In order to protect PCBs from environmental influences such as humidity, they are coated with a protective clear varnish. This ensures error-free operation. The automotive industry in particular demands a minimum thickness for this protective coating. Up to now, it was not possible to perform a measurement without destroying the target. Confocal sensors from Micro-Epsilon solve this measurement task without making contact with the target and therefore in a non-destructive manner. They provide the thickness values in real time. confocalDT IFS 2405 confocal sensors with a measuring range of 1 mm are used. These sensors are characterized by their extremely small measuring spot size of only 8 µm and excellent precision for measuring thin layers.

Controller with integrated light source for measuring rates up to 25kHz

Confocal chromatic sensors for displacement, distance, position, thickness

In addition to high accuracy with miniature dimensions, the production of electronic components also requires high speed processes that provide the highest quality. Therefore, many production steps in this area are highly automated. The company Automationpro has developed a machine that inspects the height of pressed-in contact pins on PCBs (Press Fit Technology) inline immediately after the pressing process. If the pins are not completely pressed through the openings, it is not possible to establish contact with other components, which may cause failure. Therefore, a scanCONTROL profile sensor scans each PCB in three dimensions. During this pressing process, the PCBs are fixed on a rotary table which moves the assembled module from the press-in position to the scanning position. The scanCONTROL is being moved by an actuator connected to an encoder which is being used for triggering the line scanner to ensure regular profile distances. Depending on the cycle time of the process, the component undergoes a complete scan within 7 seconds, generating 1,280 points per profile.

After the assembly process of smartphone displays, it is important to inspect the mounting tolerances of the components in order to achieve continuous quality in all production batches. Confocal chromatic sensors travel over the components and inspect the gap with extremely high accuracy.

Confocal sensor systems for displacement, distance, position and thickness

In SMT and reflow soldering processes, the coplanarity of the pins has to be inspected in order to assure a perfect soldering quality and to avoid failures. For this purpose, laser profile sensors from Micro-Epsilon are used. The scanner uses a blue laser diode which enables extremely high resolutions.

Laser scanners for 2D/3D profile measurements

With printing and exposure processes, the exact height of the print head or the distance from the object to be printed are crucial factors for the quality of the final product. Fast distance measurements with compact laser sensors from Micro-Epsilon enables fast readjustment and, in addition, edge detection.

Smart laser triangulation displacement sensor

In assembly processes of smartphones and tablets, the dimensions and the assembly gap of the gasket are inspected in order to ensure high resistance to water and dust. Measurements are performed with Micro-Epsilon laser profile sensors that provide high resolution and profile frequency.

Laser scanners for 2D/3D profile measurements

Laser triangulation sensors are used in fully automatic presence inspection of components on printed circuit boards. Very small details can be detected reliably due to the small light spot. The high measuring rate enables testing in the shortest cycle times.

Most Advanced Laser Displacement Sensor

In order to keep the adhesive dispenser always at the correct working distance, this distance value must be inspected continuously. For this purpose, compact laser sensors from Micro-Epsilon are used. Thanks to the fast measuring rate and the insensitivity to changing surface types, they continuously provide information about the distance of the glue dispenser.

Smart laser triangulation displacement sensor

Particularly with automated mounting, components must be sorted according to their color. The colorSENSOR CFO is ideally suited for these high production speeds. Adjustable colors and tolerance enable high flexibility.

Compact True Color Sensor

Scribe lines are pressed into printed circuit boards for separation purposes. Laser sensors inspect the line depth which should be consistent in order to ensure reliable separation.

optoNCDT Laser Sensoren

During the fully automatic application of heat conducting pastes, the correct dosage is a decisive factor. An overdosage of heat conducting paste impairs the thermal resistance, too little paste leads to thermal overload. The height of the paste bead is therefore detected using a laser triangulation sensor.

optoNCDT Laser Sensoren

When soldering printed circuit boards in wave soldering systems, the height of the solder wave is an important criterion for the quality of the solder joints. The level of the soldering tin is detected directly above the solder wave using an eddyNCDT displacement sensor. The influence of the solder pot level and the pump contamination is thereby compensated for.

Inductive sensors (eddy current) for displacement, distance & position

Before a car emerges from a bodyshell, it passes through numerous stations within the production, in which fully automatic processing steps are carried out. In order to enables the processing robots to recognize the exact position of the car body, several laser triangulation sensors measure the car body and transmit the position data to the robot controller.

