Zeroing In On Defects

Developing the FVision GP 50 technology internally has enabled Freudenberg Sealing Technologies to tailor individual inspection machines to specific production applications and defect parameters, explained Robert Scavuzzo, Vice President of Freudenberg’s Global Advanced Manufacturing Technology group. The automated system also minimizes the need for manual inspections, which typically take more time and are less likely to detect tiny defects.

“We’re constantly looking for ways to improve our production processes,” Scavuzzo said. “The updated machine vision technology is the next step in the evolution, helping us to more effectively meet zero-defect mandates, while providing clear benefits to our customers and end users.”

Small, Fast and Flexible

The FVision GP 50 machine can be used to inspect a wide variety of components, including small automotive seals, springs and O-rings, made of different types of materials and with different production processes. It features new image processing technology – including the ability to self-adapt to process variations – and can support as many as four cameras.

Most defects appear during the molding process as a result of material damage within the mold. Other potential problems can occur during finishing operations, such as in trimming to remove excess rubber flash.

Significantly, the FVision GP 50 inspection units will reduce the possibility of expensive customer recalls through a more robust production inspection process. The units will identify defective parts and reject them. They will also categorize and visually record the defects and produce visual alarms when too many are detected, making it possible for machine operators to access this data and apply it upstream to permanently eliminate defects from the injection process.

The data can be transferred between inspection units operating at any Freudenberg manufacturing site, creating a communication network dedicated to the elimination of product defects and the improvement in quality results.

The Big Picture

FVision GP 50 is part of Freudenberg’s efforts to standardize equipment and processes throughout its production facilities. To this end, Scavuzzo estimates that the new inspection machine could eventually be used in about 80 percent of Freudenberg’s Sealing Technologies manufacturing plants with minimal design changes, while the camera, illumination and software would be customized for specific applications.