3D Cast Component Inspection
True 3D measurements for short shot, flashing detection and correction
Casting is a precise process. Temperatures, ambient conditions, wear and tear over time, and other variables can cause flashing and short shots. With the number of parts produced by the automotive industry each year, inspection is critical to maintaining a consistent supply chain.
Inspecting molded parts is not just about passing or failing a part. Inspection is also about knowing if a part is finished or requires post-processing. In an automotive casting process application, the In-Sight 3D-L4000 from Cognex increased production of metal cast parts by analyzing volumes in an in-line inspection system from all sides of the part.
In-Sight 3D-L4000 tools were used in another application to precisely inspect automotive part volumes for flashing and short shots. In-Sight software embedded in the smart camera presented data in spreadsheets for efficient location of defects. In-house technicians were able to learn the software in minutes to easily set up, manage, and change tool settings.
To illustrate the simplicity of programming the In-Sight Volume 3D algorithms, operators only need to draw a bounding box around the object to generate a true 3D volume based on a point cloud — not just a height map — for more accurate and repeatable results.
In-Sight software, coupled with the In-Sight 3D-L4000 smart camera, provides high-quality 2K resolution, up to a 4 kHz scan rate, and patented speckle-free blue laser optics to capture true 3D images. This optical design has several benefits, including eye safe operation while delivering more light to the surface than competing solutions, more accurate 3D point clouds for measurements, and the ability to measure 100% of the In-Sight 3D-L4000’s field of view even if up to 50% of the laser is blocked by debris. This final benefit is an unprecedented achievement in 3D laser scanning, which normally limits the designer’s option to mount the scanner upside down because of concerns about debris blocking the laser light. This is an important consideration for scanning cast objects to find all short shots and areas of excessive flashing, regardless of location on the part. The Cognex 3D solution is tested and currently producing valuable results in the automotive industry for casting and other inspection processes.