Molex Connector (Chengdu) Co., Ltd. Molex Connector (Chengdu) Co., Ltd. (hereinafter referred to as Molex) is a wholly foreign-owned enterprise invested and established by Chengdu Koch Group's subsidiaries in Chengdu. The company's business scope mainly covers automotive connectors, industrial PC server high-speed interfaces, covering the world's leading automotive manufacturers and parts manufacturers. In recent years, Molex has developed a new product, the Automotive Electronics ECU Module, to open up the market, but its major connectors face two important challenges in the production development process: First, the pin-height measurement accuracy of PCB surface of product PCB board is required to be high. Because the deformation of the terminal after bending the pin and the external force of the assembly may cause the height of the pin to change, it is necessary to strictly test the height of the terminal before packaging to ensure the accuracy of the customer during use. reliability. Second, due to the large number of pins on the product, the number of connectors on the top of the connector industry has been reached, and the unit price of the products is high, and it is necessary to ensure 100% quality reliability of all terminals. Therefore, all dimensions of the product adapter and the PCB must be within the design specifications. This requires multi-camera detection. In the face of these challenges, Molex needs a vision technology provider that can provide a full range of algorithmic functions and complete solutions to help solve testing problems. After investigation, Molex found that many companies in the visual inspection industry are sharing the entire market. Among them, Cognex Corporation, which first entered the visual inspection market, has a strong technology reserve and a full-featured underlying algorithm. In the industrial scene, if the ambient light changes or the workpiece position is not fixed, or the shape of the workpiece is uncertain or the material changes, the related functions cannot be stably and effectively implemented. Such machine vision algorithms are unlikely to be accepted by users. Cognex always focuses on developing the industry's most advanced and effective machine vision algorithms and tools with benchmarks, such as PatMax®, PatMax® RedLine®, OCRMax, 1DMax+, 2DMax+, etc., ensuring that in the most challenging industrial field environments, All the machine vision functions can be achieved stably and effectively, such as positioning, assembly or alignment guidance, dimension measurement, defect or error checking, and image reading. Because of this powerful feature, Molex engineers selected two company vision products including Cognex for testing. When evaluating Cognex's DS925B laser heads, Molex engineers were surprised to find that they not only had algorithms and powerful underlying tools they were familiar with, but also had a variety of programming modes, either using VisionPRo or using Cognex Designer. To design the required program, with a high degree of freedom and custom functions. The high-precision laser heads used in the Cognex DS925B are factory-calibrated with micrometer-calibrated outputs, are real-world units of measurement, are easier to use and faster to deploy, have a loose mechanical configuration, and can generate single high-resolution 3D images. Due to the high resolution of the 3D image, accurate height values ​​and repeatability can be reflected when measuring the height of the product's PCB surface terminals, and the differences due to different terminals, materials, and coatings are avoided, which is well eliminated. Batch differences in the production process. In addition, Cognex also actively developed and launched a vision guidance solution for binocular 3D robots, as well as a new generation of DS1000 and DS900 series laser three-dimensional measurement systems that can perform three-dimensional inspections of products to help optimize quality. A wide range of height, volume, tilt, cross-section, and plane-fitting tools allow accurate measurements regardless of contrast or light. Engineers at Molex stated that "with the help of Cinevision In-Sight and VisionPRO's powerful visual tool processing capabilities and easy-to-understand, easy-to-maintain programming interface, we have established a test that can meet the needs of the field in a short time. Program and easy to maintain parameter adjustment interface." At the application site, the automated testing machine is mainly composed of five modules: 1) the product is cleaned and charged; 2) the electrical measuring module; 3) the height position measuring module; 4) the two-dimensional code marking and detection; Robotic cutting packaging. The test contents mainly include: 1) the height of the product pin relative to the plastic; 2) the positional dimension of the product pin inside the plastic and the distortion of the HSG; 3) whether the entire HSG outer contour has deformation; and 4) the height and absence of the product positioning column. The process is as follows: 1) The product is sent to the cleaning module after the bending of the pin is completed, and the product is cleaned to ensure that there are no HSG chips and other foreign materials caused in the production process; 2) After cleaning, the product comes to the power measurement module through the feeding mechanism. It mainly detects whether the product has needle leakage during the process of pin insertion and whether there is any abnormality when it is bent, including the products OS and Hipot test; 3) After passing through the power measuring module, reach the Mate adapter to measure the pin height. Since the terminal is hidden inside the HSG, it needs to be transferred to the outside through the mechanism probe to measure the height of each terminal relative to the HSG. The In-Sight 5605 is resistant to the fast and stable detection process. 4) After the pin height detection is completed, the PCB height measurement station is reached. This is the highest difficulty in the entire testing machine and is also the longest evaluation time in the previous development process. Since PCB pins are used to solder ECU modules, 100% accuracy and high quality must be guaranteed. However, the hardness of the stitches is not enough, and mechanical probes cannot be used to switch the measurement. Only the non-contact measurement system can be used for measurement, and at the same time, high accuracy, good repeatability and reproducibility are ensured, and it can withstand the verification of the MSA. . 5) After the PCB height detection is completed, go to the next station to measure the terminal position dimension of the product PCB, and then check the OK or NG of the product, and then perform two-dimensional code marking and barcode verification, and finally pack the product by robot. The above inspections greatly ensure the product's high quality and stability, while also reducing manpower, virtually eliminating the missed inspections and uncertainties brought about by human detection, to a large extent, improving the production and testing of Molex. Satisfaction and safety. "Because Cognex offers complete solution capabilities from hardware to software, everything from In-Sight to VisionPRO, from simple entry to deep customization has its presence." Molex engineers pointed out that "as a long-term partner We chose Cognex as the company’s leading supplier of vision solutions and provided us with technical support from start to finish.†Because Molex used Cognex's machine vision products to achieve a non-contact detection method, which greatly improved the company's product production efficiency and production cycle, greatly reducing the probability of leakage of defective products, guaranteeing High quality product quality and commitment to customers. Molex's engineers finally emphasized that “at the same time, due to the improvement of customer satisfaction, we have given us new orders and new product evaluations in the same type of products, which has enhanced the competitiveness and reputation of the company and other manufacturers in the series.†On-site overall inspection system architecture and layout Detection system program screen display Cognex VC5 controller and IO wiring layout
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