Smart laser triangulation displacement sensor

Fully or semi-automatic assembly of cockpit modules in the automotive industry requires the gripper tool to precisely position the assembly parts. As the laser scanners take over the measurement and positioning tasks, each cockpit module is individually adapted to the respective car body. Micro-Epsilon laser scanners are particularly suited for these measurement tasks due to their SMART functions and the particularly small and lightweight measuring head. They can be easily installed on a robot or manipulator. 

Using the SMART function, a parameterization of the sensors can be realized without further hardware components via Ethernet. In addition, measured values can be visualized and transmitted directly to the controller. The precise scanCONTROL laser profile sensor evaluates the complete profile internally and transmits the measurement values via Ethernet to the control system. This enables the actuators to change the axis positions on the gripper in order to assembly the cockpit module in the ideal position in the car body. After the cockpit is fixed, the sensor determines the installation position of the cockpit which serves as proof of quality for each vehicle.

Particularly with shiny surfaces, a faultless production chain is expected in order to lend a sophisticated visual appearance to the final product. For fully automatic defect detection on car bodies and attachments, the reflectCONTROL inspection system is used. The system projects a striped pattern onto the surface. Deviations caused by defect are recorded with two cameras and evaluated via software.

Fully automatic surface inspection of painted car bodies

As well as the visual requirements, instrumentation panels also have to fulfill functional and security requirements. Often the passenger airbag has a predetermined breaking line which is generated using a laser. This »weak point« ensures the safe opening of the airbag at the predetermined breaking line. Sink marks may appear, which can be recognized under certain light conditions. In order to recognize these defects, surfaceCONTROL inspection systems are used which enable fast and objective evaluations to be made of the characteristics of any shape deviations, both on grained and smooth surfaces.

Inspection of diffuse reflecting surfaces

Eddy current sensors from Micro-Epsilon are considered as proven measuring instruments in the test bench of combustion engines. In towing mode as well as in the firing mode, the sensors detect different quantities which contribute to the improvement of the engine characteristics. In particular, the high measuring accuracy provided under harsh conditions in the engine distinguishes the eddyNCDT eddy current sensors.

Inductive sensors (eddy current) for displacement, distance & position

During forming in the pressing plant, the presence detection and the detection of the exact sheet metal position are required. Therefore, laser triangulation sensors measure on the sheet between the dies. The challenge here is to achieve high measurement accuracy in tight spaces despite oil mist, vibrations and shocks. Since the measuring gap is very small, the diameter of the laser must be correspondingly low.

Smart laser triangulation displacement sensor

In aluminum die casting, liquid aluminum is poured into molds under high pressure and at high speeds. The high pressure acts on the closed mold and pushes it apart, which is why splinters and burrs might occur during casting. In order to measure the pressure-induced movement of the molds, eddy current sensors detect the change in distance. These robust sensors provide reliable measurement results despite high temperatures, ambient pressure and a dirty measuring gap.

Inductive sensors (eddy current) for displacement, distance & position

With the capaNCDT DTV, Micro-Epsilon has developed a product range that is specifically used for non-contact detection of the Disc Thickness Variation. Thickness measurements of brake discs can be carried out in test benches, in road tests or in car repair shops using non-contact, capacitive displacement sensors, which detect the thickness of the brake disc from both sides.

Measuring Disc Thickness Variation

The temperature behavior of brakes plays a major role in vehicle development. In particular, the duration of heating and cooling of the brake discs provides information about the efficiency of the brake system. In test bench and road tests, non-contact temperature sensors from Micro-Epsilon measure the temperature development during braking. The compact design and the short response time of the pyrometers enable universal use in test bench and road test applications.

Infrared pyrometers for universal measurements/span>

In modern production lines, scanCONTROL laser scanners are used to reliably inspect the gap sizes of the car body quickly and consistently. Thanks to surface compensation, measurements are possible on a wide variety of body paintworks.

Laser scanners for 2D/3D profile measurements

Color and intensity of vehicle lights must be reliably inspected prior to assembly and delivery. Homogenous distribution of light should also be ensured with fluctuating LED batches. The colorCONTROL MFA is a special LED test system designed to test inaccessible and widely spaced test specimens. Optical fibers enable simultaneous measurement of up to 20 measuring points.

