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Unipart Eberspracher Cognex - Case Study

Case Study: Cognex Checker Installation, Unipart Eberspacher, Coventry

Project Description: MCS Control Systems were contracted by Unipart Eberspacher to design and install an automated Poka Yoke system on Line 8 which assembles exhaust cans for Landrover. A major quality issue on a vehicle lead Unipart to review and improve the Poka Yoke system on the Can Stuffing station, which had been allowed to misassemble an exhaust can.

Approach: On the initial site survey, MCS considered using photo-electric sensors to detect the differences in the exhaust can components prior to assembly. After experimentation however, this turned out to be impractical due to the number of variants coming down the production line. After further tests on site and at our premises, MCS decided that the best approach would be the Cognex Checker system which is essentially a cost effective, very reliable Vision System, comparing up to 8 images against a live image to detect differences and not allowing the machine to function if the operator misloads components. Rigorous functionality tests were carried out on live jobs to validate the robustness of the Cognex system for all exhaust can variants. The Siemens S5 PLC that controls the line was modified and tested to prevent the exhaust cans being assembled if a misload is detected.

Results: Working closely with the client the new Cognex systems were installed and commissioned over a 3 day period with no down time and disruption to production.

 


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