Sensor systems in the car

The use of sensors in modern cars is today indispensable. Everyone is familiar with the application of ABS systems where sensors measure the wheel speed and derive control parameters from it for the brakes.

Sensor technology applied

Automotive

Many applications can be assigned to the automotive area. They range from automobile manufacturing itself to the various automotive suppliers. Quality assurance or automation are frequent application areas. The sensor families used range from laser sensors to eddy current sensors to inductive sensors.

Sensor technology applied

Compensating for axial extension of milling spindles

When processing materials using milling spindles (mainly motorised spindles), the demands for high precision are continuously increasing. In order to compensate for the axial extension of the spindle caused by thermal heating and centrifugal forces, the eddyNCDT SGS4701 measures the displacement deviation of the spindle.

Sensor technology applied

Load detection in washing machines

With modern washing machines, energy efficiency and environmental protection are becoming increasingly important. In order to achieve optimum results, the load must be measured before the washing starts. This load measurement enables an optimum and maximum load for the machine to be determined, as well as the appropriate dosage of detergent. This reduces operating costs, while also protecting the environment. A direct weight measurement using e.g. load cells is expensive. An indirect measurement of the damper displacement is much more cost effective. Micro-Epsilon offers low cost solutions for displacement measurement in high volume production, namely the magneto-inductive MDS-40-LP-F displacement sensor, which is directly integrated in the damper.

Sensor technology applied

Measuring system for strip position monitoring in a coating tank

In the electrolytic refinement of thin sheets electrical losses are minimised by a small distance between strip and anode. This requires exact strip guidance. Before the strip enters the coating tank it is guided and measured between two measuring bars with nine eddy-current sensors each. Actuators are initiated and change the position of the anodes in accordance with the strip geometry, or initiate a return to the starting position if limit values are exceeded.

Sensor technology applied

Experimental tests on a drop impact tester

In the automotive industry manufacturers go to great lengths to improve the passive safety of all vehicles in a collision. The so-called crash absorbers join the fenders with the longitudinal bearers and taken overall they can absorb energy through fixed bumpers and plastic deformation. In addition, attempts are made to reduce the vehicle weight through new designs and the use of new materials. The effect of the actual accident event can be replicated on special drop impact testers. Through the variation of the dropped weight and the height, the impact speed can reach 12.5 m/s (45 km/h). Apart from the force, the deformation is recorded during the collision with a fast triangulation sensor.

Sensor technology applied

Active suspension cylinder

Modern mobile cranes are always employed when heavy loads must be lifted quickly and at various locations. They are used, for example, in the recovery of broken down trucks. The field of operation is not restricted to paved surfaces, but also includes deployment in open terrain. Therefore, these cranes possess an adaptive design of running gear in which the suspension of each independent axle can be adapted to the relevant terrain. This is implemented using a suspension cylinder which is fitted with a displacement sensor. The sensor acquires the cylinder stroke and consequently enables the best possible adaptation to the form of the terrain.

Sensor technology applied

Precise positioning of a surgical microscope

Surgical procedures require a perfect view of the operating area. Here, the surgeon is often supported by a surgical microscope. To enable the surgeon to best position the microscope and to give the surgical team more room to move, the microscope optics are mounted to long arms on a stand.

Sensor technology applied

Overhead conveyor distance

Overhead conveyors which move automatically through the production process on a rail are used for the transportation of many components. A certain minimum distance is required so that components do not collide with each other during the transport. The optoNCDT ILR sensors have the task of maintaining this minimum distance. Attached to each overhead conveyor, they measure the distance to the next one. These sensors measure using the “Time-of-Flight” principle which is ideal for such types of application.

Sensor technology applied

Engagement length control in high performance screwdrivers

Industrial screwing in automated production systems is carried out by automatic screwdrivers. Apart from the torque, the engagement length is the most important criterion for the quality of the screwing operation. Generally, the engagement length, i.e. the screw-in depth, is determined with the aid of a mechanical end-stop or by using a limit switch. Consequently, once set, the engagement length cannot be changed during the production process. The inductive potentiometric displacement sensors in the VIP Series provide decisive advantages in this application. The continuous measurement of the engagement length from 0 to 70 mm enables screwing operations with various depths to be carried out at the same station.

Sensor technology applied

Piston position in hydraulic valves

In hydraulic drives proportional and servo valves control the volume flow of hydraulic oil. In order that an exact dosage, and therefore a controlled movement is possible, displacement sensors are integrated into the valves. These sensors acquire the position of the control piston to regulate the volume flow. An accurate, non-contact and, above all, dynamic position acquisition is required for this. An inductive displacement sensor from MICROEPSILON best fulfills these requirements.

