18.04.2011
Mapvision Quality Gate Multi-camera System Goes Digital
Mapvision's expertise combines three technologies: machine vision, image measurement and 3D design. The Quality Gate includes an imaging environment and software. The inspection environment consists of a black room or a cabinet, where the walls, the floor and the ceiling are equipped with dozens (up to 100) of cameras and lights. The inspected object, a BMW front frame for example, is taken from the production line to the cabinet, where the cameras image it from every side, supported with an optimally designed lighting. The imaging only takes a few flashing seconds, because each camera and LED performs its task according to a precisely specified cycle. The software acts as the brain of the system: it controls the imaging and performs the 3D image modelling, analysis and storage.
Dozens of Basler Ace Cameras Can Be Installed in a Single Cabinet
Functionality of the Quality Gate system is now improved by replacing the analog cameras with very precise digital GigE cameras. Sami Lehtonen, Account Manager for Orbis Machine Vision says: "Basler's ace series has been a hit product from the start. It includes all the qualifications Mapvision can hope for." The ace cameras are extremely compact and can be used with a Power over Ethernet interface, which reduces the number of cables and facilitates maintenance and installation. Ethernet transmission allows controlling of several dozens of cameras with single software. Rapid shutter times, programmable within fractions of seconds, allow effective imaging arrangements within a fast-moving production line.
The ace series is particularly attractive because of its affordable price, a feature appreciated also by Mapvision's design philosophy. Antti Knuuttila, CEO of Mapvision, refers to the Quality Gate system as a RAICtm (Redundant Array of Inexpensive Cameras): "If one of the cameras fails, the system will still be operational. The precision will reduce only slightly, because the object is imaged from so many angles."
Quality Gate - Quality Assurance for the Automotive Industry
Quality Gate is used by all the top car manufacturers and TIER 1 subcontractors, such as Magna and ThyssenKrupp. The system is mainly applied to inspection of welded components and bodies. Today, car models are introduced faster than ever, and production failures can result in extremely costly maintenance recalls, which puts a great pressure on quality control. Dimensions of components used to be inspected with mechanical and optical sensors. Mapvision's system can use machine vision software to analyse any dimensions or visual characteristics. If problems occur, the stored images can be inspected later to exactly determine the production phase, where the failure was initiated etc.
Most importantly, the Quality Gate system is very flexible - now even more so, thanks to the digital ace cameras. The cameras and the lights are fixed in the cabinet, but they can be programmed to measure new component variants or products at any time. Adjustments can be made over the Internet, which saves travelling costs and time. The system also enables short time-to-market for new models; an important competitive advantage in today's market.
"New production methods are first introduced in automotive industry in Europe, and copied afterwards in the other continents," Knuuttila says. Currently, Mapvision's development and manufacturing takes place in Vantaa, Finland, but there are plans for taking the assembly closer to the customers' production sites in the future. According to Knuuttila, there still is a demand for hundreds of Quality Gate systems annually in the automotive industry, and potential Mapvision customers include also the aircraft industry and household appliance manufacturers.
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Orbis Oy
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