With the rapid development of the new energy vehicle industry, the quality requirements for parts are becoming more and more stringent. As the core component of the key thermal management system, the geometric dimensional accuracy of the cooler assembly directly affects the heat dissipation performance and service life of the vehicle. To ensure that the cooler assembly meets the design requirements, Intsoft Tech has developed a set of automated precision inspection solutions based on machine vision for customers.
Inspection items and technical requirements
For the key dimensional characteristics of the cooler assembly of new energy vehicles, we need to detect the following three indicators: flatness, straightness and thickness of the cooler surface.
To achieve these strict technical indicators, we have designed a set of precision machine vision inspection systems that integrate image acquisition, intelligent algorithm processing and automated measurement.
Inspection solution design
Multi-angle image acquisition
We use three high-resolution industrial cameras to capture high-definition images of the cooler assembly from the top, left and right. This stereoscopic multi-view acquisition can ensure comprehensive and accurate acquisition of the geometric features of the target to be inspected.
Intelligent image processing
For the characteristics of the cooler assembly, we have developed a special image processing algorithm. The algorithm can quickly and accurately extract key dimensional parameters such as flatness, straightness and thickness, and realize fully automated measurement.
Detection method
Flatness detection
By performing edge detection and fitting analysis on the upper view image, the height difference of the cooler surface can be obtained, and the flatness index can be calculated.
Straightness detection
Using the left and right view images, we can extract the contour lines of the cooling pipe respectively, and fit the straight line through the least squares method to calculate the straightness deviation of the pipe.
Thickness detection
By measuring the distance difference between the cooler edge in the upper and left view images, the overall thickness of the cooler can be calculated.
Automated measurement process
The entire measurement process is fully automated. The operator only needs to place the cooler on the measurement platform, and the system can automatically complete the steps of image acquisition, target recognition, dimensional parameter extraction and data analysis, and output a detailed measurement report.
Implementation effect
1. Through our automated precision detection solution, customers have achieved the following significant results:
2. Measuring efficiency has been greatly improved. The detection speed has been increased by more than 4 times compared to manual measurement.
3. The measurement accuracy reaches ±0.01mm, which fully meets customer requirements.
4. Subjective differences caused by manual operation are eliminated, ensuring consistency and reliability of measurement results.
5. Timely detection and isolation of unqualified products effectively prevents the occurrence of quality problems.
