Vision Inspection
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Since our inception IAS Corp has remained FOCUSED on quality. Our powerful software tools and reliable high speed systems provide accurate results and the security of knowing every product is 100% tested and ready to ship. We can build a system for any product or process, contact us today and SEE what we have to offer.
Some past projects below - Call or email us today for more information
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Envelope quality check station | |
| National Adhesives / National Starch and Chemical - Bridgewater, NJ. | ||
| We designed and
constructed a bench top system that
could test envelopes with the same precision as Merlin
(Mail Evaluation Readability Lookup INstrument) which is a tool used by
the US Postal Service to verify first class mail, standard mail, and
periodicals against the standards set in the Domestic Mail Manual. Click here to visit USPS Merlin homepage Click here to view USPS Domestic Mail manual The system we provide checks the adhesive bond that holds the envelop together by measuring the force needed to burst the envelope. It takes multiple measurements of the adhesive that has been applied across the flap that is used for sealing. It inspects the cellophane window for defects such as rips, wrinkles, or cuts. It measures the print for proper placement and saturation of color graphics if present. The vision tasks are performed with a precision 4k x 4k high speed camera and custom IAS vision software. A black light is present to check for UV dye presence. Each test is logged to a database and can be used for trending and line statistics. In addition to making sure the envelopes will pass Merlin examination, the test results are used to ensure that the correct amount of adhesive has been used to construct the envelope. These systems are proprietary to National Adhesives and are used to help them maintain a top ranking position in the tough adhesives market. |
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High Power Microwave Susceptibility test system |
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Naval Surface Warfare Center - Dahlgren, VA. | |
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We
provided a vision system that changed the way focused
and broad range testing is conducted at the Directed
Energy Technology office at the Naval Surface Warfare
Center in Dahlgren Virginia.
Prior to contacting us tests were watched by a human and manually logged by pen and paper leaving allot of room for error. The system we provided is all computer controlled and logs results to a database so it is not influenced by human interaction. This increases accuracy and frees up time allowing the scientists to work on other projects while testing is in progress. For this project we fitted a reverberation chamber with a CCD camera for which we made a copper mounting ring with conductive glass over the lens. A standard PC with IAS Corp Vision software was used to collect data. A custom user interface program was written making system setup and data output a breeze. We cannot share all the details of testing, however, we can tell you that this system can be setup to test any device that will fit in the chamber, it is not affected by ultra high frequecies, will detect any change in status of the test subject, and will provide accurate results for all tests. The cost for testing the old way = $34,000.00 per test cycle. The cost for testing new way = $3,750.00 per test cycle plus manpower can be used to work on other projects while testing. |
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Grommet inspection system | |
| ITW Southland - Viginia Beach, VA. | ||
| Off the shelf
vision inspection equipment cannot match the abilities of this system.
It utilizes multiple cameras, custom IAS Corp vision software, Bully Boy
lighting, and advanced motion control to inspect and sort over 3600
grommets per hour. The system can be switched over from one of 6 grommet
types to another in less than 5 minutes. Each grommet's
circumference and hole diameter are measured. In addition each is
inspected for short shot, surface defects, and even cuts in the rubber
surface. This is not easy to do with dense black rubber. The
system is fully automatic. The operator loads parts in a bowl feeder.
After inspection, passing parts are counted and dumped into a shipping
container. Failed parts are sorted out into different bins
depending on the defect, the system will count these parts as well. This
system was responsible for revolutionizing the way rubber grommets are
tested.
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Diaphragm Valve inspection system | |
| Gambro Healthcare - Hampton, VA. | ||
| The vision
inspection system for this project was installed on an existing machine
that worked great with one exception. Every once in a while the
machine would install a valve backwards. This did not happen very
often but Gambro wanted to ensure that it never happed ever. The system
we provided inspects each pump to ensure that the diaphragm valve is
oriented in the correct flow direction. The system features two high
speed high resolution cameras and custom IAS Corp / Advanced Automation
Group vision software. Pumps that have valves installed correctly are
allowed to continue to the next station. Pumps that have
incorrectly installed valves or suspect valves are rejected. This
system is used for quality control on 100% of the valves installed and
it remains in use for over 10 years now.
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Fuel Injector plating inspection system | |
| Greystone of Virginia / Induplate, LLC - Toano, VA. | ||
| On this project
we constructed and installed a sophisticated vision inspection system on
Camco rotary indexing tables to inspect Robert Bosch fuel injector
bodies. The entire system is fully automatic and utilizes robotic
arms to load parts into the machine where they are inspected with eight
high speed high resolution cameras, laser micrometers, and x-ray
machines. Defects can be detected down to 0.5 micron! All parts
are removed from machine with robotic arms. Passing parts are
placed in a "passed inspection" tray. Defective or suspect parts
are sorted into trays depending on the defect allowing for fast fine
tuning of plating lines. This system is responsible for increasing
production output and reducing the amount of scrap parts made.
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Foglamp aiming station | |
| Federal-Mogul - Hampton, VA. | ||
| This station was
designed and constructed to pre-aim fog lamps for Chrysler, Dodge, and
Jeep vehicles such as Concord, Cirrus, Liberty, Caravan, Durango,
Dakota, Ram, and others. The system is semi-automatic. The
operator places a lamp on the fixture. Once the operators hands
are clear of light curtain the system will clamp the lamp to hold it.
A connector is automatically inserted into the bulb and it is
illuminated. A camera will look at the bulbs "hot spot" while a
laser looks at the lamp housing. If the assembly is within
adjustment range and the bulb was not bent during insertion into the
housing, a screwdriver will come down and adjust it to specification.
Once adjusted the system will voice announce the test results and await
the next assembly to be tested. All test data is collected to
track manufacturing and provide statistics.
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Headlamp aiming station | |
| Federal-Mogul - Hampton, VA. | ||
| This station was
designed and constructed to pre-aim head lamps for Chrysler, Dodge, and
Jeep vehicles such as Concord, Cirrus, Liberty, Caravan, Durango,
Dakota, Ram, and others. This in-line system is fully-automatic.
Head lamps enter and exit station via Bosch conveyor. Once in
position the system will clamp the head lamp to hold it. A
connector is automatically inserted into the bulb and it is illuminated.
An IAS Corp Color Scan sensor checks bulb illumination properties. A camera
detects the bulb "hot spot" while a
laser detects housing position. If the assembly is within
adjustment range and the bulb was not bent during insertion into the
housing, a screwdriver will come down and adjust it to specification.
Once adjusted the system will send parts in the correct direction
depending on failed or passed test report. All test data is collected to
track manufacturing and provide statistics. This system has been in use
since 1994.
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2008 IAS Corp