High-quality Manta cameras take clear and stable images for bearing detection
The bearing is an important component in modern machinery. Suzhou M-vision Electronic Technology Co., Ltd. specializes in developing solutions and providing technical support for machine vision equipment and software used to detect defects in the inner and outer rings of bearing cages during production. Their system developed for a world-leading rolling bearings and linear motion product supplier is equipped with two Allied Vision 5MP, Manta G-505 cameras
The challenge
Great centrifugal forces, shocks, and vibrations
When the rolling bearing is in operation, the cage must be able to withstand great centrifugal forces, shocks, and vibrations, especially with complex loads rotating at high speeds. Considerable heat is generated due to the great sliding friction between the cage and rolling body. The combination of force and heat will make the cage fail. The cage may even burn or break. Therefore, bearing manufacturing must meet the necessary high requirements placed on the materials, precision, and processing technologies.
Substandard bearing cages are produced when worn molds and unstable grinding equipment are found in the production line. Typical bearing cage defects manifest themselves as flashes on inner rings, outer rings, width surface, needle slot/slot surface, clip surface, parallel line, rib middle position, scorches, scratches, etc. A camera can help detect these defects in real-time to ensure the proper yield and serves as a reminder to service the production equipment in time.
The solution
Real-time detection
The CT (cycle time) of the production line is 0.4 seconds. To accurately view and detect defects, the camera must have high image quality and speed. After testing various brands of cameras and comparing the quality and stability of all images captured, the end customer and M-vision selected Allied Vision.
The system is equipped with two Allied Vision 5MP, Manta G-505 cameras. It is equipped with the powerful 2/3'' Sony ICX625 image sensor, which is suitable for many applications such as industrial detection and imaging. The frame rate of 15 fps allows it to acquire 15 images per second and can fully satisfy the application’s imaging requirements. The system also includes an OPTO pinhole lens PCHI 023 and OPTO pericentric lens PC 23030XS to take clear images for the outer and inner rings of the bearing cage.
There are two types of bearing cages: die cast and molding cages. Both can isolate and guide the rolling body while keeping it within the bearing. Suzhou M-vision Electronic Technology Co., Ltd. has developed a software used to detect defects in the inner and outer rings of bearing cages during production, as for example: flashes on outer ring, inner ring, on width surface, on clip surface, on parallel line, on needle slot, on rib middle position, as well as scratches and scorches.
The benefits
Improvement of production fault rate
"The M-Vision bearing cage detection system has greatly improved the production fault rate. It also reminds customers to preform timely equipment maintenance, which consistently maintains product quality. The main reason we chose Allied Vision Manta cameras is its ability to capture high quality images, allowing us to quickly determine product quality and eliminating the need to confirm the image quality repeatedly. Allied Vision cameras are very stable and reliable, even in harsh manufacturing environments. It can satisfy the requirements of 24 hours/7 days a week continuous on-line detection in customers’ factories, ensuring consistent and accurate operation of the detection system," said Mr. Cheng Xiuqing, the technical director of M-vision.
The camera: Manta G-505
Versatile high-quality Manta camera
The Manta is Allied Vision's most versatile GigE Vision camera series with a wide range of sensors and features. Thanks to the modular concept, users can choose from a wide range of hardware options including Power-over-Ethernet support, various optical filters, angled head configuration, and board-level variants.
To optimize system costs, Manta cameras also support single-cable solutions by powering and triggering the camera simultaneously via the Ethernet cable. In addition, multiple cameras can be precisely synchronized when utilizing the Precision-Time-Protocol (PTP) feature.
Highlights at a glance
High resolution images showing the smallest defects.
Reliable and realtime results guarantee fast production processes
100% inspection for high-quality products
Easy integration thanks to small size, industrial-grade standards and excellent connectivity