Loose snap fits, help me detect.

[nfl2k2]

The problem: cracked or bent tabs upon installation of a Lexan 141 lens in to an ABS piece that causes rattles or vibrations for the customer. Need to be able to detect this condition and contain the part. Defect: Lens: ABS Piece: My first thought was mount a camera above the workstation and direct light in to the lens. Then use a camera to detect if the legs are bent. Below is an example. While the image is clear and the contrast is good, I doubt detection in this manner would last long due to part variance and slight changes in operator part placement. Anyone have another detection method I can try?

[JRoss]

3d smart camera? SICK makes one that I've used, and now Cognex is starting to come out with them. They're more expensive, but there's no special lighting so it isn't too bad, especially on applications where it makes the programming much easier. One caution is that you have to move the part through the camera's field of view, preferably on a conveyor with an encoder for consistent images.