Fault-free pistons: precise 3D inspection in the rotary indexing system

The automotive industry places the highest quality demands on engine pistons. Even the smallest impact marks or surface defects can impair the functionality and longevity of the pistons. Our customer requires a high-precision inspection system that guarantees a 100% inspection of the pistons. The challenge is to integrate an automated solution into a rotary transfer system that fits seamlessly into the production process and reliably detects defects.

Our machine vision solution is based on the latest 3D technology for image acquisition and the aku.visionManager® software. The inspection system consists of two inspection stations that are integrated into the rotary indexing table. During the 360° inspection, a rotary axis enables the complete recording of the machined lateral surface of the piston with a 3D laser triangulation sensor. In addition, a linear inspection is performed in which three sensors detect the underside of the piston as well as critical areas for impact points. All inspection data is visualised and stored using the aku.visionManager® software. Unique identification of each piston ensures traceability of the results. The system enables the customer to independently teach in new piston types and flexibly adapt the test parameters.

Piston manufacturers benefit from high-precision and efficient quality control. Impact points are detected at an early stage, reliably sorting out faulty pistons and minimising rejects and complaints. Thanks to the modular software architecture, the system can be easily adapted to new requirements. The automation of the inspection steps reduces manual checks and increases process reliability.