The automated optical inspection system developed and produced by Rohwedder GmbH is mainly used for on-line quality inspection of mass-produced transmission components. Rexroth's inspection technology is used in this equipment.
Rohwedder Co., Ltd. (herein referred to as Rohwedder Co., Ltd.) uses Rexroth's inspection technology to develop and produce on-line quality inspection equipment that can perform error detection of several micrometers at an extremely high speed. In order to ensure the smooth operation of the five shifts, the main motion equipment of the system is all using Rexroth's linear axis. In addition, the device also requires a compact structure, so it uses Rexroth servo motor and Indradrive-Reglern regulator.
Mr Andreas Goertz, project leader of the Rohwedder Microtechnology Center, emphasized that “Rohwedder is one of the few manufacturers that produces both mechanical products and optical inspection instruments.†This company in Bruchsal is a company that offers micro-component production. A professional factory for processing equipment and technology. Therefore, Mr. Andreas Goertz continued: “We often work with the user's design and R&D technicians to develop innovative production processes and cost-saving automation technology equipment.†This cooperation makes it possible to “rapidly mass-produce†. Rohwedder specializes in a wide range of special machine tools, including various types of machine tools for processing mobile phone speaker parts, asthma sprayers, mechanical watches and precision parts, and SMD sensing device parts. In addition, Rohwedder also incorporates in its own service a large number of equipment for the flexible production, processing and manufacturing of different parts in ultra-clean room conditions.
Figure 1 Users can integrate automated optical inspection systems developed and produced by Rohwedder into processing lines
Engineers at Rohwedder also worked with technical staff at the Schwester-Competence Center to design and develop an AOI automated optical inspection system for transmission backplane inspection for a European auto parts supplier. The accuracy of the bottom shell of the tested transmission is a few microns, which has a decisive influence on the function and service life of the transmission. The main machine used for this special machine tool in each axis direction is Rexroth's CKK electric drive device - linear axis. The compact linear axis greatly facilitates the adjustment and commissioning of the equipment. It can be smoothly installed with special machines and ensures high reliability in five shifts.
Figure 2 Using two rotating jaws to hold the bottom shell, the bottom shell is tested
Within 2s to make a judgment
The special machine tool with integrated linear axis of Compact module can be smoothly matched with the production line to complete the processing of the transmission bottom case and transport the processed bottom case to the inspection station through the cleaning station. Two mandrels on the inspection station are used to complete the positioning and clamping of the bottom shell and raise it to a detection height suitable for rotation. The 50kHz progressive camera detects the bottom case from different angles. Mr. Andreas Goertz said: “Our inspection system collects 500 Mbytes of data for each workpiece detected.†After 2 s, the inspection software will be able to draw a “pass or fail†judgment and follow the pass at the next station. Place products in categories. Therefore, this requires that the tester must have fast data processing capabilities. The detection software should directly detect the manufacturing error of the workpiece during the inspection, analyze and judge a large amount of data, and compare it with the ideal state specified in the drawings. The average detection time of a workpiece is only 7s.
Rohwedder used five Rexroth CKK linear axis systems, servomotors, and regulators in the mechanical motion system of the AOI automated optical inspection equipment. The integrated Compact Linear Axis module with 260~600mm travel has a positioning accuracy of several micrometers. Each linear axis module consists of a refined aluminum alloy profile rail, an aluminum alloy rail cover, and a polyester seal that protects the mounting attachment. Larger screw diameters and lead screw pitches and two-way floating bearings ensure high speed and positioning accuracy.
Figure 3 Space-saving construction: Rexroth's Compact integrated linear axis can periodically transport the transmission bottom case to the inspection station.
The same dimensions
The mid-range ball screw drive with 7-stage machining accuracy allows for a small height dimension, thus reducing the space it occupies. Rohwedder uses four linear guides in the long table; in the single-axis short table, two linear guides are used. The integrated Compact module guarantees positioning accuracy of up to 0.01 mm and repeatability of 0.005 mm for each linear axis with its play-free ball screw nut. Both the ball screw guide and its drive system have the possibility of replenishing the lubricating oil from both sides, thereby reducing maintenance costs. Traverse's aluminum double row preloaded tapered roller bearings and floating double row ball bearings provide excellent protection for dynamic performance without backlash. Centering threads and fixing threads provide good installation performance. Because the same dimensions of Compact integrated rail modules are all the same, users are free to choose the ball screw drive system, toothed belt drive system and linear motor, so that users can use standard linear system components according to specific The dynamic performance and accuracy requirements constitute a linear axis. Mr. Andreas Goertz emphasized that “special requirements for linear axes are the preconditions for maintaining a reliable and long-lasting system.†24 hours of work per day puts high demands on all mechanical components of linear axes. Every downtime of the AOI automated inspection equipment will result in the suspension of the entire production line. Mr. Goertz said: "So, durability and good maintenance performance are important criteria for selecting this machine tool part."
Figure 4 Compact integrated CKK linear axis module developed and produced by Rexroth, compact size and high power
Provide a complete solution
An important decisive factor for Mr Andreas Goertz is: "We want to work with suppliers who can provide complete solutions because we want to focus our efforts on complex production processes." Rohwedder selected Rexroth The company's turnkey solutions include Indradyn motors and Indradirve regulators. According to his own years of practical experience, Mr. Goertz stated: "Utilizing the linear axis provided by multiple suppliers always brings additional costs for installation and commissioning." The matched motor and regulator combination guarantees up to 10m/s The speed of movement and the acceleration of up to 15m/s2 also guarantee extremely high efficiency and productivity. Indradrive drives can be quickly and easily integrated into different automation solutions via communication interfaces with Profibus-DP bus systems, Canopen bus systems, Sercos or Devicenet bus systems and are used throughout the world.
Figure 5 In the inspection station, the X linear axis and the Z linear axis transport the workpiece to the position most suitable for camera detection
Rohwedder also pays particular attention to the good maintenance performance of each part of this linear axis system. Its project engineer Mr. Gotthard Drexler said: "In the event of a failure, we only need to replace the control parts of the Indradirve servo drive system. The flash memory and all the saved data can be used." Rexroth's control The software already includes all necessary basic functions such as positioning drive, position adjustment, speed adjustment and torque adjustment. The standardized extension software also includes a large number of linear axis error correction, spindle control functions, axis synchronization functions, electronic cam switch functions, and built-in Motion Logic process technology packages. In the newly developed Rexroth-Indradyn-S motor, Rohwedder selected 128 Hiperface absolute signal generators per revolution, which avoids the operation of returning to the reference point when the device is restarted, saving a lot of valuable time.
Figure 6 can be made within 2s pass and fail judgment: Compact linear axis will be tested after the product to the finished area
Quick design and installation
The linear module combination can be used as a drive system, a linear guide system, and basic components to form a large number of flexible mechanical systems. Components that match the performance of the system are usually more compact and lighter than the specially designed ones. In the past, independently designed and manufactured automatic loading and unloading mechanisms and other automation devices, the integrated linear axis module can help the user to select the right system components for simple ordering and quick installation. Another advantage of the Rexroth Modular Integrated Linear Shaft is that in a series, the overall dimensions of all main and deformed components are the same. Therefore, designers can focus on the design of different drive solutions without having to bother to think about matching each other.
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