Automated Removal of Burr Problems Caused by Copper Bushing Wear and Integration of AI-Based Final Inspection System in Sprocket Parts Produced by Die-Casting Machines

Abstract

This study was conducted to eliminate critical quality defects and improve process reliability in high-pressure die-cast drum star components with an annual production volume of 600,000 units. Wear of the copper bushing used to center the steel shaft leads to aluminum leakage during the casting process, resulting in burr formation on critical surfaces that are not permitted by customer specifications. In the existing system, defects are detected through manual visual inspection, and the high production volume increases the likelihood of human errors caused by operator fatigue and reduced attention. During the last three months, this issue resulted in six customer complaints, 184 returned parts, and the reinspection of 2,300 components, highlighting the significance of the problem. To address these challenges, a fully automated deburring machine was integrated into the production line, followed by a two-layer quality control system consisting of an artificial intelligence-based machine vision system for surface inspection and laser sensors for hole inspection. The implemented system enabled 100% automated defect detection, significantly reducing quality risks and enhancing process reliability and customer satisfaction.