Sensor technology applied

On-line inspection of the dimensions of sand-lime bricks

After pressing the sand-lime brick blanks are placed onto a hardening carriage. Even smallest changes in the mixture, moisture, or in the pressing force lead to undefined growth of the bricks and make it difficult to observe the required brick height. A non-contacting laser-optical measuring system with down-stream evaluation logic is installed above the conveyor belt. This system measures the brick height and allows automatic signalling and sorting of the products that exceed the upper or lower tolerance limits.

Sensor technology applied

Measurement system for the flat setting on carding machines

The setting of the distance between the drum and the flat is crucial for carding quality of fiber, e.g. wool. Investigations have shown that manual gap settings with the gage to the left and right on the carding machine are not equal and that with the machine at standstill slight deviations from the operating conditions arise. The remedy is provided by a measuring flat rod (FCT) with two or three capacitive sensors which is exchanged for a flat rod. The sensors measure the distance to the drum via the drum width. The other distance signals are passed to the PC. The fully automatic measurement sequence eliminates erroneous settings and shortens the setup time. The inspection and documentation of the results facilitates practical quality assurance.

Sensor technology applied

Dosing systems for high-viscosity glues

In the automotive industry piston dosing systems are used for glueing car windscreens and windows. These dosing systems supply the highviscosity glue to the application gun in an exactly controllable way. The volumetric flow control required for this purpose is achieved by means of a suitable long-stroke sensor in the hydraulic cylinder. The travel signal of the piston is differentiated, and the speed signal deducted from this is supplied to the closed-loop control circuit. The filling volume is determined through the position of the piston.

Sensor technology applied

Piston ring- and piston secondary movement

Manufacturers of combustion engines require reliable data in order to determine the exact position of the piston, the piston rings and also of the existing pressure conditions. Using simulation tools, this data is primarily used to make reliable predictions about e.g. wear, friction and oil consumption. Furthermore, as well as design improvements, changes and failure analyzes can also be developed. The eddyNCDT eddy current sensor measures the piston ring- and piston secondary movements at high accuracies.

Sensor technology applied

Jib lengths of mobile cranes

The current jib length is important when calculating the torque of the load on the crane. This length is measured with an integrated draw-wire sensor. This simple and telescopic measuring principle makes wire sensors predestined for the task. The sensors can also be retrofitted.

Sensor technology applied

Crane support distance

A truck-mounted crane is frequently the better solution in many cases where loads have to be lifted. As a mobile solution, safety also plays an important role here. Therefore a load torque limiter controls whether the crane can still lift or not. In order to ensure the maximum permitted load, the side crane supports must always be completely extended. If this would not be possible due to lack of space, the crane could not be put into operation. The dynamic process for measuring how far the crane supports have been extended facilitates a calculation of the permitted load capacity. Thus, the use of truck-mounted cranes can also be ensured where space is restricted.

Sensor technology applied

Exact crusher gap adjustment in rotary crushers

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.

Sensor technology applied

Displacement sensor for washing machines

When the washing machine is loaded, the displacement sensor DRA measures how much the outer drum drops. It also measures the drum’s deflection during spin-drying. Due to the inductive measurement principle, the sensor provides absolute position measuring for static and dynamic processes. Operation and the washing result are optimized by the load measurement. The displacement sensor provides an output signal proportional to the weight. This permits full utilization of the drum volume and helps to determine the required amount of detergent.

Sensor technology applied

Strip width when trimming metal strips

As different widths are frequently required during the production of metal strips, the strips must be trimmed after the rolling process and both the cutters must be movable electrically. The distance is now measured by difference measurement using laser sensors from Micro-Epsilon so that compliance with the target dimensions no longer has to be checked manually as was the case previously. Two optoNCDT 1700 sensors are used for this.

Sensor technology applied

Lip Gap Measuring in Paper Manufacture

In paper manufacture the lip gap at the headbox determines the thickness of the paper. Paper machines usually have a lip width between 4 and 6 metres. The measuring task is a constantly monitoring the gap between the upper and lower lip as a quality relevant variable. To manage this application a non-contact eddy current displacement sensor is fitted either to one or better to both sides. A steel or aluminum target plate fitted opposite the sensor serves as a measuring target.

