Continuous visual inspection in vertical moulding systems
Boxless, vertical moulding systems are high-productivity machines. Up to now, the design of these machines and the short cycle time have meant that it was only possible to inspect using the random sample method. To do this, the machine had to be stopped. The result: Occasional defects were rarely found. Systematic defects were often detected too late and defective parts had already been cast. Inspectomation therefore advanced CORE-VISION technology further and integrated it into DISAMATIC® moulding machines. It is unique on the market. In spite of the extremely short cycle times and the compact design, COREVISION for DISAMATIC® allows the continous visual inspection of green sand moulds within cycle.
Vertically-divided moulding systems make high demands on visual inspection techniques:
Commercially available cameras and lights are too large for the restricted space available
The camera is close to the moulding chamber, so there is a high risk of blinding the lenses
Extremely short cycle times as low as 7 seconds resulting in a very short time for evaluating the inspection images
The solution from Inspectomation is unique
It is based on the CORE-VISION principle of shadow modulation. Lights which are extremely small and intense are fitted inside the moulding machine. Because the rapid cycle rate does not allow time sequential illumination from different positions, three specials light sources in the primary colours red, green and blue illuminate the mould simultaneously for a single image acquisition. The CORE-VISION software separates the three colour channels again resulting in three images from different lighting angles. The resulting three-dimensional shadow information is evaluated in real time with a powerful computer. The software automatically compensates for machine variations. The COREVISION system is connected to the control system of the DISAMATIC® machine. In this way, inspection and production processes operate hand-in-hand and unlock a range of benefits.
Defect scenarios in accordance with adjustable tolerances
Particular "Regions of Interest" can be inspected individually with different levels of sensitivity. The resulting scenarios are user-definable from the simple error message to commands such as ”do not cast“ right up to immediate machine stop.
Protection against damage to the machine
Critical defects such as missing or fallen off filters or cores trigger immediate stop of the machine, to prevent damage to the machine.
Protection against gaps when casting
When there are defects near to the bottom or side of the moulds edge, the mould will not be cast, as there is a risk that the liquid metall could run out.
Protection against expensive systematic defects
When there are defects which occur repeatedly at the same point, i.e. systematic defects, such as stickers, following a pre-defined number of occurrences the machine will stop, so that the operator can remove the cause of the defect.
No increase in cycle time, high level of efficiency
There is no inspection procedure which is more efficient. The complete visual inspection process is part of the production cycle of the DISAMATIC® machine, so no additional time is required.
More safety and increased savings
Instead of individual random sampling, every part will be consistently inspected. No down-time for inspection, less personnel costs and significantly higher quality.
Prevention of core mismatch
An additional module determines the exact core position in the mould.