Static Inspection Station

STATIC INSPECTION STATION SUMMARY
Deliver a fixture that inspects the presence of 10 identical parts and determines if their installation is required based on the color of the customer’s part. The system scans a data matrix for route readiness checks against the customer’s MES system and communicates Pass/Fail results for downstream process verification.
TEAM:
- Mechanical engineers
- Controls engineer
- Project manager
DESIGN TOOLS USED:
- Solidworks
- Studio 5000
- Python
- Excel
- VS Creator
MARKET:
Manufacturing/Operations teams who need automated inspections for quality assurance
PROJECT REQUIREMENTS
- Lighting control for deep cavity inspection: Opaque panels were used to block external light and improve imaging performance for springs located deep within round cavities.
- Future-proof communication with the MES system: The inspection system and its communication were designed to accommodate anticipated customer updates.
- Ethernet/IP communication: Ensured seamless and fast communication between all devices in the system.
- Custom VB/Python script: Developed to allow the customer to easily update allowable colors and spring requirements per color.
- Custom operator GUI: A user-friendly GUI was created using Keyence’s VS Creator programming software, providing clear indications of missing parts and system error messages.
SUMMARY OF ACTIVITIES
The Pipeline team designed and built a highly customized fixture for automated part inspection and route readiness verification. The integration of opaque panels to optimize lighting conditions enabled consistent imaging of deep-set springs. Communication was streamlined through Ethernet/IP protocols, ensuring fast and reliable data exchange.
Key functionality was achieved through a custom VB/Python script, enabling customer updates to color and spring requirements without additional programming. Additionally, the team developed an intuitive GUI to support operator interactions, including error reporting and real-time part status feedback.
This robust system successfully integrated with the customer’s MES for both route readiness checks and Pass/Fail results, supporting downstream operations with precise quality assurance.
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