Product category:
Vision and scanning systems
News Release from: Cognex UK | Subject: Machine vision
Edited by the Manufacturingtalk Editorial
Team on 21 October 2004
Automated PCB line featrures complete
traceability
A 100% automated PCB production line features complete product traceability that gives a competitive edge to a German company coping with a toughening global market.
A unique 100% automated production line features complete traceability for a German Electronics company At EbV Elektronikbau- und Vertriebs' fully automated production Plant II in Burbach, Germany, the complete production process of electronic circuit boards is structured so that both small quantities of the product can be handled with extreme flexibility, and large-scale series can be processed at high throughput speeds
This article was originally published on Manufacturingtalk on 6 Jun 2001 at 8.00am (UK)
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Complex vision technology in an affordable unit
Cognex have introduced the In-Sight 2000, an entirely new type of industrial machine vision sensor at a cost usually associated with "smart cameras"
Zero tolerance for defects is top priority while quality and efficient automation are the defining factors as traceability and documentation "from cradle-to-grave" gives the competitive edge to this German company in a toughening global market.
Andreas Fries, managing director comments, "on the one hand, we must be competitive on the consumer-markets of low-cost products, the so called China-markets.
On the other hand we must meet and fulfil the highest quality demands.
Further reading
Vision systems retrofitted like CNC
Special purpose machine tools and assembly systems, with Cognex machine vision systems as an integral part, are being supplied to the automotive industry by Douglas Curtis Machine Tools
Vision system dedicated to electronic production
Cognex has introduced Display Inspect - a machine vision software and hardware package for inspecting displays, keypads, and enclosures on LCD and LED display-based products.
New machine vision system for SMD placement
Cognex has introduced SMD4, Cognex's next-generation machine vision system for guiding the placement of surface mount devices onto printed circuit boards and other assemblies
And all this is topped with the customer's requirement for individual and distinctive flexibility in very short reaction-times.
Even a small fault in production could trigger a stop on the line and this is what we must avoid at all costs".
Hence complete traceability plays such a vital role in EbV's production strategy.
Courage to invest - located some distance from other larger players in the electronics industry, the company's primary goal since opening the site, has been to enhance the production of circuit boards and to raise automation and quality to a new level.
The company has also placed a large emphasis on development and production of control systems for Original Equipment Manufacturers (OEMs) used in areas such as heating, control engineering, weighing technology, solaria, white goods and other sectors.
Partnership - to meet these objectives and to ensure reliability of the complete line, finding a reliable partner was paramount.
Rommel, an established systems integrator, distinguished itself as a system-supplier for complete production lines with its board handling and process automation whilst providing complete traceability.
The project objective was to integrate a fault-free continuous structure of total traceability throughout the process chain, from beginning to end.
The permanent documentation of all process steps is carried out by means of various codes on the components and circuit boards.
This also must include an exact quality control of the written DPM (direct part marks).
Immediately after having been marked with the laser, the data matrix codes are checked carefully for a number of testing-characteristics by means of vision sensors.
Quick and reliable reading of the codes in all stages of production is of fundamental importance for the tracking process.
The results are then stored as archives and include all fabrication data collected up to the time the product is delivered to the customer.
With the integrated Fast Ethernet-bus and with minimal spatial requirements, the complete product family of In-Sight vision sensors from Cognex unites the advantages of intelligent cameras with those of complex image processing systems.
Rommel integrated the In-Sight line of vision sensors throughout the complete project due to the reliability, accuracy and sensitive performance of the algorithms and the Cognex vision tools, which achieved 100% reading rate quality.
Even if 60% of the matrix codes are obstructed or damaged, they still can be identified.
The tools for reading various codes are already integrated in the camera as a library, and they are based on Cognex's well-known vision software package PatMax.
The project, from planning through to installation, was carried out within approximately one year with forty two In-Sight 1010 vision sensors for fast code-reading were completely integrated in the production line.
This vision-application is unique on a scale this size.
The simple installation and the ergonomic user interface of these vision sensors proved to be especially advantageous.
If updates of the respective batches in Printed Circuit Board (PCB) production should become necessary, simple programming by means of a spreadsheet will permit the machine operators to react promptly.
In addition to this application there are several other In-Sight vision systems in use for a variety of different tasks for quality assurance.
Traceability offers a chain of advantages The permanent and reliable documentation of manufactured products provides complete transparency and understanding of the production process and any eventual problems.
Easily adapted parameters enable quick process modifications, which benefit production.
Focus is on prevention and damage control and any problems arising can be identified and localised at an early stage.
This allows for the right decisions to be made at the right time, which also leads to positive effects in the optimisation of process sequences.
Production is simplified and EbV is able to offer full traceability on each and every product delivered.
The guarantee EbV is offering their customers the highest possible guarantees on the market today.
In areas such as the automotive industry, general outline conditions already exist for the respective level of standardisation to adhere to regulation.
The problem of rejected stock has almost been eliminated and this is an important aspect with regards to safety-relevant products.
Only faultless and thoroughly documented products leave the plant.
This has already shown to be a decisive aspect in improvement of EbV's brand perception.
The certification of the company in accordance with DIN/ISO 9001/2001 is also proof of the consistent traceability-approach found at the heart of the company.
Rommel has even guaranteed EbV in writing, that the line will run at 100% reliability which is quite a promise to uphold considering all the possible liabilities that may imply.
This confidence is based on the strong partnership with Cognex regarding know-how and experience.
Fries sums it up: "No other supplier was willing to sign that agreement, and in looking back, it turned out that this reliability promise was complied with and met". Request a free brochure from Cognex UK ...
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