Sensor technology applied

Tester for pneumatic actuator

So-called muscles are developed as alternatives to hydraulic cylinders. The hose made of rubber contracts when it is filled with compressed air. An in-house tester has been developed for testing this muscle. A sensor from the optoNCDT 2200 series in this tester monitors the contraction of the muscle.

Sensor technology applied

Position measurement in Computer Tomography (CT)

In the latest CT equipment, the most effective diagnoses are determined by how precise and fast the measurement systems are (speed and resolution), as well as their cost effectiveness. Irrespective of whether spiral, helical or dual source apparatus is used, the requirements are continuing to increase. In particular, this also concerns the length measurement equipment for the horizontal reclined position. In this application, draw-wire sensors from Micro-Epsilon achieve a resolution of up to 0.001% of the measuring range; this is combined with maximum reliability, long service life and a very favorable price/performance ratio.

Sensor technology applied

Control and monitoring of the production sequence in a refinery

In the refinery crude oil is cracked by distillation to give petroleum, kerosene and diesel oil. In the fractional distillation column the crude oil is heated with superheated steam. The vapors and liquids released collect in the various stages of this column. To control and block the flow of gases and liquids the spindle drives of the numerous flow control valves are fitted with long-stroke sensors. An aluminum tube is used here as the measurement object which is moved concentrically over the sensor coil rod without making physical contact. A displacement signal in the range 4 to 20 mA is provided for the aluminum tube position or for the valve position.

Sensor technology applied

Measurement of the tilt angle on tilting trains

Through the application of tilting trains existing track can be traveled at higher speeds and consequently used more efficiently. Displacement sensors fitted to the front end of the vehicle determine the required degree of tilt of the coach body when taking bends in order to compensate for the "arising sideward acceleration". This data is passed to the control units in the following coaches which then tilt the coach bodies appropriately. When taking a bend, the coach body on the vehicle is then tilted towards the inside of the bend with the aid of hydraulic cylinders.

Sensor technology applied

Clutch wear in racing cars

Racing cars are stressed to the limits of their capabilities. It is not without reason that pioneering technologies are often first tested in racing cars before they find their way into mass production. The 24-hour race at Le Mans produces particularly high stress levels for drivers and materials. And in this respect the clutch is a component that is subjected to the highest stresses. Audi Sport therefore decided to monitor the clutch wear during the race to be able to adopt a less arduous pace at the right time or to even carry out a replacement. A displacement sensor from MICRO-EPSILONis used for this application. The sensor is located directly on the clutch release bearing and records both the normal stroke of the clutch as well as its wear.

Sensor technology applied

Checking the accuracy of robot trajectories

The measurement of the trajectory accuracy or its reproducibility is carried out along a diagonal straight line in space. The robot moves the measuring head, which is fitted with sensors, along a steel rule. The deflection of the 2m long rule due to its own weight is compensated by software. Through the arrangement with six sensors both position and orientation deviations are acquired simultaneously.

Sensor technology applied

Position checking on robots

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.

Sensor technology applied

Release of satellites into space

In order to be able to launch a satellite from the Areane rocket unobstructed into space, the nose cone section, together with the side shield, have to be separated from the main rocket immediately before the release of the satellite. Simultaneous and controlled activation of a series of preloaded springs, provide the propulsion force for the separation of the nose cone and side shield. It is of vital importance that the section separates itself in an absloute linear motion from the main rocket, with-out any non-linear tumbling movement that could cause damage to the satellite. The separation movement is controlled by 3 Draw-wire sensors mounted on the booster rocket.

Sensor technology applied

Displacement measurement on slag transporter

Draw-wire sensors are used to reduce the standstill time of slag transporters during the loading and unloading. They are installed on the tipping cylinder and the support cylinder. In this way, the signal of a limit switch no longer has to be waited for. Depending on the load state, the transporter can start the journey earlier. The sensor also withstands this demanding environment using a special case and wire extensions.

Sensor technology applied

Aerodynamics of aircraft

On their wings, aircraft have slats on the front side and flaps on the rear side which act as buoyancy aids. If these are extended unevenly or on only one side, this can cause significant problems in terms of the aerodynamics of the aircraft. Slats and flaps are retracted and extended by spindle drives. The respective spindle is connected to the drive motor in the gear bay via the drive shaft. A Wing Tip Brake is positioned on the shaft in the outboard wing area. This not only avoids any uneven extension of the slats and flaps, but also prevents any uncontrolled movements of the floating head due to external influences. In its function as a switch, the ‘induSENSOR IS-5-C-CR/WTB’ inductive sensor from Micro-Epsilon checks the position of the brake shoes.

