Unscheduled downtime of bearings may induce high costs. Early recognition of bearing damage allows for maintenance labor to be performed during scheduled standstills while minimizing costs. Acceleration sensors from Micro-Epsilon are used for early recognition of bearing damage due to their good signal-to-noise ratio. Measuring both static and dynamic accelerations, they are therefore ideally suited to oscillation measurement of bearings with a very low roller speed (≤ 0.2 Hz). Due to high resolution and temperature stability, the sensors are used in measurement tasks for the oil and gas industry, petrochemicals, power generation plants, mining, steel and cement industries and paper manufacturing.

Inrotech A/S in Denmark relies on sensors from Micro-Epsilon to achieve optimal quality of weld seams in a fully automatic process. The company has developed a welding robot called »Inrotech-Crawler« which calculates welding processes in advance before carrying them out. Therefore, the robot uses the precise measurement values provided by the powerful laser profile scanner from Micro-Epsilon.

A scanCONTROL 2900 scanner is fixed on the Inrotech-Crawler and detects the geometry of the seam to be welded before the actual welding process starts. Only these high precision profile measurements enable the process to be automated. Due to its compact, lightweight design with integrated controller, the laser profile scanner is ideally suited to this measurement task.

Various connection possibilities offered by the SDK (Software Development Kit) enable the customer to directly transmit the profile data calibrated to their own software via scanCONTROL DLL. The Weldlogic technology from Inrotech then calculates, among other things, the number of welding passes, the position of the weld seams, the weld speed and the oscillation width. Directly after the calculation, the Crawler automatically performs the welding process.

Compact laser scanner for high precision

The layer thickness of the adhesive bond is typically only a few tenths of a millimeter. The sample is now loaded by tension (axial displacement) and/or torsion. Measuring these very small displacements requires a very accurate and stable measuring system. The test set-up therefore includes three MicroEpsilon capacitive sensors, which are connected via a capaNCDT 6500 capacitive controller with DL6530 demodulator module. Using a special holder, the sensors are attached directly to the tube joining parts of the double tube sample. Two flat sensors with 2 mm measuring range measure the displacement in the axial direction and a cylindrical sensor measures the displacement by torsion. Due to the non-contact measuring technique used, it is easy to decouple axial displacement components and the torsion-induced displacement.

If the position of the material web is not recognized or is recognized incorrectly, this can result in waste from faulty cutting and machine malfunctions due to missing controller signals. Therefore, the optoCONTROL CLS-K-31 fiber optic sensor from Micro-Epsilon is used for position detection.

The sensor reliably detects the beginning of the roll. It is mounted directly on one of the cutting blades and recognizes from a distance of around 140 mm when the fabric is in the cutting position. A switching output (PNP) transmits a signal level directly to the controller and the cutting process begins. In this way, the cutting elements can be positioned exactly to 0.5 to 2 mm depending on the material. After each cut, the fabric position is recalculated. The measuring process is carried out at feed speeds of 20 m/min.

The optoCONTROL CLS-K-31 measuring system from Micro-Epsilon provides highly reliable and reproducible measurement results, which ultimately optimizes cutting accuracy, while reducing waste and process disruptions. The CLS-K-31 is even virtually insensitive to scratches and contamination on the shiny metallic surface of the roller.

Fiber optic sensors for gap, diameter, edge and presence

So far, gap measurements inside the pumps were not possible because of the extreme requirements. The sensors must be resistant to high speeds, high pressures up to 1,000 bar and temperatures above 100 °C. Furthermore, the pumps are extremely compact, which significantly limits the space available for integration of sensors. Thanks to the extremely small sensor designs and their high pressure and temperature stability, the eddyNCDT inductive miniature sensors are ideal for this application. The eddyNCDT 3300 eddy current measuring system, which is one of the most powerful systems in the world, is therefore used on the test rig for evaluating the pumps.

eddyNCDT 3300

The tailstock is an important part of a lathe or milling machine. The tailstock is used to support long workpieces by means of a center, which catches in the center hole on the front side of the workpiece. In order to detect the center tip, compact draw-wire sensors from Micro-Epsilon are used. The measuring wire is connected to the center tip and measures the displacement of the tailstock.