Sensor systems for LED color and intensity tests

Before installing front aprons, Micro-Epsilon color sensors check if the color of the attachment matches the body color. Different color groups can be defined to cover all coatings.

Compact True Color Sensor

In embossing machines, car body IDs are punched into the vehicle frame. The embossment depth must be in a defined tolerance range. In order to position the embossing tool, laser triangulation sensors from Micro-Epsilon detect the distance between the embossing tool and the component. After the embossment is finished, the sensor measures the profile of the embossment and ensures that all characters are embossed to the required depth.

Smart laser triangulation displacement sensor

In order to avoid corrosion, continuous and error-free corrosion protection is a critical factor in the painting process. As the thickness of the applied painting on burrs can only be determined under challenging limitations, it is a decisive advantage when the burrs are recognized early in the production process before the corrosion protection and other paint layers are applied. In contrast to fixed solutions that enable a random test, Micro-Epsilon offers its scanCONTROL 2910-10/BL Plug & Play system which provides the required precision with its high point resolution of approx. 8µm along the laser line in order to recognize burrs reliably even during inline measurements.

Laser scanners for 2D/3D profile measurements

When processing car brake discs, the correct brake disc must be chosen before each stage of production in order to assign them to the manufacturer's different models. Laser scanners are used to recognize and classify the brake discs. The challenge of brake disc distinction is that the test objects are the same with regard to form, height and diameter. The gapCONTROL laser scanners are used for 100 % recognition and subsequent sorting. The only distinctive feature is a gap between two ventilation blades that signifies the respective models of the manufacturer.

The MultiAir cylinder procedure patented by FIAT / Schaeffler controls individual valves independently of the camshaft. An electro-hydraulic control system provides fully variable valve control. Therefore, the stroke and the opening/closing times of the inlet valve are freely controllable. This reduces fuel consumption and CO2 emissions with a simultaneous increase in engine performance and torque. During the end-of-line inspection of the MultiAir components, a test bench simulates the conditions inside the engine. Eddy current sensors from Micro-Epsilon measure the exact valve lift.

Inductive sensors (eddy current) for displacement, distance & position

Car attachments such as parking sensors are painted separately. However, during assembly there must be no difference in color between the parking sensor and the bumper, which means the two colors must be identical. The colorSENSOR from Micro-Epsilon enables a direct color comparison between the parking sensor and the rear bumper.

Compact True Color Sensor

In the assembly line of a well-known German car manufacturer, similar car interior parts must be differentiated from each other based on the respective seam color. Previously, professional testers have visually checked the seams. In order to automate the process and to optimize it economically, colorSENSORs from Micro-Epsilon are now being used.

Compact True Color Sensor

In the automotive industry, testing the chassis is a prerequisite for driving safety. Here, sensors are required which can also withstand the high demands of road tests. For example, draw-wire sensors are mounted in parallel to the shock absorbers for the vibration displacement measurement and the data is recorded under varying road-surface properties. The displacement signal obtained is differentiated to calculate the vibration velocity and vibration acceleration.

WDS-MPM

Before a car emerges from a bodyshell, it passes through numerous stations within the production, in which fully automatic processing steps are carried out. In order to enables the processing robots to recognize the exact position of the car body, several laser triangulation sensors measure the car body and transmit the position data to the robot controller.

Smart laser triangulation displacement sensor

To ensure a homogeneous adhesive surface, capacitive displacement sensors measure the thickness of the adhesive on adhesive tapes and medical plasters. Capacitive sensors allow one-sided thickness measurement. Depending on the system structure, conductive or non-conductive adhesives can be measured.

Capacitive displacement sensors and measurement systems

Capacitive displacement sensors are used for the exact thickness measurement of wafers. Two opposing sensors detect the thickness and also determine other parameters such as deflection or sawing marks. The position of the wafer in the measuring gap may vary.

Capacitive displacement sensors and measurement systems

In assembly processes, incoming components are inspected using Micro-Epsilon fiber optic sensors. Recognizing missing SMT components enables a smooth assembly process. Their flexible design allows for the optoCONTROL CLSK probe heads to be integrated in confined spaces.