Sensor technology applied

Test facility for shock absorbers

After production the shock absorbers pass through a quality inspection facility on a transport system. Here, they are inspected for dimensional conformance, material faults and the presence of certain features. Two laser-based optical displacement sensors and appropriate CCD cameras enable the measurement of up to eight absorbers per minute. New types of absorbers can be quickly evaluated through the special teach-in routines. With the vertical and horizontal travel of the sensor, scanning of the circular contour, for example on the black rubber inserts on the knuckle eyes, is possible. Impermissible cracks or blow-outs are reliably detected. If quality defects are found, a shock absorber is provided with a fault printout on adhesive labels and included in the quality statistics.

Sensor technology applied

Camber / toe angle

The camber or the toe angle is often adjusted during the service life of a passenger car. It is also often necessary to check the adjustments in the development phase. A laser line is projected from the axis onto three CCD arrays for this. The receiving elements are arranged in a triangle and can calculate the camber and toe angle depending on the position of the line.

Ram travel at a pill press

For the examination of cohesion in pharmaceutical mixtures under the influence of pressure non-contacting eddy-current sensors , which measure the travel of the upper in the area of the bottom dead center of the upper piston are used. The measurements are not affected through process-related formation of dust. In the movement range for pill pressing a force-travel-characteristic can be measured and evaluated by the additional use of strain-gauges.

Sensor technology applied

Valve

The control piston in a valve controls the oil flow to the hydraulic cylinder. As the piston moves back and forth, drilled holes in the valve body are covered and uncovered. The piston is moved by a linear motor. For this measurement, the sensor induNCDT series LVDT from Micro-Epsilon is used. The sensor is mounted on a pressure pipe located on the valve. In this pressure line a freely moving plunger is guided, which is permanently fixed to the spool. The sensor acquires the plunger through the metal of the pressure line and in this way determines the exact position of the spool. The plunger forms a passive position transmitter having a number of advantages. The measurement occurs without contact and is not subject to pressure, because the sensor is mounted outside of the pressurised region.

Sensor technology applied

Valve lift measurement in the MultiAir cylinder

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.

Sensor technology applied

Inspection of valve cones

During the automated assembly of cylinder heads, the proper seating of the valve cones is monitored with optoNCDT laser-based triangulation sensors. This prevents valves from dropping into the combustion chamber. The axial adjustment to the relevant measurement position occurs via electric motor.

Sensor technology applied

Displacement/timing measurement in the common rail injector

Diesel engines of the latest generation no longer have a diesel injection pump to supply fuel, but instead utilize the common rail principle. In order to optimize the injector configuration for the respective engine model it is necessary to know the exact displacement/time behavior of the needle valve. This information is provided by an eddy current sensor built into
the injector.

Sensor technology applied

Active damping of liquid-cooled centrifuges

At certain configurations of speed, filling level and design parameters, liquid-filled industrial centrifuges tend to produce unstable running characteristics which can lead to failure of the centrifuge. The instability, which arises due to interaction between the fluid and the centrifuge, cannot be rectified by passive means (dampers), so therefore the instability is corrected actively with the aid of a magnetic bearing and suitable closed-loop controllers. The deflection of the rotor, which is acquired with two eddy-current sensors orientated at 90° to one another, is used as input information for the controller.

Sensor technology applied

Low cost sensors for cylinder applications

Monitoring the movement of gas pressure or hydraulic cylinders is solved very elegantly using an eddy current sensor. This sensor is integrated in the cylinder. An aluminum ring is used as the target. The sensors are designed so that they easily withstand the pressure inside the cylinder. There are attractive sensor series in the range for this application.

Sensor technology applied

Aluminum rolling - temperature measurement

Very different temperatures often occur in the various process stages. The corresponding Micro-Epsilon temperature sensors are used depending on the temperature range and application area.

Sensor technology applied

Tempering - temperature measurement

Stresses can occur during induction hardening which can be counteracted by heating up again to the tempering temperature. However, temperatures lower than those used for hardening are involved. The temperatures are measured with pyrometers from Micro-Epsilon.

Sensor technology applied

Asphalt mixing systems - temperature measurement

For temperature measurements in asphalt mixing systems, both the temperature of the mineral discharge and the temperature after mixing are measured. Infrared sensors from Micro-Epsilon are used for this which still operate reliably even under adverse environmental conditions.

