1. Inspection Objects
The system inspects various automotive interior plastic covered parts, including A/B pillar trim panels, door sill trims, central control decorative covers, side liners, rear decorative panels and other special-shaped injection molded interior components.
2. Full Inspection Requirements
- Presence/Absence Detection: Detect missing assembled parts including fastening screws, PU gaskets, waterproof buckles, airbag plugs, sealing strips, air outlets, non-woven fabrics, wiring harness motors and other built-in accessories.
- Barcode & Data Matrix Reading: Decode 2D codes and label characters on the back of workpieces for full production traceability.
- Surface Defect Inspection: Identify scratches on LOGO decorative surface, plastic cracks and surface dirt stains.
- Dimensional Measurement: Measure overall width of trim panels and critical mounting hole dimensions.
- Molding Defect Recognition: Detect injection molding defects such as material shortage, deformation and flash.
3. Vision System Hardware Configuration
3.1 FOV & Precision Parameters
- Standard FOV: 483mm×323mm, dual-camera synchronous capture; single pixel precision: 0.088mm/pixel
- Large-size FOV: 680mm×460mm; single pixel precision: 0.12mm/pixel
- Illumination scheme: 4 groups of CK-PHBL series linear bar lights arranged around the workpiece to eliminate plastic reflection. Workpieces must be placed flat, shooting surface perpendicular to lens with consistent height.
3.2 Hardware List
| No. | Product Name | Model | Qty | Remark |
|---|---|---|---|---|
| 1 | Industrial Camera | CK-E2000MI-5.5RS | 2 | Dual station synchronous image capture |
| 2 | Industrial Lens | PM1614-3MEX | 2 | For large FOV interior parts |
| 3 | Linear Bar Light | CK-PHBL-470-035X | 4 | Surround lighting, customizable length by FOV |
| 4 | Light Controller | CK-WDP-3624-4 | 1 | 4-channel independent brightness adjustment |
| 5 | Image Processor | CK-IMPRO 1802 | 1 set | Integrated vision algorithm & I/O signal output |
4. Verification Test Results
All inspection items achieve stable recognition covering all types of interior trim:
- Dimension: Accurate measurement of overall width and mounting position size;
- Assembly: Identify presence/absence of screws, buckles, plugs, non-woven fabrics, gaskets and air outlets;
- Traceability: Read and parse backside 2D codes and label text;
- Appearance: Detect LOGO surface scratches, plastic cracks and surface contamination;
- Molding: Recognize injection defects like material shortage and deformation.
5. Complete Inspection Workflow
- Workpiece in place, photoelectric sensor triggers dual cameras to capture images simultaneously.
- CKVision software runs image preprocessing: filtering, reflection suppression, contrast enhancement.
- Parallel multi-tool execution: template matching positioning, part counting, barcode decoding, dimensional measurement and scratch defect detection.
- Final OK/NG judgment: OK signal for automatic release, NG triggers alarm I/O signal.
- Local data storage, barcode data uploaded to production MES for full lifecycle traceability.