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    Piston Inspection System
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  Challenge:  
 
Visual Inspection of Piston pair of for more than eight different parts  
   
(a)
Presence absence  
   
(b)
Orientation  
   
(c)
Dimensional check  
 
Detection of Spacer (Thickness 0.3 mm)  
 
User friendly model editor and model calibration utility designing  
 
Communication with AB PLC for Sorting of Pistons after Visual Inspection  
 
   
     
  Solution offered:  
 
Piston Vision Inspection System is constructed using
 
 
NI LabVIEW 8.20 (Development Software)  
 
NI Vision 8.20 (Vision Software)  
 
NI PCI 6224 (DAQ: 32 AI, 48 DIO Card)  
 
NI 1407 (Analog frame grabber Card)  
 
5V to 24V & 24V to 5V DC converters  
 
640 x 480 WATECH’s Analog Monochrome Camera  
     
  Application:  
 

Piston Vision Inspection System is used in TMC (Tandem Master Cylinder) manufacturing industries. TMC is one of heart module in four wheels Vehicles. This TMC contains piston pair Primary and secondary each with more than eight different parts like Spring, Spring Sheet, Retainer, Primary seal, Secondary seal, Spacer etc.

Wrong orientation and absence of any one of sub part in Piston pair makes TMC leak. This will be very dangerous for any four wheel vehicle.

Piston Inspection System is used to Inspect this piston pair and finally to avoid the failure or leak of this TMC. This system also keeps record of Inspected piston pair in modular format model wise for further analysis.

 
     
  System Description:  
  Piston Vision Inspection System divided in to basically three parts  
 
Model Editor and Model Calibration: Teaching of Models  
 
Test: Visual Inspection of Piston Pair  
 
History: Modular result record keeping and Retrieve of results  
   
     
  Model Editor and Model Calibration: Teaching of Models  
 
Model Editor is very important part of piston Inspection System. With help of this utility user can Add new models of Piston pairs, Remove present model and Update can fine tune or teach present models.
 
 
 
 
(Fig: Model Editor)
 
 
After login on administrator access system will grand permission to Model editor. With help of this very simple and user friendly utility user can calibrate (teach) each part of piston pairs for any model.
 
   
     
  Test: Visual Inspection of Piston Pair  
 
Upon Start button pressing by Operator on Panel, Piston gets inspected by system. With help of LabVIEW and AB PLC piston get rotated inside the inspection box and then it is get inspected for different part.
 
 
 
 
(Fig: Ok Piston Pair)
 
   
     
 
 
 
(Fig: Rejected Piston Pair)
 
     
  History: Modular result record keeping and Retrieve of results filess  
 
History Screen allows user to retrieve test result in modular format for production.
 
 
 
     
  Conclusion:  
Powerful programming environments like Lab VIEW and Vision Development Module helped us to provide a very optimum solution in very short time span of 6 weeks.
 
 
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