Insight

For the last three years Dimac has been working on an investment campaign within its R&D department, which is aimed at enabling the company to introduce new hardware and software technologies for sorting machines that offer 100% control. 

Thanks to this campaign Dimac has been able to introduce a host of developments to its machinery that offer customers better solutions and services. For instance, Dimac has introduced the latest generation of microprocessor controllers to increase the computing power in its machines’ image processing. It has also adopted higher resolution digital cameras for increasingly sophisticated and accurate controls at very high production rates. By implementing measurement functions of complex geometries on images obtained by direct lighting and software algorithms, based on artificial intelligence, it was also possible to approach new types of defects and diversify what the business was able to offer. 

“Thanks to our R&D investments we have patented some innovative automation solutions for Statistical Process Control (SPC) on fasteners, making data and measurements available in SQL format for ‘real time’ exchange with the ERP systems of our customers,” explains Dimac Srl. “These developments materialised in the design of three new models of MCV6, SPC-EVO and SPC 360° glass rotary table machines – the first two of which were presented at the wire^® Düsseldorf show in June this year.”

The MCV6 is a large diameter glass rotary table that allows for the inspection of pieces at high-speed thanks to the reduced centrifugal force. The feeding system can be customised according to the geometry and orientation of the pieces. Optical inspection stations have also been developed for accurate dimensional inspections using part profile analysis and for surface flaw detection with configurable lighting technologies. 

The next generation hardware and software technology that equips the MCV6 includes algorithms for high-speed dimensional checks, AI for surface inspection and NDT controls for special parts and fasteners. This machine is also equipped with a special management of pseudo-rejects that can be automatically rechecked to optimise the efficiency of the sorting cycle.

The SPC-EVO semi-automatic SPC control and data collection optical system is suitable for parts with flat geometry such as washers, retaining rings, spacers, chain plates and products from fine blanking. The machine is suitable for the SPC measurement of a batch of parts taken from any production machine and for batches of samples for PPAP. The system also features the new Dimac SPCx software developed to measure any geometric feature visible in the image by part profile or by direct lightening – with an accuracy of up to ±5μm.

Parts for SPC control are filled by the operator into a blister, off the machine. The blister is then inserted in the SPC-EVO and the inspection plan is activated by a barcode reader. When the CYCLE START button is pressed, the SPC-EVO loads every single part from the blister and measures it automatically. Measured data and statistical calculations are also available in ‘real time’, in a suitable format for a company’s ERP quality management system. 

Dimac has been able to develop these machines even within the challenging environment currently in the market, such as the shortage of electronic components and related price increases. “The delays and uncertainties relating to the delivery of components and electronic boards have forced us to carry out intense market research to find compatible and reliable alternative components to replace the missing ones,” explains Dimac. “We had to reconfigure the machines and related projects to make them flexible in the adoption of alternative components. This process also involved the development of more parameterisable software, without changing the main functions of our user interface – namely the extreme ease of use oriented to operators in the world of fasteners.”

Dimac invests in its production site

Dimac has not only been investing in its R&D capabilities, but has also been building a new production site, which will sit alongside its exisisting site and will be inaugrated by the end of 2022. “The new site will effectively optimise the space available for the design and development of our wide range of inspection machinery and equipment,” points out Dimac. “The site will also include new offices and a new showroom – where we can test and demonstrate the capabilities of our machinery.”

To add to the investment within its production, Dimac has also looked to expand its sales network – opening new agencies in South America and eastern Europe.