Draw-wire displacement sensors

Modern machine tools have complex magazines with various tools that are automatically picked up by the machine. In order for these tools to be accurately picked up, the tool holders must be precisely positioned. To check the position of the tool holders, optoNCDT 1420 laser sensors are used, which measure the metallic holders from above and from the side. These smart laser sensors stand out due to their high measuring rates while providing precise measurement values, despite strongly reflecting, metallic surfaces.

Smart laser triangulation displacement sensor

To illuminate individual components on the wafer, the lithographic devices move the wafer to the respective position. Capacitive displacement sensors measure the position of the travel path in order to enable nanometer-accurate positioning.

Capacitive displacement sensors and measurement systems

The SGS 4701 displacement measuring system (Spindle Growth System) is developed specifically for high speed milling machine applications. Due to high machining speeds and the heat generated, the linear thermal expansion of the spindle in the precision machine tool must to be compensated for in order to keep the tool in a defined position at all times.

The SGS sensor measures the thermal and centrifugal force expansion of the spindle. These measurement values are fed into the CNC machine tool as correction values, compensating for any positioning errors. The SGS 4701 operates on the eddy current measuring principle. This non-contact measurement method is wear-free. Furthermore, the measurement procedure is resistant to disturbances such as heat, dust and oil.

eddyNCDT SGS4701

Often, initiators and switching rings, which provide a switching signal, are used to monitor the clamping position in high-performance tool machines. However, these require complex adjustment and set up. Analog sensors from the Micro-Epsilon LVP series offer significant improvements. The cylindrical sensor is integrated into the release device and directly measures the clamping stroke of the drawbar. On the drawbar, a ring is fastened, which acts as the target for the sensor. The LVP sensor can be universally used with the most varied types of tool due to an extremely compact sensor design. The sensor supplies an analog signal according to the stroke motion of the drawbar when clamping the tool. Consequently, continuous monitoring is possible without the switching point having to be laboriously set mechanically. The miniaturized sensor electronic unit can either be accommodated at the point of measurement or in the control cabinet. Thanks to its high accuracy, the LVP sensor contributes significantly to meeting the ever increasing demands on machine tool precision and availability.

Inductive sensors for specific applications

Due to high machining speeds and the heat generated, the linear thermal expansion in milling spindles needs to be compensated for in order to keep the tool in a defined position at all times. The SGS sensor developed by Micro-Epsilon measures the thermal and centrifugal force expansion of the spindle. As well as measuring linear thermal expansion, the temperature of the sensor is also detected and output.

eddyNCDT SGS4701

In this application, the MDS sensor recognizes foreign bodies in blister machines during the tablet packaging process. Via the movement of overhead touching rollers, foreign bodies between the blister packaging and covering material can be detected. Exceeding a pre-defined point triggers an alarm.

Magneto-inductive distance sensors

During the filling of drinks cartons, the exact dosage is a critical factor. The sensor measures the valve lift of the filling line and requests several switching points in a measuring range of 35mm. The sealed stainless steel housings of the MDS-45-Mxx series are ideal for the food industry.

Magneto-inductive distance sensors

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

Hydrostatic bearings are used in large plant and machinery such as stone mills, telescopic installations etc. Monitoring the gap size is a critical factor, as any disturbances in the hydraulics can cause pressure drops, which in extreme cases, can cause the gap to close, resulting in damage to the bearings and ultimately system failure. Here, it is important to have a system that is easy to install as also ageing plants have to be retrofitted. Due to the long service life and the worldwide use of this plant, the sensor should be easy to replace. For this reason, non-contact eddy current displacement sensors of the eddyNCDT 3001 series are used.

eddyNCDT 3001

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

If movement of the paper web in the calender is not exactly executed in one line, the heated calender roller is pressed directly onto the coating of the opposite roller, which can damage it. Repairing this special coating or even replacing the whole roller would be very costly, which is why it is mandatory to control the position of the web edge. This is where laser line sensors from Micro-Epsilon are utilized, transferring the exact position of the web edge directly to the machine control system.

Laser scanners for 2D/3D profile measurements

Users of injection molding machines for plastics processing are facing increased quality requirements imposed by end-users, in particular for automotive applications. Because of this trend, the importance of inline temperature control right after extrusion as a global quality attribute is growing.

