Dimac Linear Camera Control Station - 360° Visual Inspection of Side Surfaces

The use of linear cameras, combined with a 360° coded rotation station, allows the acquisition of the image of the complete lateral development of metal components with cylindrical geometry.

Linear cameras allow the analysis of the entire surface of the examined part. The illumination is uniform over the whole surface of the part and the development is reported on a plane. These two factors simplify the analysis of the images, particularly for the search for defects related to the continuity of surfaces or profiles.

This type of analysis can provide surface and dimensional data: presence of surface inhomogeneities (lines, scratches) dimensional control of the correct phase between two asymmetric elements of the part (for example two radial holes) presence of open cracks.

How it works

The control station with a linear camera can be installed on the Dimac MCV1 and MCV3 series machines, automatic metal table sorters with indexed or continuous motion for hanging metal parts.
In the control station, parts are gently lifted from the dial from below and rotated between two pins. A high-resolution camera on the line side, equipped with a special LED bar light, scans the lateral surface of the component row by row. After a single rotation, the lateral surface is displayed on the screen as a 2D image, where the computer vision software can identify and label the defective features.

The application software stores these defects and uses its recognition algorithm to ensure a 100% accurate inspection and sorting process.

Dimac has invested considerable effort in creating a robust and user-friendly station. The hardware and software configurations are designed for simple operation and intuitive programming.

Thanks to these features, the station achieves impressive cycle times, processing up to 150-200 parts per minute and setting the benchmark for the detection of lateral cylindrical surface defects in automotive and aerospace fasteners, as well as in fittings and bushings for hydraulic applications.

This versatile solution adapts to components of varying shapes and sizes, allowing for a wide range of applications. Here are some case studies that demonstrate its effectiveness

M4x20 stainless steel screws

This type of screw has occasional cracks on the head, open or with closed edges. The material, non-magnetic stainless steel, responds poorly to eddy current equipment. The position of the cracks, generally located on the side of the head, also makes inspection using a surface camera that frames the piece from the side of the key impression ineffective: for geometric reasons, only the cracks on the upper surface are visible.

In this case, the linear camera provides an optimal response: it allows all the cracks to be intercepted, from the finest to the open ones, without false rejects. The rate is over 110 pieces per minute.

The case study of the bushings highlights the ability of the linear camera to identify, with a single instrument, surface inhomogeneities of very variable origin. In this case, the defects can be classified as scratches in various directions, cracks, bubbles, rust stains, geometric malformations, and gaps in the material at the edges. Using a linear camera, all these defects can be traced within the same image. In this case, we discover that the linear camera can identify a wide range of aesthetic defects.

Another interesting application of a linear camera is to measure the angle between two asymmetric elements in the piece. In the case study, for example, the angle between the milled side in the flange and the notch is used as a code for the type of piece. Measuring the position of the notch concerning the milled side allows the pieces to be separated into three different batches. Using a linear camera, control is easy and takes the form of measuring the distance between the two clear areas in the development of the flange.