Machine Vision Systems & Software Case Studies

Poka-Yoke System Checks Automotive Frame

By Bob Rongo, Decision Technology, LLC

This Poka Yoke system (sometimes referred to as a Poke Yoke system) was designed and built to verify that 40 plus mounting fasteners are present on an automotive frame assembly. As the frame enters the first station of the assembly line (validation station) a series of 12 cameras are used to check presence/absence and that certain fasteners are facing the in the proper direction (orientation). Also, the approximate size of certain critical holes is checked to ensure the stamping operation. Detected failures are circled in red on a 3-D rendering of the frame assembly (operator screen) so that operators can quickly identify the point of failure and resolve the problem prior to the frame reaching the next station. The frame moves station to station via an overhead conveyor system.

Although the system uses 12 cameras, it has a single point of control and interface resulting in a highly integrated and cohesive 12-camera inspection station. All part programming is performed using an feature orientated style teach screen that services all 12 cameras. The system runs one part but has been designed to handle multiple part numbers.

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