Gear Tooth Profile Inspection Using DENSO + QRS Vision

Industry > AutomotiveIndustry > MachineApplication > InspectionSector > Manufacturing

#BinPicking#3DVision#2DInspection#GearToothInspection#RobotSorting#ManufacturingAutomation

Process Overview

This solution is an automated sorting system that combines QRS 2D/3D vision inspection with a DENSO VS robot to pick randomly placed gears, inspect gear tooth geometry, and separate OK parts from NG parts.

With QRS’s in-house vision technology, the system can be tuned and customized to match specific site conditions, enabling precise inspection across various gear shapes and models.

This project was implemented to automate the inspection process after bin picking.

Components

Robot	DENSO VS-060 6-axis articulated robot Payload: 4 kg Max reach: 605 mm Weight: 28 kg Repeatability: ±0.02 mm Standard cycle time: 0.35 sec Max tool speed: 9,390 mm/s Dustproof/clean option available
Peripherals	Tool: Electric gripper Vision system: QRS Q3D-IS (near-field type) Gear position recognition: 3.2MP, 2048 × 1536 pixels Sensing method: Structured light Scanning range: 176 × 132 to 706 × 529 mm (area) Measurement distance: 300 / 600 / 1200 mm Supports color / shape / edge recognition and image correction QRS Q2D: 2D inspection (deep learning algorithm included) Alignment: Sorting and inspection based on product geometry Measurement: Shape, length, weld bead thickness, and other dimensional measurement available Inspection: Shape, defects, missing parts, color, sequence inspection available Compatible robot brands: HYUNDAI, NACHI, EPSON, DENSO, YASKAWA, STAUBLI, FANUC, KUKA, UR, etc. Work cell, robot base Inspection result display monitor (QRS) Sorting rack

Robot

DENSO VS-060
6-axis articulated robot
Payload: 4 kg
Max reach: 605 mm
Weight: 28 kg
Repeatability: ±0.02 mm
Standard cycle time: 0.35 sec
Max tool speed: 9,390 mm/s
Dustproof/clean option available

Peripherals

Tool: Electric gripper
Vision system: QRS Q3D-IS (near-field type)
Gear position recognition: 3.2MP, 2048 × 1536 pixels
Sensing method: Structured light
Scanning range: 176 × 132 to 706 × 529 mm (area)
Measurement distance: 300 / 600 / 1200 mm
Supports color / shape / edge recognition and image correction
QRS Q2D: 2D inspection (deep learning algorithm included)
Alignment: Sorting and inspection based on product geometry
Measurement: Shape, length, weld bead thickness, and other dimensional measurement available
Inspection: Shape, defects, missing parts, color, sequence inspection available
Compatible robot brands: HYUNDAI, NACHI, EPSON, DENSO, YASKAWA, STAUBLI, FANUC, KUKA, UR, etc.
Work cell, robot base
Inspection result display monitor (QRS)
Sorting rack

Workflow

STEP 1.	Detect the target gear in a randomly stacked bin using 3D vision
STEP 2.	pick the detected gear and perform OK/NG inspection using 2D vision
STEP 3.	unload and sort to designated locations based on the inspection result

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Features

Fast and accurate sorting performance
High-speed robot handling (max tool speed up to 9 m/s) for improved throughput
Reduced cycle time by performing vision recognition in sync with robot motion
Robust 3D recognition for complex-shaped parts (position & pose)
Micron-level dimensional inspection capability using 2D vision
Vision solution build by dedicated vision specialists
Strong customization and tuning flexibility with in-house vision development capability
1-year warranty coverage for stable operation

Results

Key Benefits	Reduced manpower for quality inspection and sorting Lower defect-related cost and improved customer-perceived quality
Client Feedback	Under varying product and environmental conditions, inspection errors occurred frequently and it was difficult to respond quickly when new products were added. With QRS’s on-site-tailored support backed by dedicated vision expertise, responsiveness improved significantly and satisfaction with the outcomes was high.

Gear Tooth Profile Inspection Using DENSO + QRS Vision

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Application Field: Industry > Automotive, Industry > Machine, Application > Inspection, Sector > Manufacturing

Related Use Cases

Process Overview

This solution is an automated sorting system that combines QRS 2D/3D vision inspection with a DENSO VS robot to pick randomly placed gears, inspect gear tooth geometry, and separate OK parts from NG parts.

With QRS’s in-house vision technology, the system can be tuned and customized to match specific site conditions, enabling precise inspection across various gear shapes and models.

This project was implemented to automate the inspection process after bin picking.

Components

Workflow

Features

Results

Gear Tooth Profile Inspection Using DENSO + QRS Vision

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