ID readers provide turbocharger traceability
A
Cognex UK product story
Edited by the Engineeringtalk editorial team
May 8, 2008
The DataMan 7500 and the DataMan 100 were used to identify the individual code on components in Borg Warner's turbochargers.
By deploying the DataMan 7500 and DataMan 100 ID readers as well as the In-Sight 5110 vision systems from Cognex, Borg Warner Turbo Systems in Germany took the quality control of their turbocharger production in a new direction.
Some 3.5 million turbochargers leave the BorgWarner Turbo Systems production plant every year.
More than 2000 staff look after products, markets and development.
The core assembly is the first production state of the turbocharger and it is to this that all remaining components are fitted.
Turbochargers are the small power stations which have advanced the diesel engine more than almost any other technology, especially in cars.
Being exposed to temperatures of up to 1050C and pressures of up to 3bar, perfect production quality is essential.
One of the project objectives was to use Cognex ID Readers - the DataMan 7500 and the DataMan 100 - to identify the individual code on a component.
After several test runs, it was decided to use an adhesive label with a 2D matrix code printed on it so components could be coded quickly and easily.
The code can easily be read, even when dirty.
From the first steps of assembling parts to the final inspection, all important production parameters are detected, inspected and the results stored in the central database at BorgWarner for further processing.
This not only minimises errors in production, but if defects are subsequently detected, the data biography of the turbocharger reconstructs the production conditions, preventing any disputes arising from claims by automotive manufacturers and limiting the investigation.
A PC is installed at every workstation and at each one, operators use the DataMan 7500 to scan the code.
The data created can then be accurately assigned to the current core assembly.
The data system specifies working steps and inspection criteria and once work is complete, decides whether to approve the component.
BorgWarner uses the DataMan 100 to control the data management of the balancing unit, which ensures the concentric running of the turbocharger.
Finally the turbo charger rating plates are marked with a Data Matrix code in accordance with the customer classification.
Within a fraction of a second, a Cognex In-Sight 5110 tests the Data Matrix code for code quality so that even after the adhesive labels have been destroyed by thermal action during production, the setting and assembly values detected can still be linked to the turbo charger number via the database, even years after it was manufactured.
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