Optical inspection checks formed parts

Testing cold-formed components more precisely

mm, 07.05.2024, 11:03

Optical inspection checks formed parts

An optical free-fall inspection system, which was developed as part of a research project funded by the German Federal Ministry for Economic Affairs and Climate Protection, inspects cold-formed components for geometric dimensional accuracy and surface quality with an accuracy of a few hundredths of a millimeter. The technology makes it possible to produce components with low manufacturing tolerances in future by forming instead of energy-intensive machining.

Forming processes have advantages in the production of metal components: Cold forming in particular requires less than half the energy compared to machining. Another plus: formed parts have excellent mechanical properties. However, the manufacturing accuracy of forming is often not sufficient for precision components, so more precise machining processes are used. High-precision inline quality control is a prerequisite for wider use of forming.

The new inspection system is to be used at the end of multi-stage forming processes. Here, the components are transported individually into a hollow sphere via a conveyor belt every second without any additional handling. Sixteen cameras distributed evenly over the surface of the sphere simultaneously record the component as it falls freely through the sphere, so that every part is imaged at least once. The system inspects components with an edge length of 0.5 to 6 centimeters. Fast data evaluation enables direct feedback into the production process in order to adjust process parameters and thus reduce rejects. During run-in processes or possible changes to material properties, for example when changing coils, the measurement technology helps to adapt the process more quickly.

With the possibility of traceability, the inline inspection system lays the foundation for self-learning optimization of forming processes. Fraunhofer IPM is presenting the system together with Sotec at the Hannover Messe at the joint stand of the Federal Ministry of Economics and Climate Protection BMWK.

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