Sensor technology applied

Building materials – temperature measurement

Micro-Epsilon temperature sensors are always used for the manufacture of construction materials when the monitoring and control of the temperature are critical for the product quality and productivity. The most important application areas are the cement industry, the production of plasterboard sheets and the pretensioning of architectural glass.

Sensor technology applied

Non-contact IR temperature measurement of plastic film

Non-contact temperature measurement of thin plastic films is in practice a difficult measurement task. Depending on the type of plastic, the measurement must be performed in different spectral ranges. In research and development of printable films, the surface temperature of heated plastic films is detected using a CTP-7 pyrometer (spectral range 7.9µm). Furthermore, the thermoMETER CTP-3 thermometer with a spectral range of 3.43µm is also suitable for non-contact temperature measurement of plastic films.

Sensor technology applied

Bolts – temperature measurement

Bolts are preheated to 400 °C - 500 °C in order to be pressed easily by the die. Micro-Epsilon pyrometers are used to measure the temperature. Maintenance of the optimum preheating temperature is important in order to ensure a smooth production process and to increase the process speed.

Sensor technology applied

Brake disc temperature measurement for Formula Student

In the optimization of braking systems for the High Octane Motorsports e.V. racing car at the University Erlangen-Nürnberg, the temperature rise of the brake disc needs to be measured during on-road testing.

Sensor technology applied

Iron and steel molten mass - temperature measurement

Infrared temperature sensors from Micro-Epsilon measure the temperature of the molten mass in casting plants immediately before filling the moulds. The temperature values are used for monitoring the specified target temperatures.

Sensor technology applied

Flat glass - temperature measurement

Temperature plays an important role in the glass industry for many manufacturing and production processes. It is a matter of obtaining precise temperature measurements of transparent (glass) and non-transparent (moulds, crown and side walls of the glass furnace) objects.

Sensor technology applied

Bottle and hollow glass - temperature measurement

Special sensors which are used for permanent temperature monitoring are installed at the individual stations of the glass production line.

Sensor technology applied

Film extrusion - temperature measurement

Infrared temperature sensors from Micro-Epsilon measure the film temperature before the three-roller mill. An optimal regulation of the process temperatures is made possible due to the precise temperature values which results in a constantly high product quality.

Sensor technology applied

Casting - temperature measurement

The measurement and the documentation of the production parameters in foundries are playing more and more important roles for the compliance with the quality requirements. Particular attention must be paid here to the measurement of the temperature in the production process.

Sensor technology applied

Plaster hardening - temperature measurement

Stationary Micro-Epsilon temperature sensors are used for optimization of the additives during plaster hardening. Due to the constant temperature monitoring of the hardening reaction, defects can be detected immediately and thus sustainably increase the quality.

Sensor technology applied

Glass machining – temperature measurement

In order to be able to bend and shape flat glass, the exact glass surface temperature must be taken into account. Special pyrometers from Micro-Epsilon have been developed for measuring in glass manufacturing.

Sensor technology applied

Glass industry / glass - temperature measurement

Temperature plays an important role in the glass industry for many manufacturing and production processes. It is a matter of obtaining precise temperature measurements of transparent (glass) and non-transparent (moulds, crown and side walls of the glass furnace) objects.

Sensor technology applied

Glass drop measurement - temperature measurement

The use of non-contact temperature measurement equipment is required for measuring the glass drop temperature. Pyrometers from Micro-Epsilon are particularly suitable due to the fast operating processes.

Sensor technology applied

Hardening – temperature measurement

In order to manufacture constant high quality products, the temperature of the workpieces must be precisely measured during the hardening. Non-contact infrared sensors from Micro-Epsilon are suitable for hardening processes due to their particular characteristics.

Sensor technology applied

Cooling process - temperature measurement

After pressing, the heated metal object is subjected to the cooling process. In order to guarantee a high quality finished product, a controlled cooling rate is necessary. Non-contact thermometers from Micro-Epsilon are particularly suitable for the temperature monitoring.

Sensor technology applied

Foodstuffs - temperature measurement

Constant temperature monitoring for the quality assurance is a must for monitoring production processes, foodstuffs storage and the sale of foodstuffs. Non-contact infrared thermometers are particularly used in the areas of storage, transport and manufacturing processes such as baking, freezing, roasting and refining.

Sensor technology applied

Glued wood - temperature measurement

After drying and sorting the wood laminates, they are cut to the required length, glued, stacked and pressed afterwards. They are heated using microwaves for the glue drying and the individual glue layers are measured with a very small infrared spot size. The extremely small measuring spot diameter of the Micro-Epsilon thermometers makes friction-free measurement possible.

