FAW Car Co., Ltd. (hereinafter referred to as FAW Car) is a holding subsidiary of China FAW Group and the first joint-stock listed company in China's car manufacturing industry. The company's main business is the development, manufacture and sale of passenger cars and their accessories. The factory has four major workshops, including stamping, welding, painting and final assembly. It has an annual output of hundreds of thousands of passenger cars of various types. The models include red flag, Pentium and Mazda6.
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FAW Car is committed to making the best cars, making driving more happier, making employees happier, making society more harmonious and achieving first-class brands. With this concept, the production line adopts advanced standard automation processes, focusing on new technology applications to improve efficiency and product quality, reduce waste, and save staff's labor intensity.
The automobile production line assembles various components such as body panels, engines, transmissions, and electrical appliances in a certain order (sheet stamping, welding, engine assembly, painting process, vehicle assembly, etc.). In the production process, it needs to be assembled and transferred to the next process position through various transmission and clamping devices according to different workpiece structures and installation requirements.
Usually when different models pass the exchange slip in the workshop, there is a head between the skid and the vehicle to transmit the corresponding data to the control room. However, the complicated environment may cause the signal to be lost, resulting in inaccurate positioning and false positioning. The corresponding models of the skid are mismatched and there is no verification step. The status of the different models is unknown. As a result, assembly errors and damages in the next process will occur, and the calibration will be time consuming and affect the production progress of the entire workshop.
At this time, the engineers of FAW Car learned that Volkswagen used Cognex products to solve similar problems. The engineers of FAW Car also personally visited the Volkswagen Company for on-the-spot visits. They saw Cognex's numerous application examples at Volkswagen.
“Cognex smart cameras can be seen everywhere in the production line, such as the lack of detection products. QR code recognition tracking is widely used in engine lines. There are also applications for guiding robot measurement in auto parts factories.†Engineer of FAW Car “These are the reliable and accurate classic applications we have witnessed, and they work very well, some of which are highly recommended by foreign production line manufacturers,†they pointed out.
As a result, the engineers of FAW Cars found Cognex and exchanged solutions with them. “Cognex technicians showed us the powerful visual recognition capabilities and technical application parameters of the In-Sight vision system,†said an engineer at FAW Car. “When I see the product can accurately identify the fuzzy features, I will I feel very advanced, this is exactly what we need."
Next, Cognex's technicians worked with engineers at FAW Car to study how to use Cognex smart cameras to identify vehicle features, judge and distinguish. “After on-site investigation, corresponding to the production situation throughout the day, we will shave some of the glass windows (the glass corridor has direct sunlight in the morning and evening, which will affect the machine identification), and increase the light source to reduce the environmental interference.†FAW The car's engineer said, "The most important thing after that is to add the camera photo transmission signal to the system and equip it with the on-site result display device. This process is very smooth and simple, and it doesn't take much time to adjust the work."
“In terms of the customer applications we are exposed to, in most cases users are concerned about communication issues, and the In-Sight vision system is doing very well in this regard,†Cognex technicians said. “Every camera is at least There are two I/O signal lines, as well as 232 communication and network port communication lines, and the corresponding module combinations can be added according to requirements."
The Cognex In-Sight vision system's smart camera supports almost all communication methods. It can realize the interaction of PLC and camera information commands through input and output commands, while 232 communication is more suitable for transmitting device coordinates, characters and other data. Now, the more widely used communication method is network transmission because it supports communication protocols (Profinet, TCP/IP, Ethernet/IP, Ethernet native, Ethernet strings) that directly transmit data over the network. It is possible to adapt the Profibus application through the conversion component, directly interact with the PLC through the configuration file, and debug the program.
After the installation of In-Sight vision system on the production line of FAW Car, the on-site process is as follows: 1) The vehicle passes from the welding shop through the lifting platform, transmission line, rotary table, transplanter to the sliding switch position; 2) transplanting machine Through the body, the original slipper returns, while the next station slides into place, the transplanter moves to the next station, the lifter picks up the car, the transplanter withdraws, the lifter falls; 3) the car body falls down On the æ’¬, the lifter continues to fall into place, the sensor generates a signal, the PLC triggers the camera to take a photo; 4) the camera processes the image, and the result is sent to the PLC, and the image is transmitted to the touch screen through the switch; 5) the PLC obtains the result, and the transmission continues with the pass. The error is repeated or replaced.
After using the In-Sight vision system, the FAW car can automatically judge the image recognition when the car body falls onto the skid. The camera will alarm the vehicles that have not fallen in, and the system will let the elevator fall back to the vehicle according to the procedure. Until it falls in, it solves the problem of the previous mistakes and slips easily.
The In-Sight vision system perfectly solves the problem of identifying the car production line of FAW Car. “Before I saw the transmission line stopped without an alarm, I had to send someone to check the situation on the spot. The monitoring room was very far from the station. It was very troublesome to send someone to run once, and sometimes it was innocent.†Zhou Shifu, a monitoring room officer, said. “It’s much easier now, and you can see the production on the production line in the control room.â€
“After installing the In-Sight7200 smart camera, the identification model was almost missed again, achieving a false positive rate of 0.05% (the margin is not wrong), while the previous error rate was around 1%, which greatly improved the efficiency and quality of the production line. "The engineers of FAW Cars stressed that "the performance of In-Sight vision system is surprising and the effect is more satisfactory. We intend to carry out the same transformation on other production lines in the future, I think we will continue to use Cognex. product."
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