Mechanical Assembly Calibration

ModnyCo developed a specialized Windows form application in C# to address alignment challenges during production, in a client’s complex mechanical assembly. The application utilized image processing to detect and guide adjustments for misalignments in sub-assemblies, streamlining the calibration process. This innovative solution simplified the adjustment process for operators, ensuring precision post-tightening verification and significantly reducing manufacturing costs by diminishing the reliance on manual, engineer-led calibration.

Addressed a client's complex mechanical assembly issue, involving misalignments in sub-assemblies causing measurement errors.
Developed a Windows form application in C# for use in the manufacturing process.
Implemented image processing using the assembly's camera to detect alignment tolerances.
Provided simple arrow guides in the application to direct operators for precise component adjustments.
Included a verification step post-tightening to check for any new misalignments.
The application simplified the calibration process, making it accessible to operators without specialized engineering skills.
Significantly reduced manufacturing costs by eliminating the need for experienced engineers to manually adjust components.

In one of our projects at ModnyCo, we faced a unique challenge presented by a client. Their complex mechanical assembly, consisting of multiple sub-assemblies, was experiencing alignment issues during the manufacturing process. These misalignments in millimetres, were significant enough to cause unexpected errors in the measurement process of the final assembly.
To tackle this problem, we developed a specialized Windows form application written in C#. The application was designed to be an integral part of the manufacturing process, streamlining the calibration of the assembly units. Its main function was to utilize the camera already present in the assembly for precise image processing. This process involved detecting tolerances within the assembly unit and its sensitive components, a task that required high accuracy given the fine margins of error.

The application was not just a diagnostic tool but also a guide for the assembly operators. Using simple arrow guides displayed on the interface, it directed the operators to make minor adjustments to various components, nudging them into the desired alignment range. This interactive guidance was crucial in simplifying the calibration process, making it more accessible to operators without specialized engineering knowledge.
Once the initial adjustments were made, the application instructed the operators to secure the components firmly in place. Post-tightening, it ran another set of tests to confirm that the process of tightening the components hadn't inadvertently caused any new misalignments. This two-step verification ensured that the final assembly maintained the highest standards of accuracy and quality.

The implementation of this assisted calibration application had a profound impact on the manufacturing process. It not only simplified the complex task of aligning multiple components but also significantly reduced manufacturing costs. Previously, the client had relied on experienced engineers to manually perform these adjustments – a time-consuming and costly endeavour. Our solution democratized the process, allowing operators with varying levels of expertise to achieve the same high level of precision.

This project exemplified ModnyCo's ability to provide innovative, cost-effective solutions to complex engineering challenges. By combining software development with an understanding of mechanical assembly processes, we were able to deliver a tool that not only enhanced the efficiency of the manufacturing process but also maintained the high-quality standards required by the client.

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