Previously, we mentioned the stats on vehicle accidents and recalls in SA caused by safety system components. Installing our vision systems to guide the pick-and-place process and provide complete traceability. Which could reduce accidents and recalls caused by brake failures.

Brake Valve Component Inspection

Machine vision systems provide brake valve component inspection solutions.

Here’s how it works:

1. 1. Automated Inspection: Cognex In-Sight vision systems offer non-contact inspection for brake valves. A robot places each valve within the field of view of the vision system. The system then inspects every part, identifying defects. If a defect is found, the robot sorts the part for rework. This automation ensures tough quality standards are met and maintained, minimising the chance of defective parts and recalls
   2. Flexibility: The combination of robot and vision system allows adjustments for new valve designs. Manufacturers can teach the system to manipulate and inspect different valve configurations, adapting to changing requirements.

Brake Pad Inspection

Installing vision systems to guide the pick-and-place process and provide complete traceability could reduce accidents from brake failures. Brake pad performance is critical to ensure safe braking. Brake pads are manufactured to high-quality standards with multiple processing steps.Each part must be inspected to ensure it meets rigorous quality specifications. Typical inspections include verifying that the brake pad has the correct friction material, its measurements meet specified tolerances, and the pad has been ground correctly. Manual inspection is difficult to achieve due to the high speed of production.

In-Sight vision systems have also been successfully integrated into brake pad production lines. These systems provide a simple yet effective solution for automated brake pad inspection. By identifying defects, they help eliminate faulty brake pads and prevent recalls.

Recalls related to brake components can seriously affect safety and trust in the automotive industry. We can expect even more innovative solutions to enhance automotive safety as technology advances.

Stay tuned for the next part of this series, where we discuss solutions available to reduce seat belt component recalls.

The NIST (National Institute of Standards and Technology) defines smart manufacturing as: “fully integrated, collaborative manufacturing systems that respond in real-time to meet changing demands and conditions in the factory, the supply network, and customer needs”.

Smart manufacturing is grounded in cloud connectivity. It combines human creativity, digitally connected machines and assets, and AI-powered systems and analytics. Integrating AI and smart tools helps fuel adaptability and speeds up the capacity to customise outputs based on real-time data and intel. The visibility, agility, and resilience of smart manufacturing make it a cornerstone of more efficient supply chain models and overall business operations.

Empower your factory with cutting-edge technology and secure a leading position in the market. Smart manufacturing integrates advanced technologies to optimise production processes, enhance efficiency, and drive innovation.Amid unprecedented competition, today’s businesses need to consider more than profit as a measure of success. Long-term stability and customer loyalty arise from benefits that are felt across the business—from customers to staff and even the environment.Efficiency and productivity: With automation, real-time data analytics, and integrated manufacturing solutions, your teams can work faster, smarter, and safer. Predictive maintenance and automated workflows can help your IoT-connected machines and assets operate at peak levels with more streamlined outputs.Agility and responsiveness: At each stage in the process, smart manufacturing solutions and data analytics allow you to respond quickly to market changes – pivoting your manufacturing workflows and personalising your products with speed and acuity.Sustainability: The data gathered by smart manufacturing technologies can help enact strategic and cost-effective plans to streamline operations and lower energy usage. From sustainable product design to greener logistics, smart solutions can support your sustainable initiatives.Improved quality control: From the frustration of bad reviews to the catastrophe of a product recall, smart manufacturing solutions can integrate across your supply chain and manufacturing operations to ensure that quality standards are visible and verifiable at every stage.End-to-end savings: Digital integration from one end of your supply chain to the other allows for better forecasting, inventory management, and logistic solutions. This means fewer risks, less spending and – best of all – happier customers.Machine vision is an essential element of automation and will be critical to creating Industry 4.0’s smart factories. No other aspect of the production line captures more information or is more valuable than machine vision in assessing products, finding defects, and collecting data to direct the operation and optimise the productivity of robots and other equipment. Unlike simple sensors, vision sensors generate large amounts of image data, intensifying their utility in an Industry 4.0 environment.

