In the automotive field, the production efficiency of parts and product quality have always been important factors that limit stamping capacity. Increasing production speed will inevitably shorten the inspection time of each part. In order to better ensure and improve the quality, it is necessary to increase the number of personnel and enhance their inspection capabilities. At the same time, the unique fatigue and differentiation of manual testing make it difficult to achieve uniform quality standards for parts. Therefore, how to identify parts defects more accurately and quickly has always been the direction of Beijing Benz and the entire automobile industry.
Introduction of ABIS Ⅱ Optical Inspection System
Figure 1 Overall layout of optical inspection
ABIS Ⅱ optical inspection system (Figure 1) is currently known as one of the most accurate and efficient production auxiliary systems for inspecting the surface quality of parts. The principle (Figure 2) is to form a grating on the surface of the part by optical projection, use the camera to collect the effective detection area, and analyze the fringe in the shooting area through the ABIS Ⅱ system, and identify the part on the part by combining the shape change of the fringe and the characteristics of the surface defect For related defects, the location, size and severity of the defects will be reflected in the optical inspection report, as shown in Figure 3.
Beijing Benz owned the first ABIS Ⅱ offline optical inspection system in China in 2016. The introduction of this technology provides new opportunities and challenges for Beijing Benz Stamping Plant. The advantages of ABIS Ⅱ offline optical inspection system are mainly reflected in the following 4 points.
⑴ Fast detection speed. The surface inspection of most parts can be completed in about 40s. Compared with manual inspection, a single piece takes an average of 5 minutes, and the efficiency is significantly improved.
Figure 2 Principle of optical detection
⑵The defect results can be quantified. Defects can be classified according to grades and displayed quantitatively, which greatly avoids the ambiguity and difference of manual judgment of defects.
⑶ Easy to operate. Through computer operation, the parts do not need to be polished, which effectively improves the work intensity and working environment.
⑷ Defect standard can be edited. On the basis of the system defect database, the BBAC surface defect evaluation standard can be input to the ABIS system to make it consistent with the BBAC quality standard.
As the first system introduced in China, how to adapt to China’s national conditions and give full play to the advantages of the equipment has become the most urgent and severe test. After a long period of exploration and familiarization with the system, Beijing Benz Stamping Factory, combined with the programming optimization cycle and the identification of defects, has formulated a “three-step” strategic policy to achieve more practical and faster production applications.
“Three Steps” Strategic Policy
The first step: explore the application mode, plan a feasible plan
In order to realize the equipment serialization production application, not only need to have a comprehensive understanding of the optical inspection system and stamping production mode, but also need to consider the overall use of the equipment from the perspective of the operator, aiming to systematically and comprehensively carry out reasonable and efficient equipment application Planning.
Therefore, to ensure that the verification results are accurate and effective, the first step of the application operation must be completed by the engineer. To develop a feasible plan for production use, the following 5 factors need to be considered: ⑴The production cycle of each part and the production quantity of each batch; ⑵Measure the time required for each part and the difficulty of transportation; ⑶Currently available The number and size of the parts to be inspected online; (4) The number of parts that still need to be optimized online; (5) The number, type and programming plan of the parts that need to be programmed later.
Figure 3 Optical inspection report
Figure 4 ABIS optical inspection system inspection process
Finally, through the actual measurement of each part, the measurement frequency suitable for different parts is worked out. It not only needs to meet the measurement requirements, but also needs to have sufficient operability. At the same time, according to the actual parts inspection operation steps, sort out the operation process (Figure 4), standardize the operation sequence and handling methods when problems occur.
The second step: special training by dedicated personnel, professional training of skills
In order to improve the technical level of professionals, a fixed-point and directional method is used to train optical inspection operators to ensure the sharing of special skills and the promotion of difficult problems. In addition, in daily work, the optical inspection operator can undertake the main optimization work, and at the same time, it can perform temporary treatment when encountering problems, so as to prevent engineers from being unable to arrive at the site in time and delay production. The training of special talents is divided into three contents. Through progressive training, the understanding of optical inspection is gradually completed and familiar to full mastery.
Figure 5 Light inspection operators perform on-site parts inspection
Figure 6 On-site standard operation instruction training for inspection team personnel
⑴The principle of optical detection and the handling of common problems. Optical inspection operators need to master the principles of related equipment and be familiar with the functions of the tools used in hardware and software. When encountering general equipment or system failures, it can determine the cause of the problem in the first time, and can handle some simple problems.
⑵On-site inspection operation and report analysis. Familiar with the operation steps and essentials of parts inspection, and can guide other personnel to perform simple on-site operations. For the optical inspection report, it can conduct a comprehensive analysis of the system, and have the ability to distinguish and distinguish the defects displayed in the report.
⑶ Optical inspection program programming and optimization. Understand each step of programming and learn to find operational problems in programming. Master the programming and optimize the setting of inspection tools, and be familiar with important information such as the selection of each programming position, the use of tools, and the adjustment of the grinding direction. It can optimize the parts that have completed the preliminary programming online and guide the production and use.
The third step: popularize the detection operation and promote the use of serialization
In order to realize the popularization and serialization of offline optical inspection, on-site inspectors can use the system to inspect and identify defects. Therefore, conduct comprehensive operation training for the inspection team to make the operation of the equipment more efficient and serve the production more realistically.
The overall training is carried out as follows: ⑴Improve the operation process, formulate optical inspection operation and record standard operation instructions; ⑵Combine the training content, formulate a detailed training plan, and divide the training tasks at each stage; ⑶On-site guidance training, systematic inspection classes Double-shift personnel training and on-site practical guidance; ⑷Later problem solving, in addition to on-site temporary problem handling, regular problem discussions and answers are arranged.
Through the application and practice of the “three-step” strategic policy of the ABIS Ⅱ offline optical inspection system, the inspection team has been able to independently complete the inspection of parts and the recording of related problems. With the support and promotion of leaders at all levels, the Beijing Benz Stamping Plant has basically realized the serial application of the optical inspection system. This is the first attempt of China’s ABIS Ⅱ offline optical inspection to be put into production and use, and it is also an important milestone for the continuous innovation and excellence of Beijing Benz Stamping Plant. I believe that in the future exploration and improvement, the ABIS Ⅱ offline optical inspection system can be more accurate and comprehensive in terms of technology and application.