How to verify the pressure strength of air conditioning condensers using a vision system?

Bartlomiej Juszczyk, Piotr Jaworski, 2023.02.07, Vision systems

Vision quality assessment systems are used in various applications where it is important to check such features as: dimensions, assembly correctness, surface properties, shape, color, etc. They are an important module of robotic assembly lines, they are a source of information about defects in technological processes. An example is a station designed for visual inspection of the compliance of condensers after a pressure test.

Quality tests of condensers

The aluminum tubes that make up the condenser should be properly formed, which depends, among other things, on the quality of the brazing process of the internal fins. The condenser as part of the air conditioning system must be tested with the appropriate pressure to check its tightness. In case of incorrect brazing, the pressure test causes the tube to deform.

It may still be tight, but such deformation should cause the condenser to be rejected as defective. Most often, a maximum of a single unsoldered fin is acceptable.

Vision inspection station

One condenser contains many tubes and fins to check. The vision system of such a station is movable, equipped with 5 to 7 cameras depending on the size of the condenser. Provides automatic assessment of the entire component for tube distortion with an accuracy of 0.05mm. Several passes are made and from 1000 to 2000 photos. The software allows to locate defects by specifying the camera number and X,Y coordinates. The measurement result is given in % of the nominal height of the tube, i.e. a result close to 100% will be an OK result, while for example 224% will mean a significant deformation. The machine is intended for use in series production. It is equipped with a reader, printer and a system for sticking labels after the test. The station can be adapted to handle various condenser references. The operator performs loading and unloading of the condenser.

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