The Problem Statement:
India’s leading Automotive manufacturer wanted to establish a reliable and consistent method of checking surface defects like patches and cracks on camshafts commonly found on the components due to errors in machining operations.
The automotive industry has a high requirement of finely finished camshafts. It is critical to detect surface defects such as patches and cracks since these defects induce noise, vibrations, and harshness post assembly. There is also a detrimental effect on engine performance.
Defects detected manually were highly prone to subjectivity and were not a satisfactory method of quality control. Besides being subjective, it was also a time-consuming process. The effectiveness of manual inspection decreased as workers doing the tedious, repetitive job got fatigued, working in varying light conditions in the harsh industrial environment. Operators often passed defective shafts as ‘OK’ which were issued to the Production line where the defective shaft could not be identified until the engine was fully tested.
The Automotive manufacturer had to then engage additional resources to disassemble the faulty engine and send it for rework, which took time and was expensive and an inefficient process. It was, therefore, important for the automotive maker to come up with a reliable and consistent method for detecting defects on shafts which eliminated subjectivity.
The Automotive manufacturer deployed OPTIVITY® Camshaft Surface Inspection System, an intelligent AI vision-based shaft inspection system from Griffyn Robotech. The system rapidly checked anomalous patches and defects on camshaft surface, which largely went undetected when inspected manually. The system leveraged an advanced image processing deep learning algorithm, which processed all captured parameters (data) of the shaft, identifying defects with 100% accuracy helping the Automotive manufacturer to assemble camshafts with zero defects and 100 % quality assurance.
How did the OPTIVITY® Camshaft Inspection System Work?
A reference model was made in which the system was trained with input images where surface defects were classified into OK parts without surface defects such as cracks and patches) and not OK (parts with surface defects such as cracks and patches). Based on these images, the deep learning algorithm of the OPTIVITY® Camshaft Surface Inspection system learned the acceptable form of surface quality of camshafts in varying light conditions. The OPTIVITY® Camshaft Inspection System camera with efficient image illumination, captured images of the camshaft which were extracted and compared with the reference model. This enabled the system to notify images of camshafts that fell outside the acceptable range of surface quality, helping the automotive maker to detect surface defects reliably and consistently on camshafts.
Benefits to Customer:
Improved Accuracy with Decreased Cycle Time
With OPTIVITY® Camshaft Inspection System, the automotive maker established a robust system of inspecting surface defects on camshafts. The cycle time of the operation decreased by 60%.
The manual inspection, was prone to errors and was done in 40 seconds for one camshaft, OPTIVITY® Camshaft Inspection System, could do the same operation in 12 seconds with improved accuracy.
|Parameter||Manual Inspection||OPTIVITY® Camshaft System from Griffyn Robotech|
|Inspection time||40 Seconds/shaft||12 Seconds/ shaft|
|Net benefit in Cycle time by using OPTIVITY® Camshaft Inspection system||28 Seconds/shaft|
Vision technology with AI will increasingly be adopted by manufacturers to improve productivity, product quality, and operator safety. With detailed specific industry knowledge, we at Griffyn Robotech have introduced the intelligent inspection solution-OPTIVITY®, which provides complete inspection coverage for large and small components with ease and precision. At Griffyn Robotech, we provide the necessary customization and fully automated, high-speed vision inspection systems using leading-edge technologies such as Robotics, machine vision, and AI.
Connect with us today to know how vision inspection technology can help your manufacturing facility be Industry 4.0 ready
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