Thermal imaging cameras for industrial temperature monitoring

Harsh industrial environments place high demands on optical displacement sensors – precise measurements must still be possible despite dust and high processing speeds. The optoNCDT 1750 and optoNCDT 2300 series of laser sensors have overcome these challenges for many years. However, if motion disturbances (e.g. belt movements, radial movements of pulleys, and base body vibrations) occur that are greater than the object being measured, the measurement process may be impeded or made impossible, for example folds in a belt.

Universal laser sensor for industry & automation

Most Advanced Laser Displacement Sensor

In aluminum casting plants or foundries, the cast is poured into shape to form small bars, known as pig irons. The charging level in the forming process is critical in ensuring consistent weight of the pigs. Using a special non-contact measuring device, the depth of fill is recorded. For these applications, an Austrian system builder uses laser scanners.

Laser scanners for 2D/3D profile measurements

During the manufacture of veneer strips from laminated wood, the precision of the cutting disk determines the quality of the final product. High demands are placed on the veneer strips in terms of dimensional conformance. The thickness of the strips must be less than 1 mm and may only have tolerances in the micrometer range. In order to comply with the quality criteria, the radial deviation of the cutting disk is measured and monitored during the production process using a non-contact optoNCDT 2300 laser triangulation sensor. This means that high demands are placed on the measuring system: Dust, chippings and a shiny target surface must not affect the measurement accuracy. The cutting disk has a diameter of 3200 mm and is equipped with 24 knives. The rotation speed is 180 to 210 rpm.

optoNCDT Laser Sensoren

The introduction of the international standard ISO 9283 demands new non-contacting measurement methods. The measurement system for the position measurement is composed of a measurement cube with a defined weight, a sensor and a support. The sensor is equipped with six U15 eddy current sensors. During the measurement the robot moves the measurement cube into the sensor range. The data from the eddy current sensors is passed via a fast interface to the PC where it is processed. Measurement inaccuracies due to linearity and tilting errors (parallelism between the sensor and measurement object) and thermal effects are additionally compensated in the measurement software.

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

Rotary crushers for quarries or ore mines can grind up to 3500 t of material to the desired grain size in one hour. For this purpose an eccentric bearing bush generates a rotary-oscillating movement of the crusher axle, thereby constantly changing the gap between the crusher jaws and the crushing cone. For grinding the set gap continuously moves along the inside perimeter of the crushing room. With a longdistance sensor in the hydraulic cylinder the crushing gap can be exactly adjusted by raising and lowering the axle.

induSENSOR EDS

Inductive sensors (LVDT) and gauges

For the prompt detection of incorrect thickness of aluminum strips, optoNCDT laser triangulation sensors are used as modern alternative solution to isotopic measuring systems. At the measurement location, the sensors are mounted opposite to each other, above and below the conveyed aluminum strip. Regardless of the exact height position of the strip, the sensors provide the exact material thickness based on a simple distance signal coupling, F=Ref. - (A + B).

optoNCDT Laser Sensoren

Measuring and inspection systems for the metal processing industry

The requirements on the surface quality of rolled sheet metal are continually increasing. This may be steel sheet which is used, for example, for stainless steel fronts in kitchens, or also aluminum sheet used in the automotive field. The surface must be flawless to offer the customer a high quality visual appearance. Consequently, measurement equipment is employed in rolling mills to acquire the so-called flatness of the rolled sheet metal. Flatness is taken to mean the surface evenness of the sheet in the unstressed state.

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

A consistent yarn thickness is a prerequisite in the textile industry for high quality products. Therefore, the naturally occurring yarn thickness fluctuations must be eliminated. The yarn is drawn to a constant thickness using a stretching tool. The measured data for controlling the stretching tool are provided by an eddy current sensor which indirectly measures the thickness. The thickness is transmitted to the eddy current sensor using sensing rollers. After the stretching, the result of the processing operation is also checked by an eddy current sensor.

