In the automotive industry, accuracy, speed, and efficiency are essential for machine vision applications. Compact lighting solutions offer the ultimate level of performance especially when inspecting complex components like electrical connectors. Through high quality, energy efficient illumination, these small devices reduce costs and improve productivity for automotive manufacturers.
The Z-Spot spot light was designed to offer a compact lighting solution for generating high brightness in high speed applications whilst enabling seamless integration with manufacturing systems. Its adaptability for various working distances enables it to provide high brightness regardless of the distance for high speed automotive processes. Electrical connectors contain detailed parts with different surfaces and components so they require maximum lighting conditions for detailed inspections.
Challenges
- Ease of integration: Positioning the spot light in a machine vision application can be challenging, particularly in automotive manufacturing systems with limited space. As a result, the product must be easy to use with an intuitive and efficient configuration process to ensure seamless integration without effecting the system’s performance.
- Powerful and precise lighting: For high speed production systems, focused light is essential for the system to operate at maximum efficiency. The challenge involves maintaining high brightness at the same time at the required working distance. This is useful for detecting surface imperfections, such as damages or defects on the electrical connectors.
- Flexibility of use: Electrical connectors come in a variety of designs, so the Z-Spot spot light must be adaptable to meet the client’s needs. Operators might need to adjust the product over time (e.g. changes to the brightness levels or operate at different working distances) to suit a variety of applications.
Solution
- Compact and robust design: Our Z-Spot spot light was easily integrated in a narrow space in the machine vision system with M30 mounting and M12 5-pin connector. Its compact and robust design makes it an ideal solution for demanding industrial environments in the automotive industry. We combined the Z-Spot with Cognex IS3805M camera in WHI thanks to a simple M12 5P wiring interface enabling the devices can work seamlessly.
- Focused illumination: The Z-Spot WHI was selected to generate intense focused light for the machine vision system for high precision inspections of the electrical connectors. The spot light provides powerful, accurate illumination, which is concentrated to a single point, ensuring perfect homogeneity.
- Adjustable features: For different working distances, the Z-Spot is extremely flexible. The built-in lockable zoom lens adjusts to the desired 20x20mm field of view to effectively provide a beam of light at a 400mm working distance.
