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Case Study: Custom Imaging Solution for Robotic Welding Machine Application

A well known machine vision company has chosen Lumenera to design and manufacture the vision component of its next generation robotic welding machine inspection system . Lumenera was chosen for its expertise in custom and OEM imaging solutions, enabling it’s customer to deliver improved product quality, better operational processes, and reduce costs.

Traditionally, robotic welders had to manually inspect each weld tip. This process took considerable time and required that the cell be completely shut down during the inspection process. In other cases, robotic welders would just assume the tip was no longer useful after a certain number of welds, and would waste resources and dollars by throwing the tip away without knowing its true quality. In order to avoid interrupted production and maximize valuable time and money, an imaging solution was required that would specifically analyze the welding tips to determine if they needed to be dressed and ensure they were not damaged or misshaped. When a mashed or mushroom shaped tip was found, the part was dressed in order to produce a proper arc.

In developing its prototype, our customer was in need of a “one-stop-shop” that could assist with the development of its model, the creation of a custom enclosure, the addition of specific components, the assembly of the camera and the delivery of one complete, seamless solution. Relying on only one company to manage its project eliminated the timely task of finding multiple suppliers.

Lumenera’s expertise in custom and OEM imaging solutions made it the company of choice, enabling its customer to focus on its core competencies. Lumenera was chosen for this large camera project for the following reasons:

Feature Rich API: The ease-of-use of Lumenera’s feature rich API allowed its customer to quickly integrate images into its Neural Network processing environment.

One-Stop-Shop: Lumenera was able to provide its customer with a complete solution. Responsibilities included help with its initial design, installation of an LED light and controlling its intensity, connecting to the PC104 embedded computer, and assembling the complete solution in a customized enclosure.

Megapixel Resolution: Provided a more precise measurement tool, increased accuracy, and the ability to detect much smaller defects.

Embedded “Smart” Solution: Essentially, Lumenera’s solution functioned as a smart camera, with an embedded computer that allowed full camera control and ran the customer's custom solution.

Custom & OEM Camera Provider: Lumenera has developed a reputation as the industry’s leading custom camera provider. It has designed over 80 camera models for unique OEM requirements, based on CMOS, CCD, Cooled CCD, IR bolometer sensors of all resolutions and performance.

Cost-Effective Solution: The superior image quality of megapixel resolution made this a cost-effective solution as only one camera was required per cell. Lumenera was able to leverage existing partnerships with suppliers to create the entire solution, at a reduced rate.

Large Number of Engineering Staff: This customer had a problem finding a company that could even discuss a custom implementation. Lumenera’s large number of engineering staff provided a knowledgeable resource from conception, through development and implementation.

Timely Modifications: Rely on Lumenera’s expertise for timely results, ranging from small hardware and software adjustments such as private labelled enclosures, to complete made-to-spec solutions with alternate form-factors and unique mechanicals.

Flexible Architecture: Allowed for rapid prototyping and quick time to market.

Mechanical Enclosure Design: Customized designs met a variety of environmental requirements and project restrictions, including enclosure design, mechanicals and hardware modifications.

Superior Technical Assistance Centre: Lumenera’s TAC team was fully committed to supporting its customers vision needs through product development, design, integration, deployment and post-sales support.

Customer demands for process improvements, shorter build and inspection cycles, and of course at lower cost, are key drivers for new product development. Our trained professionals will work closely with your Project Managers and Engineering Teams to better meet your application requirements, and assist you with integration of our standard and customized imaging solutions. Contact Lumenera for your next imaging project at info@lumenera.com.

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