significant margin for error.

-  Failure to accurately determine the presence/absence of screws on the object may result in defective machines being sent to the customer, which will then incur additional costs for the company responsible for maintaining and repairing those machines, and also adversely affect their brand in the market.

Solution:

-  4 high resolution industrial machine vision cameras with integrated lights were mounted on the four inspected sides to check the presence/absence of screws on the components.

-  The cameras were enclosed in a secure housing to keep the camera position and status intact and for easy maintenance.

-  Dedicated high intensity industrial grade LEDs were used to ensure proper illumination.

-  An industrial PC was connected to fetch images and process them in real time.

-  All other system modules were organized in a compact panel for safety.

Maintenance:

-  The challenge is checking for presence/absence of screws as they are very small in size, a particular screw located inside a small conduit on the surface is a bit difficult to check, for this a dedicated industrial grade lighting system has been used to ensure that the object is properly illuminated.

-  Another obstacle is that the screws are present in different locations on all three variants and the system has to be heavily trained to check at certain locations for presence/absence of screws.

Image:

Result:

-  The above solution has been successfully implemented on all three variants