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Disc brake vision inspection system

25 Oct 2013

An industrial vision system to inspect disc brakes has been developed for Knorr-Bremse, the world’s leading manufacturer of disc brakes for commercial vehicles. Developed by STEMMER IMAGING in collaboration with Neupro-Solutions and featuring line laser illumination, three cameras and intelligent imaging software, the system inspects the brake assemblies and checks the correct mounting by comparing the results to stored data. This ensures correct and therefore safe operation in the vehicle.

The Knorr-Bremse manufacturing facility produces 1,200 different brake types for use in commercial vehicles, ranging from 6-ton to 44-ton trucks, buses and towing vehicles through to the trailer sector. The inspection system allows inspection of 64 different characteristics.

The disc brakes leave production mounted on a workpiece carrier and are checked with great precision in a dedicated inspection area. The entire measurement process including laser triangulation, pattern recognition, colour recognition and measurement of components is carried out within milliseconds to determine whether the brake is correctly mounted according to the specified parts list and assembly guidelines held in the database. If a defect is detected, the database contains information as to whether it can be eliminated by reworking.

The system utilises three AVT cameras equipped with Schneider Kreuznach lenses and two line lasers from Z-Laser. The automated inspection is carried out using Sherlock image processing software from Teledyne DALSA. A Neupro- Sherlock plugin for Oracle transfers the data to the database. Both image data and inspection data are archived in the database and then transferred to a higher-level control.

The individual inspection algorithms are global and are recalled via the database using the part number of the particular brake assembly. In addition, it is possible to statistically evaluate the measurement data stored in the database and to perform a statistical approximation within the predefined threshold values.

Allied Vision

Stadtroda, Germany

For 25 years, Allied Vision has been helping people to be faster, more precise, and more efficient in whatever matters to them. From raising production standards to detect diseases faster, proving scientific theories true, monitoring traffic intelligently or simply knowing who crossed the finish line first – with their technology and expertise, Allied Vision helps customers to gain insight by seeing more and hence be more successful in what they do.

STEMMER IMAGING

Puchheim, Germany

STEMMER IMAGING has been one of the leaders in the machine vision market since 1987. It is one of Europe's largest technology providers in this field. In 1997 STEMMER IMAGING presented Common Vision Blox (CVB), a powerful programming library for fast and reliable development and implementation of vision solutions, which has been deployed successfully throughout the world in more than 40,000 imaging applications in various industries.

Teledyne DALSA

Waterloo, Canada

Teledyne DALSA is one of the largest companies serving the machine vision industry and is unique in that it is vertically integrated; from sensor design and manufacture, through image capture and processing, to software for imaging optimisations and analysis.

Z-Laser

Freiburg, Germany

Since being founded in 1985, Z-Laser has been an innovative manufacturer of intelligent laser technologies in the fields of metrology, industrial machine vision, positioning, and medical technology.

Z-Laser ZM18-LP - Line laser with Powell lens
  • Focusable optics: single line, Powell lens
  • Compact and robust housing
  • Different output levels and aperture angles available
Allied Vision Manta

Feature rich digital cameras with resolutions ranging from VGA (0.3 megapixel) up to 12 megapixel. Industrial GigE Vision interface (with POE options) with frame rates of up to 125 frames per second.

Teledyne DALSA Sherlock

Powerful and flexible vision application for factory automation