The inspection object is the workpiece of the wire harness plastic plug. The workpiece has no color and grain difference, and the only distinguishing feature is the height difference of the shell structure:

Front: comes with raised structure

Reverse side: The corresponding position is a recessed structure.

Positive and negative height difference: stable 2-3mm

Different from the static detection station, the automatic transmission line has two major interference factors, which become the "detection blind area" of conventional sensors ":

1. Large vibration interference of equipment:The conveyor belt and drive motor run continuously, and there is high frequency and small jitter in the workpiece conveying process, which can easily cause the detection value drift and signal jitter;

2. There is injection tolerance for materials:There is a slight deviation in the bump height of batch workpieces, and the fixed threshold detection is prone to misjudgment.

For field conditions and testing requirements,Akusense The recommended selection of MLD25 series laser displacement sensor, relying on the mature laser triangulation principle, to achieve micron-level high-precision displacement detection, perfect adaptation of small bump segment difference recognition scene.

The sensor emits a laser beam to vertically irradiate the workpiece detection surface, captures the position change of the reflected spot through a high-precision CMOS receiver, and converts the precise distance between the sensor and the measured surface in real time with a built-in algorithm to convert the physical height difference of the workpiece bump into a stable and identifiable digital displacement value.

Ultra-high detection accuracy:The repetition accuracy can reach 3 wires (3μm), far exceeding the height difference of 2-3mm workpiece, easily capturing the small segment difference and material tolerance change;

Strong anti-vibration stability output:Equipped with intelligent digital filtering and hysteresis algorithm, effectively filter the numerical fluctuation caused by the vibration of the production line, and eliminate the signal jump;

Simple debugging adaptation:Support one-key teaching, interval custom adjustment, no need for complex programming, on-site rapid adaptation of material deviation;

Industrial Durability:Cast aluminum body IP67 protection, suitable for workshop dust, slight oil pollution, continuous vibration of the harsh industrial conditions.

Two-point teaching interval fault tolerance determination

Aiming at the double interference of field vibration and material tolerance,Akusense Engineers abandon the traditional fixed threshold determination method and adopt a two-point teaching method threshold interval expansion scheme to solve the problem of false detection from the root!

✅The first step: double reference point teaching calibration

On-site through the sensor one-key teaching function, respectively enter the standard workpiece data:

Place the positive raised workpiece, teach and record the positive standard height value;

Place the reverse recessed workpiece, teach and record the standard height value of the reverse side;

The sensor automatically generates two sets of independent determination criteria, positive and negative, to accurately distinguish between the two states of concave and convex.

✅The second step: interval expansion, fault tolerance and anti-interference

Combining the field vibration fluctuation range and the workpiece injection tolerance, appropriately enlarge the positive and negative judgment threshold interval, and reserve sufficient fault tolerance space:

Positive determination interval: covering the tolerance vibration fluctuation error of the workpiece;

Reverse determination interval: independent fault tolerance interval, no overlap with the forward interval;

Completely solve the problem of numerical drift caused by vibration beating and material size deviation. As long as the measured height falls within the corresponding interval, the positive and negative states of the workpiece can be accurately determined.

When the sensor measures the threshold and determines that it is the reverse side, it will send a signal to drive the mechanism to turn the material to the front side and then transfer it to the next station.

Most of the time, customers are not afraid of insufficient precision, but of "disobedience" in the on-site environment-vibration, temperature and dust. If they come casually, they can make a good plan in the laboratory roll over on site.

If you are faced with similar detection problems-whether it is vibration, high reflection, or other complex conditions, please feel free to exchange and discuss.