Process Development
Our process technology team develops all processes, which are needed in our automation projects. Often, this development already takes place in the early acquisition and conceptual phase of a project. It constitutes the basis for the system and software design and strongly reduces project risks.
Our process technology team has its own testing facility and equipment. Both allow to develop all processes needed under industrialized production conditions, using industrialized systems. All process development uses customer sample parts. Doing so, all processing parameters are unambiguously fixed and all processed parts can be checked for all relevant quality items by our customers.
Examples for process developments are :
- Processing tests with robots (grinding, polishing, deburring)
- Feasability checks for optical testing- and inspection procedures
- Assembly sequences for modules
As a result of process develoment, we do know all design data for our systems. The sequence of individual processes, their critical parameters and their performance, e.g. their cycle times, are well determined. This influences for example the design of the system logistics in order to achieve the targeted system autonomy. Beside of this, system control and software programming is strongly supported by these results.
Beispiele aus der Prozessentwicklung
Processing of engine rotors (blisks)
New technology of aerospace engines bases on blisks. The entire rotor is milled from one single body. This technology needs the post-processing of critical milling zones. This is exactly, what INSYS robot cells ensure with outstanding precision.
Processing of hip stems
Process developments have successfully been completed for implants of widely varying shape and origine, being in industrial operation on many robot cells. Examples include hip stems, hip plates, intramedullary nails and femurs.
Deburring of watch cases
Edge processing in the hardly accessible interface area between watch case and bracelet has successfully been achieved in a pre-engineering study of a customer project.
Text recognition
Text identification and checking is one of the standard requirements in vision control. Frequently, a reliable text identification procedure can only be granted by feasability tests, reflecting specific text parameters and quality, base material and neighbourhood conditions.
Configuration and dimension checking of parts
Checking the configuration of scissor tips is a classical example for a vision application as an element of quality assurance. In this case, vision control is integrated in an assembly line for scissors.
Vision based analysis of surface quality
Waste particles, scratches and mechanical defects are cleary and reliably detected by vision control. Filings on top of machined parts are recognised. Each type of defect is found by specifically tuned intelligent image analysis.