Image Processing Significantly More Productive Fan Manufacturing

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Image processing systems from Vision On Line ensure reliable and economical quality control during the production of fans for diesel engines at a globally operating U.S. manufacturer.

Engines for automobiles are highly technically advanced systems and essential for the functionality of the overall product. For this reason, every single component of a power unit matters: all components must meet exact specifications and be correctly integrated to function flawlessly over the expected lifespan.

This also applies to the fans in engines, which ensure necessary cooling. If these components fail, it can lead to the engine block overheating and, in the worst case, engine damage. This is not only troublesome and costly for the driver but can also damage a brand's reputation, potentially leading to a loss in sales.

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Versatile Automotive Components

One of the world's leading manufacturers of automotive components supplies nearly all major automakers with its technologies. Its product portfolio covers virtually all required segments for both internal combustion engine vehicles and electromobility, including solutions ranging from the actual drivetrain to battery systems and charging stations. In the temperature management segment, the American company's offerings also include fans for large engines, such as those used in trucks, construction machinery, and other commercial vehicles. Since the beginning of 2024, Vision On Line's image processing systems have ensured reliable and cost-effective quality control of these fans at four inspection stations.

The company aimed to increase the level of automation in the production process and supply its customers with only guaranteed flawless fans for later installation in engines, thereby avoiding potentially high follow-up costs in case of defects.

Andreas Schaarschmidt, Managing Director, Vision On Line

"To implement the required image processing systems, the company sought an experienced partner. We had already successfully supported the company in previous projects, so we were very familiar with the manufacturer's expectations and processes. Within a few months, we were able to develop a powerful solution that met all requirements," says Schaarschmidt.

High Accuracy Required

The image processing systems from Vision On Line were integrated into the production process of the fans at four stations, where the components are balanced after manufacturing. Once a test piece is placed, the integrated vision system initially detects a metallic, black-painted metal part that contains a Data Matrix code with information about the specific fan model. As soon as the vision system reads this information from the centrally placed metal part, it communicates the data to the manufacturer's internal PC-based control system to retrieve the target values for the fan under inspection.

In the next step, the image processing system checks a series of component features for compliance with specifications. Among other things, it examines the correct number and geometric dimensions of the individual fan blades. For optimal operation of the finished fans, it is crucial that oversprays or missing material are reliably detected with an accuracy of ±0.04 inches.

The measured data is subsequently compared with the specified values of the central control system, and the inspected fan can proceed to the next steps for static balancing and later be delivered to customers for installation in engines if all specified parameters are met. Defective components are removed from the process and either reworked or disposed of, depending on the type of defect.

Optimally Selected Image Processing

The scope of work for Vision On Line was extensive: On the one hand, this manufacturer previously had no system in place where such fans were automatically inspected, which could have simply been optimized. On the other hand, the test components required a precisely tailored design of the image processing system, as the fans, with diameters of up to 31.5 inches, necessitated a relatively large field of view.

We were only able to achieve the required accuracy by selecting a large, powerful overhead lighting system from Büchner and a high-resolution 20 MP camera from SVS-Vistek with the appropriate optics from OPT.

Andreas Schaarschmidt, Managing Director, Vision On Line

The evaluation of the captured images is carried out using the Halcon software library from MVTec.

A crucial factor of the final image processing system in this application was the lighting, for which Vision On Line selected a custom model from the TLS series by Büchner Lichtsysteme GmbH. These overhead area illuminations operate with direct or diffuse light, are available in the light colors blue, green, red, white, and infrared, and allow for multiple camera openings if needed.

Another key feature for the application was that the dimensions of the illuminated area could be selected in 0.8 inches increments, up to 6.6 ft × 9.8 ft. Depending on the task, TLS illuminations are equipped with suitable LEDs in a very fine grid to achieve maximum intensity and homogeneity. For the fan inspection, Büchner produced a TLS variant with an illuminated area of approximately 24 in × 24 in and a total of 3,500 blue LEDs, with an electrical power of 177 watts, which can theoretically operate in flash mode at currents of up to 112 amperes. For optimal...

In close consultation with Vision On Line, Büchner also designed a specific mount for the lighting, enabling the selected camera to be installed in the camera opening of the lighting.

When selecting the appropriate camera, Schaarschmidt relied on his extensive experience with SVS-Vistek: “In the past, we have very often integrated industrial cameras from this partner into our systems because we are absolutely convinced of the quality of these products. Additionally, due to the in-house manufacturing of the cameras at SVS-Vistek in Gilching, we can rely on the reliable delivery of the ordered cameras, which is a particularly important factor in project work.”

For inspecting the fans of the American manufacturer, the exo183MGE model is used. It is particularly suitable for this application due to its high resolution of 20 megapixels and a data rate of up to 120 megabits per second via the integrated GigE Vision interface. The integrated 4-channel power strobe controller in these cameras enables precise timing control of the LED illumination—another advantage, as this eliminates the need for an external controller typically required, thereby reducing the overall cost of the image processing system.

Productivity Increased

Based on feasibility studies precisely tailored to the task, Vision On Line ensured in advance that the selected image processing components deliver optimal results in this application. Additionally, the vision experts supported the fan manufacturer in integrating the vision system into the facility and in programming.

Another challenge for Vision On Line was integrating the image processing system into the internal PC-based control system to seamlessly utilize and document the results of the vision inspections within the facility.

With four inspection systems commissioned in 2024, the U.S. corporation was able to significantly increase its productivity in fan manufacturing and identify defects in components more quickly and reliably. Due to these positive results, the company is currently, according to Schaarschmidt, reassessing quality inspection processes for other products at multiple locations and upgrading them with Vision On Line's image processing systems.

Peter Stiefenhöfer, PS Marcom Services

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