Coherix Spotlight: Real-Time Bead Inspection Featured on Dispensing.com
Why Manufacturers Need Real-Time Bead Inspection & Adaptive Process Control: A Discussion with Coherix
Original article from dispensing.com
In dispensing applications, one missing or misplaced adhesive bead can lead to major issues that can cost a business wasted time and money. Fortunately, these problems may be avoided.
We talked with two team members from Coherix about robot vision systems and the growing need for real-time adhesive bead inspection and adaptive process control in automated dispensing applications.
Who Is Coherix?
Coherix is a company that creates 3D adaptive process control systems for dispensing applications. It is an American company based in Michigan but has operations worldwide with over 5,000 systems installed globally. Coherix has been in the industry since 2003 and is leading the way in real-time adhesive bead inspection and adaptive process control for sealants, adhesives, and other material dispensing.
We talked with Steven Pagalos (pictured) and Josh Anton about their thoughts on the future of automated adhesive dispensing in manufacturing. Steven Pagalos is one of Coherix’s Technical Account Managers. He has been with Coherix for 16 years and was previously an Application Engineering Manager for the company. He was able to shed light on the more technical side of this equipment. To translate some of the engineer-ese, we also spoke with Josh Anton, the Marketing Communications Manager for Coherix.
Dispensing Systems Alone
While automated and robotic dispensing systems are great for several reasons, including increasing throughput and improving efficiency, they are not perfect. Issues can arise when it comes to quality control and accurate material dispensing.
As Anton noted, “A lot of dispensing machines will tell you how much volume comes out of the dispensing nozzle but can’t tell you if it ends up on the part, the floor, or if it’s on the right part of the part.”
Consequently, an entire run of products could have misplaced adhesive, an incorrect amount of adhesive, or missing adhesive altogether. These defects can quickly add up and cost manufacturers valuable time and money they can never get back.
Giving Robots Eyes
To combat these problems, Coherix and other companies developed robot vision systems that use cameras or sensors to inspect the dispensing process. Anton simplified this as, “We’re providing the eyes for the robot.”
Pagalos further explained, “We’re measuring the bead in 3D. We understand how much material is being dispensed and where it’s being dispensed.” Robot vision systems do adhesive bead inspection to not only assess whether or not the adhesive was applied, but also to track metrics like bead placement, volume, length, and continuity.
These systems are often attached directly to the dispensing nozzle and may be connected to computer software and integrated with the manufacturing process. They can be used in a variety of dispensing applications.
Moving to Real-Time
While robot vision systems can give insight into adhesive bead dispensing, there are some limitations. Many systems work in 2D and are limited in their glue bead inspection to after the fact. They typically only assess whether or not the bead was dispensed and if it is in the right spot after dispensing is over.
Coherix started with 3D, knowing the challenges and limitations of 2D systems. “We learned in our development of the system about some of the challenges around existing systems, 2D systems primarily-lighting was a challenge, color of the material, color of the parts, and user experience. So all of those things fed into our development of a 3D solution.” Pagalos explained.
Coherix’s 3D system uses a laser to read 400 times a second to inspect the bead in real time, including its volume, length, and continuity. Consequently, it can get a more comprehensive picture of the dispensed adhesive or material.
Inspection Is Necessary, But Non-Value Add
Although helpful, robot vision systems are often seen as an add-on to automated dispensing systems that can help manufacturers check adhesive bead inspection off their list.
As Pagalos noted, “To quote our CEO, ‘Inspection is necessary, but non-value add.’ So what that means is people have the equipment, they’re dispensing a bead, and they don’t want to inspect it if they don’t have to; they just want it to work. But for many applications, you have to guarantee that the material is there and there’s enough of it.”
A large portion of Coherix’s business comes from the automotive industry, including vehicle subassembly, general assembly, battery manufacturing, and final assembly. Not only is accurate dispensing imperative due to the nature of these applications, but also a growing number of tiers and OEMs are mandating the use of robot vision systems in manufacturing.
While the 3D, real-time bead inspection may just be a way to stay compliant with these regulations, Coherix is offering a lot more.