Schneider Electric's headquarters in Paris
Télémécanique, a Schneider Electric brand, produces the Osiswitch Compact line of circuit breakers. Each individual circuit breaker is assembled manually, which requires a 100% reliable inspection rate of each component to verify each breaker before packaging. The Osiswitch Compact line can create up to 2,000 different product types from 100 different components.
Due to the sheer variety of product types that can be produced, a traditional mechanical system would not meet the quality standard regarding inspection that is required. It became clear that vision technology was the only solution.
About Schneider Electric
Schneider Electric was first established in 1836, then known as Schneider & Cie, and specialises in digital automation and energy management. The French multinational company combines energy technologies, real-time automation, software, and services to supply its customers with solutions.
Cognex and Esox create a vision station to improve inspection quality levels at Schneider Electric
The digital automation specialists chose Cognex as its new visual supplier due to its global presence and high-quality technology reputation. Initially, Cognex and its partner integrator Esox completed a feasibility study and proposed an inspection solution to fulfil Schneider Electric’s needs.
“At Schneider Electric, we give great importance to product quality, and we invest in this at all levels of production,” said Nicholas Charollais, Marketing Manager at Schneider Electric. “Our biggest risk as regards quality control being an unsatisfactory order, we need an inspection solution capable of verifying that each product packaged matches the right product reference. Fully automating the inspection line was therefore essential.”
The vision system proposed by Cognex allows for the complete assembly inspection of each component of any product by analysing the product references. Schneider’s new vision system was developed by Esox using Cognex’s VisionPro software which allows for a multi-display of images.
Esox’s vision station consists of two cameras, five LED light sources, and a laser beam. The first high-resolution camera (1600x1200 pixels) inspects the underneath part of the piece and checks the code inscribed on the contacts. While the second camera inspects the upper part of the piece. Images acquired during the inspection process are recorded in the inspection database.
Due to the variability of components, creating an effective lighting system was a major challenge. But Cognex’s partner conceived an optical system using a software tool programmed to operate according to exposure times. Lighting can be adapted according to the product reference, with several lighting variations available depending on the product family.
During ongoing product inspection, the vision system can display one or more images for each product component. In fact, the system can display up to 12 images in the form of frames, with each image captured using the most appropriate lighting. Images are then processed by the software with inspection results appearing on each frame with red and green labels, allowing the operator to visualise any problems quickly.
Key features of Cognex's VisionPro software:
Cognex VisionPro software
- Designed to set up and deploy vision applications.
- Can access a library of pattern matching, blob, caliper, line location, image filtering, optical character recognition and verification (OCR and OCV), and AI-based vision tools.
- Performs a wide range of functions including geometric objection location, inspection, identification, measurement, and alignment.
- Has specialised functions for semiconductor and electronics applications.
- 1D and 2D barcode reading capabilities.
- The software is fully integrated with extensive .NET C# and C++ class libraries and user controls.
Has the Cognex and Esox vision system changed production at Schneider Electric?
The vision platform was tested in France, with tests being completed “in record time.” Schneider Electric first installed one of these vision systems at one of its Spanish production sites. According to the digital automation specialists, “two weeks were enough to confirm the capabilities and the sturdiness of the Cognex system.” Following the successful first installation, the production line was transferred to the site in Batam, Indonesia.
Schneider’s French sites can monitor production processes occurring at the site in Indonesia. Workers at the French site can monitor images of faulty components, control the inspection parameters, and make modifications to programming that are occurring at the Indonesian site.
With all statistics now being archived by the system, it is now possible for Schneider to monitor and confirm all non-conforming defects, identifying any false rejects if necessary. This level of control also translates to total traceability of inspected production and helps Schneider achieve its quality assurance goals. Looking to the future, the digital automation specialists hope to build upon this success and install the same application at its Limoges site.