In Inter Control, Nürnberg, 100% high-quality image processing technology is used to control the high quality of the products and ultimately contribute to the production base. The image processing system is based on a structure consisting of a high-energy video system and software and program management modules, thus completing the complex requirements for verifying a range of labels for approximately 150 products. In order to cope with the increasing competitive pressure by improving product quality, Inter Control decided to solve the problem of quality control using image processing technology at the Nürnberg production site. The electromechanical components of the household appliance industry, the heating and ventilation air conditioning sector, and the temperature regulators in the automation system must be 100% quality controlled. In the automated manufacturing process of the thermostat, it consists of a ceramic base equipped with a bimetallic mechanism and a number of connectors and various fixing possibilities. The starting point is to ensure that the components are not broken on the ceramic base. The company has collected ideas for proposals and solutions, and there are many different system solutions for this task. According to this necessity, the production process and 100% quality control must be designed to be as effective as possible, and the requirements must be greatly expanded. In terms of various difficulties related to this, ceramic suppliers have already issued advance warnings, and they have also actively discussed image processing and problems such as ceramic crack formation. Must test 200 different varieties About 50 million ceramic products are processed each year, and only an absolutely safe and reliable working system can be used. In addition, there is a problem in that different ceramic bases and assembled components produce a total of about 200 different varieties. The Firth Bildverarbeitungs-Systemhauses 3D Motion solution proposal is based on a structure consisting of a high-energy video system and software and program management modules, which completes the complex requirements of testing a range of labels for approximately 150 products. This efficient and inexpensive system solution was quickly implemented and installed. The series of requirements originally proposed were gradually expanded and added to the further requirements of image processing. Today, this system solution is absolutely safe and reliable for two or three shifts of fully automated production runs with an efficiency of 80 components per minute. Object-oriented thinking simplifies operations The video specialist in Fürth analyzed the range of products and developed an effective image processing system. When the machine is machined automatically, the same base plate can be fitted with different ceramic bases for assembly with different contacts. In addition, there are many different joints, such as joints of the same construction, but the joints are bent at an angle. In programming, a wide variety of models need to be managed effectively. In fact, this task is not just a video sensor. Thanks to the object-oriented approach, the possibility of meeting various requirements is achieved in the maintenance of programming and management and inspection tasks. Traditionally, a test procedure has been developed for each model in 10 different categories. Thanks to the object-oriented operation, only the base plate is scanned and all inspection procedures are adjusted accordingly. This simplifies the management of the inspection program, saves costs, makes the work method transparent, safer and more flexible. Figure 1 In the space-saving structure, the image processing system consisting of the visual sensor In-Sight 5400 and the lighting device is directly installed in the fully automatic installation equipment. All inspection procedures for approximately 150 categories were all stored in Cognex's In-Sight 5400. The In-Sight vision sensor has an Ethernet interface with IP67 protection and can be used as a separate image processing unit without a computer. The sophisticated image processing algorithm makes the system highly reliable, the operation interface is easy to operate, and the operator can program and read data for new varieties even without comprehensive image processing knowledge. The verified object identification is as follows: check the specified part on the frame, the geometry of the joint, the angular position of the joint, the diameter of the hole on the base plate, the type of flange, and the color mark on the ceramic part. In the space-saving structure, the image processing system consisting of the visual sensor In-Sight 5400 and the illuminating device is directly built in the fully automatic mounting device (Fig. 1). Multifaceted observation and identification of cracks All work for image processing takes about 0.3 s in one cycle time. Examination of crack formation is complicated because problems such as identification by dirt are quite difficult to solve. Therefore, other video system capabilities have been developed to identify cracks by multi-faceted viewing of components. Inter Control's employees delved into image processing technology with great enthusiasm and thus established a valuable authority system. These uses should continue to expand and the company has plans to apply these mature programs and experiences to subsidiaries and their special machines. Due to the gradual exploration of complex fault problems, it is getting closer to the narrow range of licensed fault parameters. In the past, it has always been the case that it is always difficult to avoid entraining one or two wrong parts at the time of delivery because of the change in batch size. The geometry of these parts can now be discovered immediately and sorted out as the wrong part. There are also problems in the fault detection that need to be overcome, such as oil pollution problems. If a dark stain appears due to oil droplets, then no false faults are allowed, and such problem areas are eliminated in a reliable manner. The In-Sight 5400 Vision Sensor's image processing tools also have a large potential for fault detection, which has proven to be one of its strengths. The built-in image processing device reduces the burden on the operator to perform visual inspection before. Once there are three consecutive faulty parts passing through the inspection device, the machine automatically stops. Only products that have passed 100% inspection are placed on the distribution pallet and leave the automated processing line (Figure 2). The fault sources in the process are collected and analyzed in a statistical manner, countermeasures are taken, and the process is rationally adjusted. Figure 2 Only products that have passed 100% inspection are placed on the distribution pallet and leave the automated processing line. In terms of household appliances, global competition is fierce, and in addition to price, quality plays an increasingly important role. If the past failure rate has reached a minimum, then through the use of image processing technology for strict quality monitoring, the failure rate has dropped to 25 to 50ppm (parts per million), complaints or returns have not happened. For the world's home appliance industry spare parts suppliers, this important result is of great benefit. Because the complaint not only caused huge cost of product recall, but also caused great damage to the company's image, and led to a substantial increase in management expenses and negotiation costs. Eliminating this fault area greatly simplifies the process of communication and communication with customers. Other automatic machine tools are gradually expanded The successful experience of using existing testing equipment has led to the gradual transformation of three other automatic machine tools for production, with expansion and image processing equipment. The technical knowledge gained from efficient image processing technology will also be used for the subsidiary of Inter Control and the special machine manufacturing of Bad Kissingen. 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Approximately 80 components are added to the automatic machine every minute and can pass through the checkpoint while the conveyor is running. Each individual thermostat can accurately inspect a series of ç‘•ç–µ marks, such as ceramic cracks, cracks and correction angles between contacts, by means of image processing techniques. 
