Canadian vision

One customer, Van-Rob Stamping in Aurora, Ont., installed a Global Controls vision control system relatively recently and is finding the system easy to use and functions as required.

The company designs and manufactures metal stampings, modular welded assemblies, structural welded assemblies, mechanical assemblies and heat shields for automobile manufacturers. Established in 1979, the company has grown into a global multi-plant organization operating from more than a million and a half square feet with press capacities of 100 to 1,600 tons.

The Global Controls vision control system is used to monitor multiple fastener operations used in automotive sub-structure instrument panel assembly. In essence, fasteners can be installed manually or robotically. Since the former method can be costly and subject to human error, robotic assembly usually makes more sense. The main function of the automated vision inspection system, then, is to verify the presence or absence of all the fasteners that are being installed by a robot.

In operation, there are two different “families” of frames, and each “family” has four different frames. The vision system identifies the missing fasteners and displays their location on the user interface. In addition, the system keeps record of all 38 fasteners in a table format. As a processing tool, it helps the engineering department fine tune the fastener-installing robot on a weekly basis.

Another important part of the assembly operation at Van-Rob Stampings is verification that all fasteners are installed correctly before the parts are sent to customers.

The vision also reduces some non-value human inspection labour that can be moved into a production role. Barry Kavanaugh, corporate process engineering manager at Van-Rob Stampings, notes that because the company has a multiple-fastener operation, it would need several operators for the manual inspection process. Using a vision control system, he says, increases accuracy and obviates the need for manual inspection.

“In using the Global Controls all-Canadian system,” he says, “we have been able to reduce manpower while having the added option to use ‘picture traceability’ for every part produced in our Scarborough plant.”

Kavanaugh says the new system is easy to program, gives better statistical feedback on the fasteners been monitored, is PC based, very user friendly and extremely fast.

Ease of use
According to Kavanaugh, there are several off-the-shelf items available on the market, but none can provide the necessary user-support needed. He says Global Controls has the knowledge, support and expertise required to keep its systems in the forefront of technology. In addition, the product’s adaptability to his particular company needs was relatively easy.