The customer, Federal-Mogul Unitec, needed to replace an aging inspection station that was unable to reliably detect defects during the sandblasting and adhesive application processes on brake pad backing plates. The existing inspection of non-conforming parts was slow, error-prone, and did not meet the requirements for 100% production inspection.
We designed and delivered a refurbished machine with automatic optical inspection (AOI) that completely replaced the old equipment—including disassembly, installation, and commissioning.
Key features of the solution:
- Removal of the original system
- Camera inspection using Keyence VS cameras with SmartView lighting – detection of defects in sandblasting and adhesive application
- A reliable mechanical manipulator for automatically removing non-conforming parts from the production line
- Control system Siemens S7-1500 / ET200SP
- Integration with the production system (MES)
- Archiving data to a database and FTP server for traceability
Results for the customer:
- 100% automatic inspection of every item on the line without the need for manual sorting
- Preventing defective items from entering subsequent stages of production
- Full traceability – each item is recorded along with the inspection results
- Seamless integration into the existing production line
Are you looking for a reliable solution for automated quality control in your production process? We’d be happy to discuss the options with you—whether you’re replacing outdated technology or starting a new project from scratch.