Traceability offers a variety of solutions for smart manufacturing:Machine Vision: Machine vision is an essential element of automation and is critical for Industry 4.0’s smart factories. It captures more information than any other aspect of the production line, making it invaluable in assessing products, finding defects, and collecting data to direct the operation and optimise the productivity of robots and other equipment.Self-learning Equipment: Automation line equipment will provide increasing levels of self-learning, self-controlling, and self-optimizing capabilities to quickly and accurately complete complex tasks with minimal intervention.Optimisation to Production Lines: Manufacturers will enjoy greater flexibility as robots, machine vision systems, raw materials inputs, and other aspects of the production line can communicate with each other directly.Big Data: Industry 4.0 capabilities will transform raw data into actionable information and insights that can drive real, measurable performance improvements.Communication of Production Data: Manufacturing systems’ communication networks will scan for input from the marketplace and use this information to fine-tune production parameters.Cloud Computing: Workers will have instant access to data and operations information via the cloud and mobile devices, which will allow them to access critical and time-sensitive information.Mobile Solutions: A comprehensive mobile barcode scanning solution for your smart devices.Innovative Solutions: innovative solutions, such as the SnAPP Vision Sensor and L38 3D Vision System, offer user-friendly interfaces, robust capabilities, and high-speed processing to improve accuracy and efficiency in various industries.

According to the Road Traffic Management Corporation, 14.1 % of road crashes in South Africa are caused by factors “associated with the mechanics of the vehicles involved”. The State of Road Safety Report revealed that 420 fatal road accidents in a single year resulted from mechanical failures.Some of the top mechanical failures causing vehicle accidents include faulty brakes, tyre issues and steering defects. Other common mechanical failures that could lead to road accidents are car engine parts. While some recalls make headlines due to their scale and impact, others happen quietly, often without the owner’s awareness.

Safety Recalls are mandated by law and involve defects that could lead to losing control over a moving vehicle or potentially harming occupants and other road users. Manufacturers are encouraged to issue safety recalls voluntarily in South Africa, but the National Consumer Commission (NCC) can also step in if necessary. Affected vehicle owners receive notifications, and arrangements are made for repair work.

While global recall events have decreased, South Africa has seen an increase in affected units. This highlights the need for proactive solutions to prevent costly recalls; in this blog post, we discuss the importance of having machine vision systems in place to ensure that brake valve components and brake pads work correctly when needed in a vehicle.

Manufacturers face the challenge of maintaining high-quality standards while producing brake valve components. These components are crucial for safe braking systems, and any defects can lead to recalls and compromised safety. Assemblies might have missing, loose, or damaged parts, and manual inspectors often struggle to identify all defects, especially given strict safety quality standards.

Over the next few weeks, we will advise you of available machine vision solutions to ensure quality and minimise defects in vehicle safety systems. Stay tuned for more insights on this topic!

In the intricate world of manufacturing and product identification, precision matters. Many industries use marking machines to serialize or imprint their products with critical information—think barcodes, production dates, and business details. But what’s the go-to technique for industries dealing with metals, composites, hard plastics, and other rigid materials? Enter dot peen marking!

What Is Dot Peen Marking?

Dot peen marking is a versatile and widely used method. It involves creating patterns of tiny dots on a surface using a specialized marking tool. These dots form alphanumeric characters, logos, or codes.

Why is it so popular? Let’s dive in:
Speed and Depth: Dot peen markers can work swiftly and penetrate deeper than other marking tools. When you need efficiency without compromising quality, dot peen is your ally.

Whether it’s serial codes for material tracking or anti-theft measures, dot peen marking ensures that crucial data stays put. No more guessing games!

Ideal for Rigid Materials: From heavy-duty metals to robust plastics, Dot Peen handles them all. It’s like giving your products a permanent, data-rich identity.

Curious about dot peen marking? Check out this comprehensive guide.

Imagine an automobile where every system and component is built to perfection.

With the help of machine vision, this vision is becoming a reality. These intelligent “eyes” transform the automotive industry, ensuring flawless parts, precise assembly, and, ultimately, safer and more reliable vehicles.

From assembly to final inspection, nearly every system and component within a gas-powered, hybrid, or electric vehicle is manufactured with machine vision technology. Cognex 3D machine vision systems enable automotive part manufacturers and vehicle assembly plants to achieve exceptional quality and safety and meet their production goals.

How does it work?
Machine vision systems use cameras and sophisticated algorithms to analyse images and perform automated inspections. Think of them as robots with superpowers of sight, able to detect even the smallest imperfections that might escape the human eye.

Where is it used?
Almost everywhere! Machine vision is crucial in various automotive applications, from tyres and wheels to safety systems, powertrains, and electronic components.