Automotive Fuse Box Inspection

1. Automotive Fuse Box Inspection

2. Braas Company Info • Founded in 1961 by Jim Braas • ESOP Company • 4 physical branches – MN, WI, IL, FL (+ IA,SD,MX) • Fluid Power and Motion Control/Automation focus • 105 employees • Over 15 years in Machine Vision • Industries Served: Medical, Electronics, Pharma, Automotive Tier, Packaging

3. Primary Product Lines Denso didn’t get the memo about blue logos

4. Application Data • Part is automotive fuse block assembly. • Goal: Identify bent & missing pins inside of connector sockets. • Pin locations must be relative to each other within +/- .005” • 3 sockets per assembly. Each required Hi-Res camera to achieve required resolution (1376 x 1035). • Different lighting required for each socket due to shape and depth differences. • Hardware selected: VA41 w/ 3, Mpixel cameras.

5. Target Part (Sockets shown in red)

6. Socket 1 Details Multiple pin heights Reflective particles in socket housing Different sized pin tips Red LED Dome light selected.

7. Socket 1 Lighting Results Pin tips much more distinct. Dust particles not as noticeable

8. Socket 2 Details Consistent heights Reflective particles in socket housing Pins high in Socket Red LED Low Angle Ring Light selected.

9. Socket 2 Lighting Results Pin tips much more distinct. Match Tool used for presence and location

10. Socket 3 Details Consistent heights Reflective particles in socket housing Pins LOW in Socket Array too wide for Dome. Red LED Low Angle Linear arrays

11. Socket 3 Lighting Results Pin tips much more distinct. Match Tool used for presence and location

12. INspect Solution (Locator & Pin Tips) • Housing Socket used as Locator • Match Tool used to find pin tips

13. Inspect Solution (Location of Pin Tips) • Match Tool Used to find pin tips • Model drawn around entire perimeter of pin to minimize errors from background (dust). Search widow enlarged to capture pin movement • Point tool enabled to track pin movement from nominal part model Detail of Pin Tip Match Tool

14. Inspect Solution (Distance between pins) • Length Tools attached to center point of pin tip Match tools • Length tools used to check distance from one pin to another for interface with plug

15. Inspect Solution (Pin Array to Socket Edge) • Mid Point calculated between pin tips • 2 point tools and pencil tool used to generate line on socket edge • Distance from mid point to socket edged calculated (to account for interface with mating plug) • One Distance Tool used for each set of pin tips (all reference same socket edge). One tool shown for clarity).

16. Additional application info Additional VA21 also used to detect placement and orientation of mounting feet, and to read bar code under fuse box.

17. Wrap Up Items sold for application • 1 VA41 w/ 3 Mpixel cameras • 1 VA21 w/ 2 low res cameras • 1 LED Dome, 1 LED Low Angle, 2 LED Linear Arrays, 2 High Freq florescent (VA21) • 5 lenses and extension tubes of various sizes • 2 power supplies • 1 Industrial Switch Additional Notes • 2 additional systems have been sold for similar applications to this customer. • Currently customer has 9 Dalsa/IPD systems in house. • Former DVT/Cognex user. • Customer now looking at Sherlock for future applications. They have grown more comfortable in vision programming, and are enjoying the flexibility of Sherlock

18. Than You! Questions?