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Kolektor Sikom has shortened the SPC measurement time by 93% with machine vision technology

Client's Challenge

Kolektor Sikom is the leading producer and global supplier of commutators. It places great importance on the quality processes, achieving the defect rate < 5ppm. Regular SPC measurements of commutators are performed every day, twice per shift and when the production of a new product type is started. This inspection was previously done manually and it took up to 330 minutes. In addition to the inspection at the initial lines, SPC is done also after a specific process is completed (moulding, sawing etc.), which required additional 350 minutes of manual work.

Not only that this approach was time and resource consuming, it was also less efficient in case a defect was discovered – the information about the defect was delayed by several hours and the entire output produced in a given time period had to be eliminated.

An investment into the automation was therefore more than justified. Client chose a solution, which automated the SPC measurements and is built on machine vision principles. The solution shortened the inspection time to one twentieth of the previously required time.

Solutions

Custom made optical measurement machine for SPC measurements was delivered; the design of the machine is extremely universal, in order to support many different types of commutators. It enables the client to autonomously add new products, simply through an easy-to-use graphical user interface.

Features

• Single inspection of a set of samples (blister trays with 64 cavities for commutators).
• Universal design to support multiple types of commutators with one single machine.
• Robot is used for manipulation of parts to and between (3) measuring sites.
• Touch screen for simplified and improved user experience.
• Machine performs control of ~15 parameters, including:
  • dimensional measurements (height, diameter, bore diameter, width and depth of each slot),
  • measurement of angles between slots, symmetries of brushes and slots, etc.,
  • position tolerances, concentricity (centricity of boring), symmetry,
  • perfect radial run-out.
• Cycle time (per pallet): 20 min.

Benefits

In addition to the considerably reduced SPC measurement time, the control is more precise and more reliable. Thanks to the reduced control time, also the detection of defects is much faster, which helps reduce scrap and save costs. The staff performing the measurements are thus free to perform other tasks.

Author: Mateja Celcer