Fiber optic sensors for gap, diameter, edge and presence

Rubber mats for the structure sealing must exhibit a specified thickness for durability and tear resistance. The thickness of the films is measured directly after the extrusion. The optoNCDT 1750 sensors used measure the distance to the rubber despite poor reflectivity. The thickness is determined from the sensor signal and the distance to a reference roller. The user thus recognizes already starting deviations from the target thickness.

Universal laser sensor for industry & automation

In fully automated sawmills, the position of wooden boards before sawing must be determined so that they can be cut precisely. Micro-Epsilon laser displacement sensors detect the position of the boards from two sides and output the board position to the controller.

Smart laser triangulation displacement sensor

When printing woods with decors, optoCONTROL micrometers are used to control the positions of the plate. This prevents the printing head from colliding with the plate. These laser micrometers measure directly on wood and monitor the tools.

High resolution optical micrometer

Laser scanners from Micro-Epsilon are used to inspect wood reliefs. They check the groove depth and provide reliable measurement results regardless of the type of wood.

Laser scanners for 2D/3D profile measurements

Laser scanners from Micro-Epsilon are used for the profile measurement of parquet boards and baseboards. They inspect geometric characteristics such as groove height, gap dimensions and absolute dimensions to ensure homogeneous product quality.

Laser scanners for 2D/3D profile measurements

In order to ensure consistent color of different front panels, color sensors from Micro-Epsilon are used. The sensors inspect the color of the kitchen fronts in the painting plant. Color sensors ensure that the color shade is within the specified tolerances. Even the smallest color deviations imperceptible to the human eye can be detected reliably.

Compact True Color Sensor

For thickness and width measurement of plates, planks and beams, two optoNCDT laser sensors are used. If this arrangement is complemented by further sensors, one synchronized measurement process can combine the inspection of torsion with control of dimensions.

Smart laser triangulation displacement sensor

Before installing front aprons, Micro-Epsilon color sensors check if the color of the attachment matches the body color. Different color groups can be defined to cover all coatings.

Compact True Color Sensor

Plastic floorboards are made of colored granules and shaped by deep-drawing. After the production process, it must be guaranteed that the color of the floorboards is homogenous and that there are no color differences.

High Speed Photospectrometer colorCONTROL ACS7000

Company „Schüco“ manufactures PVC window frames. The PVC profiles are provided with a protective film after they are extruded. This film protects the frames from scratches and dirt. The colorCONTROL ACS7000 color measurement system checks if the protective film has been applied correctly.

High Speed Photospectrometer colorCONTROL ACS7000

Industrial robots have become indispensable in modern production facilities due to their reliability and high speed. During set up and also at regular intervals within the scope of quality assurance, the robot axes must be adjusted. Here, electronic adjustment probes have already replaced mechanical probes. The measurement probes mounted on the robot axes acquire the zero point during the axis rotation using a probe tip. The integral electronics evaluates the probe signal and transmits a switching signal to the robot controller.

induSENSOR LVDT gages DTA series

Inductive sensors (LVDT) and gauges

In aircraft construction, several hundred thousand rivets are usually used. Fully automatic machines are precisely fitting rivet holes and rivets. An optical inspection system from Micro-Epsilon inspects the inside diameter of the rivet holes without contact.

Before an airplane can start, the temperature in the brakes must be below a certain limit. To determine the temperature, non-contact temperature sensors from Micro-Epsilon are used in the landing gear.

Infrared pyrometers for universal measurements

Before an aircraft starts, the doors are locked centrally. In order to determine the status of the locking, inductive displacement sensors from Micro-Epsilon are used. These detect the end position directly on the door lock.

Inductive sensors (eddy current) for displacement, distance & position

The so-called Wing Tip Brake sits on the shaft in the outer wing area. It avoids uneven extension of slats and flaps and uncontrolled movements of the buoyancy aids by external influences. Inductive displacement sensors from Micro-Epsilon detect the position of the brake shoes.

Inductive sensors (eddy current) for displacement, distance & position

In order to optimize the behavior of wings during a flight, the wings are already subjected to vibration tests during the construction. 120 wireSENSOR draw-wire sensors are connected to the wing and synchronized. In this way, any change of the wing form in the vertical direction can be tracked.

Draw-wire displacement sensors