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

Laser scanners from Micro-Epsilon are used for high speed and fully automatic inspection of empty containers at bottlers and breweries. For this application, the Micro-Epsilon agent Tipteh has designed a test system based on laser line triangulation, which is used when the bottle crates are received. This inline system is equipped with five scanCONTROL 2900-50 laser line triangulation sensors from Micro-Epsilon. The crates are conveyed on a belt and scanned from above. Each scanner measures a row of bottles in the crates. Presence monitoring is carried out at conveyor speeds of up to 850 mm/s. The scanner uses the respective bottle height to determine whether the correct type of bottle is in the crate. The bottle height must not deviate more than 3 mm from the target height of the respective bottle type. Compared with a solution based on conventional image processing systems, laser scanners from Micro-Epsilon not only monitor bottle presence but also bottle height. In addition, logged data for subsequent statistics, evaluations and process optimization can be acquired.

Laser scanners for 2D/3D profile measurements

Before the printing process, a reference mark is embossed into the bottles. Due to the depression of the embossment, the color of the reference mark deviates slightly from the rest of the bottle surface. The colorSENSOR CFO100 detects this minimal color difference, which enables the exact determination of the printing position below the embossment. For a flawless print, accurate and reproducible positioning is crucial. If the marking is missing, the bottle is considered as faulty and will be rejected immediately. Therefore at the same time, a good / bad evaluation can be carried out as part of a quality control. A machine turns the cosmetics bottle while the colorSENSOR CFO100 constantly measures the surface of the bottle at a distance of less than 10 mm. The embossment is detected quickly and reliably. Next, the exact position for the bottle printing is determined and further process steps can be carried out. The colorSENSOR shows clear advantages over other measuring methods. First, it masters the semi-transparent surface easily. Second, it is ideally suited to this kind of position measurement task due to its favorable price/performance ratio.

Compact True Color Sensor

In order to meet production tolerances, the contour of optical lenses such as eyeglass lenses or objectives, confocal chromatic sensors are used. Based on the distance values, statements about the surface properties can also be made. The sensors enable a large tilt angle which means they can also detect highly curved surfaces.

Confocal sensor systems for displacement, distance, position and thickness

In order to meet production tolerances, the center thickness of optical lenses such as eyeglass lenses or objectives is measured using confocal chromatic sensors. The measurement is performed from one side and can also be carried out with very thin lenses.

Confocal sensor systems for displacement, distance, position and thickness

With the wall thickness and roundness measurements in star wheel inspection machines, a fast measuring rate is required in order to support the ongoing process. Micro-Epsilon’s confocal chromatic measuring systems provide a high measuring rate and fast exposure time control. This also enables the measurement of thickness when the glass colors vary.

Confocal sensor systems for displacement, distance, position and thickness

After the tin bath, flat glass has a temperature of approx. 600 °C. At the transition to the cooling zone and in the other subsequent cooling zones, thermoIMAGER infrared cameras are used for temperature inspection. Infrared cameras enable non-contact temperature monitoring of the cooling process from a safe distance to the glass. Thanks to the TIM Connect Software, the thermoIMAGER cameras can also be used as line scan cameras. The software enables the user to choose any line from the detector array and to position it.

Thermal imaging cameras for industrial temperature monitoring

For quality control and process control during the production of safety glass, confocal chromatic displacement sensors with a multi-peak function are used. Confocal chromatic sensors from Micro-Epsilon enable thickness measurements to micron accuracy. confocalDT sensors detect up to 5 layers by evaluating 6 measurement values on the boundary areas.

Confocal sensor systems for displacement, distance, position and thickness

With the roundness measurement of container glass, a fast measuring rate is required in order to support the ongoing process. Confocal chromatic sensors from Micro-Epsilon are used for thickness measurements in the star wheel while providing high measuring rates and accuracy in order to ensure reliable operation.

Confocal sensor systems for displacement, distance, position and thickness

For 24-hour operation in the glass production involving more than 5 million measuring cycles pear year, Micro-Epsilon has developed an inductive EDS displacement sensor. This sensor determines the exact plunger position in IS machines and allows for the production to be carried out according to predefined specifications. In order to increase resistance to lubricants and shock loads, the entire sensor and electronics are now welded into a tight stainless steel housing.

induSENSOR EDS

The color is the crucial and visually distinctive feature of glass products. This is particularly true with natural and recycled raw materials based on varying compositions, where continuous and objective control of the color effect is an essential prerequisite for consistent quality. The ACS3 transmission sensor from Micro-Epsilon is used to inspect the glass colors and shades continuously.

