General poka-yoke systems
At the assembly station a camera verifies each step in turn: screws fitted, connector seated, label in place and its code readable. The stopper does not release the pallet to the next station until every step on the checklist has passed.
The result of every step and the label code read are stored with the pallet ID; on a missing step the stopper stays closed and the corresponding row is flagged on the checklist display. Once all steps have passed the stopper opens.
- 01 Loading
- 02 Screws
- 03 Connector
- 04 Label
- 05 Release
The part arrives on its carrier pallet; the photo-sensor sees the pallet and the stopper is closed.
- Screws
- —
- Steps passed
- —
- Label code
- —
Scenes are illustrative simulations; they are not customer references or performance guarantees.
Need
Assembly steps are done by hand and a step can be skipped; screw heads, the connector and the label are small and low in contrast on the light-coloured body. The difference between a half-seated and a fully seated connector is a few millimetres.
Solution approach
A top-view smart camera is triggered after each step and a pallet-presence photo-sensor starts the check. Each region is evaluated by its own criterion: presence and brightness for the screw head, edge position for the connector, presence and a readable code for the label. The stopper does not release the pallet until every region has passed.
Process steps
- 01
Loading
The part arrives on its carrier pallet; the photo-sensor sees the pallet and the stopper is closed.
- 02
Screws
The four screw positions are checked in the image; a missing screw is flagged.
- 03
Connector
The connector is verified to be fully seated in its socket.
- 04
Label
Label presence and position are verified and its code is read.
- 05
Release
With every step passed the stopper opens.
Related applications
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