Solutions/Track Record
- Home
- Solutions/Track Record
- Visual Gatekeeper (VGK) – 100% Inspection of Complex Shaped Objects
100% Inspection of Complex Shaped Objects – Visual Gatekeeper (VGK)
For forged/cast products, car bodies, and other complex parts/products, Visual Gatekeeper enables inline inspection of dimensions, deformation, chipping, and burrs at measurement points set on 3D CAD data. Visual Gatekeeper truly acts as a “gatekeeper,” playing an active role in various production processes.
Solution Overview
Traditionally, inspection of cast and forged products has involved sampling, bringing the samples to an inspection laboratory, and performing inspections using contact/non-contact 3D measurement equipment and expensive measurement software.
Visual Gatekeeper (VGK) enables dimensional and shape inspection of every single manufactured part simply by using a 3D vision sensor installed on the production line to capture images.
Measurement points and measurement types (deformation, dimensions, burrs, chips) can be set on the master CAD data.
Our unique measurement method allows us to measure the processing and assembly accuracy of sheet metal products/parts such as car bodies, which previously required special jigs.
The time required from the start of measurement to the output of results is only a few seconds, and the measurement data can also be used as traceability data for shipped products.
Target work
- forged products
- Castings
- Vehicle body, etc.
specification
| Specification Items | Content |
|---|---|
| Shooting time | 0.4 to 0.8 seconds |
| Analysis time | 1 to 2 seconds * |
| Inspection accuracy | ±0.1 mm ※ |
| Measurement items | Deformation, dimensions, burrs, chips |
| Variety setting | Registering varieties using 3D CAD data |
| Equipment configuration | 3D vision sensor (YCAM3D), visual controller, monitor |
| External device connection | Data can be provided to sequencers, etc. |
| External device communication | [Output] Status: Ready, Busy, Error Result: OK, NG, Measured Value [Input] Shooting trigger, Product type change, Product information |
*This may vary depending on the subject being photographed.
Examples of VGK
Mazda Motor Corporation’s crankshaft material defect inspection system
This article introduces an example of how Visual Gate Keeper is being used in Mazda Motor Corporation’s crankshaft manufacturing process.
In the automobile manufacturing process, measuring complex three-dimensional shapes such as crankshafts and car bodies presents a challenge.
“Visual Gate Keeper” addresses these on-site needs.
– Capture using the 3D vision sensor “YCAM3D” – approximately 0.5 seconds
– Test results output in approximately 2 seconds → Enables 100% inspection.
– Provision of traceability data
We achieved this.
Video of inline inspection using YCAM3D
Scenes from the operational site
The operator’s room displays a “real-time inspection results screen,” allowing for visual confirmation of the shape inspection color map. Furthermore, the system automatically stops the cycle in the event of abnormal measurement values.
For products with complex shapes, such as crankshafts, it enables quantitative evaluation by outputting the distance between distant surfaces and 3D deformation as numerical values or color maps.
Visual inspection by an operator
Real-time inspection screen video
* The images and videos on this page are used with the permission of Mazda Motor Corporation, and any reproduction or reuse elsewhere is strictly prohibited.