Robot Vision Camera Bracket Automotive Parts Inspection Application Case

At an automotive parts manufacturing plant, we integrated an adjustable-angle vision camera bracket into their industrial robot system for online quality inspection of transmission gears. The system uses a high-precision camera to perform automated visual inspection of gear tooth profile, dimensions, and surface defects, replacing traditional manual inspection methods and improving inspection efficiency and accuracy.

1. Requirements Analysis: The customer required 100% online inspection of transmission gears on their production line, including tooth integrity, dimensional accuracy, and surface scratch detection.
2. System Integration: The adjustable-angle vision camera bracket was mounted on the end-effector of a six-axis robot. A 2-megapixel industrial-grade global shutter camera was selected, equipped with a ring LED lighting system.
3. Angle Adjustment: Utilizing the bracket's 360° rotation and ±90° tilt capabilities, the camera angle was precisely adjusted to face the gear inspection area directly, ensuring no visual dead spots.
4. Stability Test: The bracket's stability was tested during robot movement, confirming that the camera had no significant vibration at high speeds, ensuring image acquisition clarity.
5. Inspection Process:
   • The robot picks up the gear and moves it to the inspection station
   • The vision system triggers the camera to capture gear images
   • Image processing algorithms analyze tooth profile, dimensions, and surface quality
   • Based on the results, the system automatically categorizes qualified and defective parts
6. Optimization Adjustment: Based on initial operation results, fine-tuning of camera angle and lighting angle was performed to optimize inspection accuracy.

• Inspection Efficiency: The inspection cycle time was reduced from 15 seconds per part with manual inspection to 3 seconds per part
• Inspection Accuracy: The missed detection rate decreased from 5% with manual inspection to below 0.1%
• Stability: The bracket remained stable after 24 hours of continuous operation, with no angular deviation
• ROI: The customer recovered the investment cost of the automated inspection system within 6 months