High Speed Photospectrometer colorCONTROL ACS7000

For the production of display glass, glass sheets with consistent thickness are required. The production process is regulated based on the measured results. Confocal chromatic sensors from Micro-Epsilon are used to detect the thickness from one side. Due to their high measuring rate, the sensors are also applied in high speed processes. When the sensors operate in a traversing manner or in several tracks, the planarity of complete sheets can be documented.

Confocal sensor systems for displacement, distance, position and thickness

Glasses are often reinforced with safety and security films which provide increased splinter protection. In order to measure the film layer and to determine the thickness of the applied adhesive, confocal chromatic sensors from Micro-Epsilon are used. These measure the thickness of the finest of layers from one side. With one measurement, the thickness of the glass, film and the applied adhesive can be determined.

Confocal sensor systems for displacement, distance, position and thickness

Fully-automatic defect detection on shiny surfaces is based on deflectometry systems. Extremely small inclusions or defects are detected reliably.

Automated inspection of shiny surfaces

In many handling processes, precise positioning of glass sheets is required. The position of the sheets is determined via the detection of the glass edges. Laser profile sensors from Micro-Epsilon measure the edge position at several points and transmit this information to the control system.

Laser scanners for 2D/3D profile measurements

When printing on materials such as glass and ceramics, very fine detailed structures are applied on the carrier material, which requires precise positioning of the print head. For distance measurements, optoNCDT 1420 laser triangulation sensors from Micro-Epsilon are used. With a measuring range of 10mm, these determine at various points in the print head the respective distance from the surface to be printed. The data obtained enables the determination of the edges and the surface tilt and therefore the exact positioning of the print head.

Smart laser triangulation displacement sensor

In container glass production, the process relevant temperature must be inspected at different points. Non-contact temperature sensors are used during the shaping process that involves temperatures in excess of 500 °C. As the shaping process lasts for just a few seconds, the sensor response time is critical. During both the forming process of the parison and the final shaping process, the heat treatment of the glass can be influenced either by directly measuring the glass surface or by indirectly measuring the surface of the forming tool. At the end of the production process, the glass is tempered again to reduce the stress in the container. Therefore, the glass is heated again and then cooled for a period of up to 30 minutes in a cooling tunnel. When the containers leave the heating zone, the cooling process is monitored using non-contact temperature sensors.

Infrared pyrometer with laser sighting for the glass industry

With the wall thickness and roundness measurements in star wheel inspection machines, a fast measuring rate is required in order to support the ongoing process. Micro-Epsilon’s confocal chromatic measuring systems provide a high measuring rate and fast exposure time control. This also enables the measurement of thickness when the glass colors vary.

Confocal sensor systems for displacement, distance, position and thickness

Anti-reflective coated glass is inspected during the coating process using laser-optical displacement sensors from Micro-Epsilon in order to determine undulations and torsion. The planarity of the coated glass surface is measured in several tracks. Based on the patented Blue Laser Technology, optoNCDT 2300-2DR sensors provide high measurement accuracies on coated glass surfaces.

Blue Laser triangulation sensors for difficult surface types

Test, inspection and certification authorities offer mobile oscillation measuring systems for wind turbines without permanently installed Condition Monitoring Systems. They are used for prototype plants in the development phase, for production and construction supervision, as well as for measurements during operation. In mobile vibration measurement systems, high-precision and temperature-stable acceleration sensors from Micro-Epsilon are used. The acceleration sensors provide precise information about vibrations that can occur, for example, at the rotor, tower or generator.

Wind turbines generate environmentally friendly power, but are often rather unpopular with their residents in the neighborhood, as they also generate noise. One of the noise sources in wind turbines is the drive train. In particular, gears and generators create noise. In order to minimize this noise, different measures can be taken. To measure these oscillations and evaluate the effectiveness of noise reduction measures, acceleration sensors from Micro-Epsilon are used.

Oscillation of the drive train (rotor imbalance, overloading) exceeding the limit values may lead to a failure of components and plant parts. Prerequisite for early recognition of damage and for predictive maintenance is the safe and accurate oscillation measurement of the rotor bearing, gearbox (rolling bearings, gear wheels) and generator. To measure these oscillations, high-precision and temperature-stable acceleration sensors from Micro-Epsilon are used.

