The Modular Multi-aspect Optical Inspection System for the Quality Control of Polymer Elements

The article presents a quality control system for polymer components produced by injection molding, covering both the control of visual surface defects, known as inclusions, and precise geometry control. The system is modular, i.e., it is composed of a series of stations that control different aspects of the element. The system includes two cameras placed in dome illuminators and an array of four laser profilometers. It is designed for industrial application, where accuracy and inspection speed are critical, and its parameters allow it to be used in typical production lines without limiting production speed. The produced elements are controlled with much greater precision than before its implementation. The system can inspect 30 elements per minute, detecting inclusions of 350 μm in diameter and geometric differences between the pattern and the injection of up to 100 μm. It can be applied in all industries where injection-molded plastic parts are commonly used, such as the automotive, electronics industries, and home appliances. The prototype of the presented system was awarded a gold medal at the Automaticon fair in Warsaw.