Detection of Presence/Absence | Atonm CL4 Color Sensor Accurately Identifies Missing C-Type Clips on Workpieces

I. Customer Requirement Background

A manufacturing enterprise needs to fit C-type circlips onto the pins of workpieces during the production process to ensure the structural stability and functional reliability of the products. However, missing C-type circlips often occur in the manual assembly process.

Given the small size of C-type circlips, visual inspection is inefficient and prone to misjudgment, which leads to quality risks for products entering subsequent processes. This not only increases the cost of product rework but also may undermine the enterprise's brand reputation. Therefore, the customer is in urgent need of an efficient and accurate detection solution that can quickly identify whether C-type circlips are properly fitted onto the pins.

II. Solution

Atonm provided the CL4 Color Sensor as the core detection device for the client. Boasting high sensitivity and precise color recognition capability, the Atonm CL4 Color Sensor can quickly distinguish the surface colors of different objects.

Its working principle is as follows: when a workpiece passes the CL4 Color Sensor on the production line, the light spot emitted by the sensor irradiates the pin position. If the C-type circlip is missing from the pin, there will be a distinct color difference between the detected surface of the pin (the pin is silver while the surrounding area is black) and that when the C-type circlip is properly fitted (both the pin and the surrounding area are silver). In such a case, the sensor will immediately identify the discrepancy and output a signal to indicate the missing circlip issue. If the C-type circlip is correctly installed on the pin, the sensor will recognize the expected color and remain silent, signifying that the assembly is up to standard.

III. Implementation Process

Equipment Installation

Technicians installed the Atonm CL4 Color Sensor behind the station where C-type circlips are assembled onto workpieces. The sensor was positioned to ensure its detection angle and distance accurately cover the pin location, while avoiding any interference with the normal operation of the production line.

Parameter Calibration

Based on the color characteristics of the C-type circlips and pins, detailed parameter settings and calibration were performed on the CL4 Color Sensor. Color thresholds were defined to distinguish between the presence and absence of circlips, ensuring the sensor could perform stable and accurate detection.

System Integration

The sensor was integrated with the production line's alarm and control systems. When a missing circlip was detected and a signal was output, the production line would immediately trigger an alarm and pause operation, allowing staff to address the issue promptly.

IV. Application Effects

Significantly Improved Detection Accuracy

After the installation of the Atonm CL4 Color Sensor, the detection accuracy of C-type circlips on the production line was enhanced. This prevented products with missing circlips from entering subsequent processes, effectively ensuring product quality.

Remarkably Increased Production Efficiency

Compared with manual inspection of each workpiece, the sensor’s rapid detection capability eliminated the restriction of production line speed by manual testing efficiency. Production efficiency was increased by 30%, greatly boosting the enterprise’s production capacity.

Effectively Reduced Costs

It cut down the additional costs caused by product rework and customer complaints, while also reducing the enterprise’s reliance on manual inspection and saving labor costs. It is estimated that the solution can help the enterprise save hundreds of thousands of yuan in comprehensive costs annually.

V. Conclusion

With its outstanding color recognition performance and stable, reliable operation, the Atonm CL4 Color Sensor has successfully resolved the client’s challenges in detecting C-type circlip assembly. It provides strong support for the client’s product quality and production efficiency. If you have similar needs, please contact Atonm, and we will provide you with a one-stop solution.