Vision inspection systems based on barcode readers are essential for acquiring accurate assembly information and managing historical records for each component on automotive assembly lines. The system must be robust enough to overcome adverse conditions such as oil, dust, humidity, and vibration to achieve accurate code readings. Because these factors directly impact inspection results, they must be considered when implementing a vision system. Automotive transmission manufacturer Hanwha TechM uses In-Sight® barcode readers, leveraging their wide field of view and high definition to overcome these challenges on assembly lines.
Hanwha TechM manufactures transmissions for Ford Motor Company. Ford needed a more accurate barcode reading solution to improve productivity and achieve zero-defect production at its manufacturing plant in Chongqing, China. This solution needed to ensure precise assembly and detection of missing transmission carrier components. To meet this challenge, Hanwha TechM deployed In-Sight barcode readers, successfully achieving the highest read rates, improving productivity, and deploying a comprehensive historical record management system to meet Ford's requirements.
Stringent reading conditions on the transmitter assembly line
The transmission carrier, including input, output, and reaction carrier components, uses Direct Part Marking (DPM) two-dimensional data matrix codes laser-marked on these components. These codes contain crucial information, including batch number, serial number, manufacturing information, and production time and date. This code is read by a code reader to verify that the correct parts were used during assembly and that historical record and process management were performed. These parts can then be managed throughout the entire production, assembly, and distribution process. Accurate code reading is directly proportional to production efficiency, product quality, and a robust historical record management system.
High read rate and user convenience
Park Woo-Sung, Senior Sales Engineer at SHTECH, the system integrator that partnered with Cognex Korea in this solution, stated, “Our biggest concern on the carrier assembly line is the inability to align DPM codes in the same location because the parts are circular. High read rates are only possible when the codes on the parts are marked in different locations, using a wide viewing angle.” He continued, “Because Cognex’s In-Sight barcode readers offer a wide viewing angle and high definition, we can achieve better read performance under any alignment conditions.”
He added, "Furthermore, the In-Sight reader supports Ethernet, allowing direct communication with the factory network. Therefore, we can easily set up and operate the communication without a PC. Because the In-Sight Explorer software can control different operating conditions, it significantly improves user convenience, compatibility, and flexibility."
Hanwha TechM has long dominated the South Korean market for engine and transmission assembly. As South Korea's largest automaker, Hanwha TechM has deployed its solutions in the engine and transmission assembly lines of major Chinese automakers, including GM, Ford, and Hyundai/Kia. Hanwha TechM regularly uses Cognex products for reading and visual inspection. An official from Hanwha TechM's powertrain division stated, "Cognex products include robust IP-level hardware, sufficient to withstand the harsh automotive manufacturing environment. Their high read rates, ease of use, and strong compatibility with other interfaces have earned them high praise." He added, "SHTECH's excellent technical support and timely response further enhance the satisfaction and appeal of Cognex's products."
