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Brake discs are manufactured in grey cast iron, therefore they may have holes that are only exposed during grinding. These holes on the surfaces should be dimensioned during the inspection and the depth of the balance milling should be measured.
In addition to the pure safety aspect of automotive brakes, an aesthetic component is also becoming increasingly important as they are visible in certain cars and thus part of the visual appearance. Brake discs with visible defects are not acceptable for buyers of these mostly high-priced vehicles, even if the braking function is not impaired by these "blemishes".
However, inspecting brake discs is not easy due to the illumination situation. The surfaces are polished and have grinding grooves, which are inevitable during production and produce certain artefacts. To make matters worse, fingerprints or fine-grained sand as a residue of the previous grinding and washing processes are often easily misidentified as unacceptable defects by 2D image processing systems, which is why we relied on 3D machine vision for our solution.
For this application we used a Teledyne DALSA Z-Trak2 series 3D profile sensor, that is laser triangulation based and offer a scanning speed of up to 45,000 profiles/s and a resolution of 2,048 pixels per profile and is perfectly suited for this task due to its robust, compact design and IP67 enclosure. In addition, the device is already calibrated at the factory and can be integrated into inspection systems without any major effort.
Evaluation fo the position and size of the defects was done in Halcon.
Find our more about 3D laser triangulation and the Z-Trak2 high performance 3D profile sensors here.
Your individual solution
We would be happy to discuss your ideas and requirements in detail and develop a special solution together with you, tailored to your individual needs.