The machine vision solution from VITRONIC for reliable and reproducible 100% inspection of welded seams is used by leading automotive manufacturers and their component suppliers across the globe. It is used, for example, to inspect brazed and welded seams on axle components, bodywork, wheels, seats, exhaust systems and battery modules.
At the heart of the optical system solution for weld seam inspection is a sophisticated user interface for the teach-in of seams. VITRONIC is setting new standards with its complete reworking of the VIROwsi software, in particular the intuitive use of the entire system and its extensive analysis options.
VIROwsi system software is clear and easy to use
The system software needs to be able to offer a wide range of functions. These include a user interface for setting the parameters of machine vision components and for configuring new seams, as well as image evaluation, logging and data archiving.
The configuration of new seams requires the creation of inspection programs, so-called recipes, which serve to precisely define parameters such as inspection sequence, inspection limits and inspection criteria in accordance with production requirements.
In the case of an existing inspection process, adjustments may also need to be made. For example, the inspection limits may need to be changed. These changes can be done while an inspection is in progress. Once confirmed by the user, they are applied to the inspection of the next part.
Creating and adjusting recipes is normally a complex process, requiring both expert knowledge of welding technology and a thorough understanding of the inspection software. As this represents a core function of the software, its design plays a key role in the acceptance of the inspection system as a whole.
This is precisely where VITRONIC's new VIROwsi software shines. The graphic design of the user interface and the system's intuitive navigation enable an easy teach-in of inspection sequences and inspection limits. Users can also select from a wide range of configuration functions. They can access pre-defined templates of standard seam types, or have scan frequency and ranges calculated automatically.
Thanks to a guided teach-in and clear on-screen visualization, a trained user will be capable of setting the parameters for any future inspection program (or even creating it from scratch) for new or modified components.
In principle, the weld engineer can optimize a recipe based on historic inspection results at his or her desk, so as to avoid disruption of the production process and downtimes.
Database-supported analysis and documentation of production and process quality
Inspection results are also presented in a very clear and structured format in different views of the VITRONIC system. Defects such as pores and holes are displayed in high-precision 3D. VIROwsi classifies the defects and shows detailed information about the position and type of defect in each case. To provide users with a clear overview, the inspection results for individual seams are visualized in real-time on a photo of the component.
All information is immediately calculated into a view of real-time statistics. In parallel, it is stored in an integrated database where it is linked with component and seam ids for subsequent tracking, evaluation, and statistics. That means that detailed inspection results and parameters are seamlessly documented. With the help of the database-supported evaluation tool and the real-time statistics function process deviations can be detected early on.