Modular robot test cell

Aside from optical and acoustic modules for the automatic 100% testing of mass productions (turned parts, milled parts, bore holes, plastic injection molded parts etc.) PENTACON designs and manufactures complete units unifying several testing equipments. This ranges from machine vision (attributive as well as measuring) up to the acoustic and magnetic testing of cracks.

We test surfaces on cracks, blowholes, damages of the edges or completeness of the contour. We specialized in the acoustic testing of hairline cracks or break outs. The main advantage of the acoustic method is the testing of complex geometries where common testing methods like "eddy-current-testing" quickly reaches the limits of feasibility.

Video

Video

Modules

During the optical testing of the surface the workpiece is placed in front of a digital industry camera, rotated around its own axis and captured. The unwound shell surface will then be checked against a pre-set template by a software algorithm evaluating the size and position of the defect. For more complex part geometries we use several cameras which are positioned accordingly and parallel capture various tracks at the same time.

For optical testing we use high resolution lenses by Jos. Schneider Optische Werke GmbH. The software algorithm is based on the Matrox image library.

The acoustic audio method allows a better testing of hairline cracks or break outs than optical methods. At the audio testing the workpiece is placed on an acoustically decoupled tray and put into vibration by a hammer. The resultion tone can be matched with a reference tone and evaluated. The geometry of the part is irrelevant.

Similar to the optical testing of the outer contour the inner contour of a workpiece can be tested automatically in a robot test cell as well. Using a turning station in the course of the testing sequence the turned part is flipped and tested optically. An image of part is captured by an industrial matrix camera equipped with a lens made by Jos. Schneider and illuminated by transmitted light. In particular protrusions, cavities or other damages from the forging process can be detected quickly and cost efficient. The evaluation is done by a software double checking the captured images with a template.

The cycles time (without the handling) is 1 second.

The inner contour is captured by an industrial camera illuminated by transmitted light.
Inner contour testing

The inner contour is captured by an industrial camera illuminated by transmitted light.

Robot Handling

For the feeding and discharging we use robots from STÄUBLI, Universal Robots, KAWASAKI or Mitsubishi. The system can be designed that the robot either picks a pre-sorted and oriented workpiece ("pick and place") and feeds it to the modular testing sequence. Or at 2D picking the workpiece is taken from an Anyfeeder and oriented by the robot.