To date, bearing gaps were measured during standstill based on a tactile principle. Therefore, long inspection intervals were required, which in turn, may increase the risk of a complete plant failure. Moreover, these deliberate stoppages intended for measuring and inspection purposes cause considerable additional costs. Micro-Epsilon acquires the measurement values during plant operation, thereby enabling reliable, cost-saving real-time analysis. This measurement task is performed with the inductive eddyNCDT 3005 measuring system based on eddy currents. It includes a sensor with a measuring range up to 6 mm, which is permanently connected to the controller via a 1 m long cable. As the system is oil-tight both on the front and rear side, it is ideally suited to this application even when typical oil pressures reach 1 to 2 bar in the bearing. The eddyNCDT 3005 inductive system is already being used in wind turbines to analyze and optimize the maintenance intervals of wind turbines. In addition, the data acquired in the test bench throughout the design period can be taken into account and used for dimensioning purposes of new components. The sensors can be used in the test bench and in high volume applications for Condition Monitoring. Serial use offers major advantages as the sensor technology can already be aligned and precisely adjusted during installation and initial operation.

Test rigs have been developed for load tests on wind turbine rotor blades and simulate the real loads caused by high winds and weather. The tip of the rotor blade can be distorted by up to 10m due to mechanical loads. Draw-wire sensors are used on the test rig for measuring the distortion. Two sensors per traction point measure the deflection and torsion of the rotor blade. The draw-wire sensors operate with measuring ranges between 3 m and 10 m. The digital signal output is provided for further simulations.

Draw-wire displacement sensors

In order to monitor rotor behavior in the generator, capacitive displacement sensors measure the gap between stator and rotor. Despite high temperatures and electromagnetic fields, capacitive sensors from Micro-Epsilon provide unmatched accuracies. In addition to continuous measurement for predictive maintenance, the measurement can also be used when setting the generator.

Capacitive displacement sensors and measurement systems

In order to control air supply, the air flaps automatically open and close depending on the temperature. Draw-wire displacement sensors monitor the position of the open air flap.

Draw-wire displacement sensors

Aligning solar panels in relation to the course of the sun increases the energy yield, and therefore the plant effectiveness. Inclination sensors ensure that the panels are always properly aligned.

Wind turbines are exposed to oscillations and shock loads. In order to avoid damage and expensive downtime, these tower oscillations are monitored. When exceeding limit values, the plant is reliably shut down. From load history, lifetime prediction can be deduced. Prerequisite is the reliable and accurate detection of loads. Inclination and acceleration sensors from Micro-Epsilon detect the tower oscillation to the highest precision. Even with strongly fluctuating temperatures, inclination and acceleration sensors provide reliable measurements due to their excellent temperature stability.

In order to monitor the supporting moments, eddy current displacement sensors measure the distance between the nacelle and the tower, which enables early recognition of any oscillations. Therefore, the plant can be switched off in time when the wind load is too high.

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

Laser triangulation sensors measure the distance from the foundation in order to detect the tower movements. High measuring rates enable to detect vibrations directly. Depending on the number of sensors installed, detailed evaluations about the vibration behavior can be determined. When the tower movement is too strong, the rotor blades are removed from the wind in order to avoid possible damage.

Smart laser triangulation displacement sensor

Eddy current displacement sensors measure the axial, radial or tangential deflection of the clutch disc. These robust sensors are designed for harsh ambient conditions and, due to their extremely compact size, can also be integrated in restricted installation spaces. The sensor provides stable measurement results despite high pressures and temperatures.

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

The gearbox temperature in wind turbines is measured continuously during operation. Heating up of components may indicate a potential problem with a component. If a certain threshold is exceeded, subsequent remedial action can be started or maintenance planned.

Infrared sensors and thermal imagers for precise temperature measurement

With regard to predictive maintenance, the oil gap should be measured, i.e. the distance between the bearing surface and the shaft filled with lubricants. Despite pressure, high temperatures and lubricants, robust eddy current sensors from Micro-Epsilon can provide a permanent statement about the lubricating gap based on high measurement accuracy.

eddyNCDT 3001

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