Sensor technology applied

Soldering systems - temperature measurement

Metal teeth for saw blades are soldered in soldering machines. In doing so, a fast IR temperature measurement provides exact regulation and prevents mechanical stresses in the saw blade and the danger of crack formation.

Sensor technology applied

Measuring of the haptic contact temperature

Contact or touch temperature is an important parameter in the tactile quality of a surface. The feeling of the temperature that a material causes can be determined by using a measuring system. If this parameter is known, an objective feeling of quality can be made. The measurement results are shown on a sensotact-scale – a tactile reference system. A physical basis for these values is created by measuring the temperature of the surface shim. Afterwards a step-less measuring analog of the reference scale is possible. In the measuring system, temperature sensors of the thermoMETER CSmicro series are used.

Sensor technology applied

Paper, packaging industry - temperature measurement

Non-contact IR thermometers from Micro-Epsilon are used for fast and non-contact temperature measurement for the manufacture of paper products, particularly in the areas of coating and drying.

Sensor technology applied

Melting furnace – temperature measurement

The non-contact temperature measurement in glass furnaces, melting furnaces and feeders is a more and more frequently used alternative to measurement with thermal elements. Micro-Epsilon provides infrared temperature measurement systems particularly for this area which can operate efficiently even without cooling at an ambient temperature of up to 250 °C.

Sensor technology applied

Softcalender - temperature measurement

Pyrometers from Micro-Epsilon enable the monitoring of fast rotating objects such as, e.g. softcalenders for paper manufacture. The system permanently monitors the fast rotating rolls.

Sensor technology applied

TIM 160 for injection mould applications

Users of injection  mould 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 online temperature control right after extrusion as a global quality attribute is growing.

Sensor technology applied

TIM 160 for injection mould applications

Users  of  injection  mould  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 online temperature control right after extrusion as a global quality attribute is growing.

Sensor technology applied

Steel production and processing - temperature measurement

Infrared thermometers from Micro-Epsilon are used for almost every production stage in the manufacture of steel and aluminum. The precision pyrometers from Micro-Epsilon are used in order to obtain reliable data for efficient process control. Application areas • Casting • Preheating • Warm and cold rolling • Forging, annealing, hardening.

Sensor technology applied

Extrusion - temperature measurement

Precise temperature measurement at several places is necessary for extrusion: after preheating the bolt, for the discharge of the profile from the die and for quenching the extruded product. An additional check of the tool temperature is usually carried out in order to obtain optimum production results.

Sensor technology applied

Temperature measurement of PCBs

High quality PCBs with SMD components are repaired in rework stations. Hot air is used to remove any defective components and residual solder, to perform solder paste printing and to solder new components into place. The repair process starts automatically when the PCB reaches a specific surface temperature, which simplifies the replacement of defective SMD components. In addition, automatic start-up significantly reduces both the thermal load on the PCB and process time. For accurate temperature measurements, Finetech uses the thermoMETER CT non-contact infrared temperature sensor from Micro-Epsilon.

Sensor technology applied

Temperature measurement for vacuum mold equipment

Thermal vacuum mold equipment is used for the decentralized manufacture of mouth guards for teeth. A special film is heated for this and drawn into a shape using a vacuum. The temperature is measured without contact using thermoMETER CS so that the film has the correct temperature and elasticity for the reshaping. The measurement is performed quickly, precisely and without effects on the target.

Sensor technology applied

Tunnel kiln - temperature measurement

The use of precision pyrometers is indispensable for optimum furnace regulation in order to measure the exact internal temperature. The Micro-Epsilon temperature sensors have successfully proven themselves for the stationary measurement on the furnace.

Sensor technology applied

Glass pretensioning - temperature measurement

CTlaserGLASS has been specially developed for applications in the glass processing industry, in particular for glass bending, forming and hardening processes. The non-contact thermometer ensures precise monitoring of the temperatures.

Sensor technology applied

Special roll gap measurement on calender press

For continuous, uniform material processing in the field of sealing technology, the gap between the rolls must be set with the hydraulic adjustment device and maintained constant. For this reason the top and bottom rolls are provided with a shoulder and an aluminum ring as measurement objects to the left and right. Using the aluminum ring, errors due to the roll material can be avoided. Two eddy current sensors mounted opposite one another measure the distance to the aluminum ring from a fixed reference point. The roll gap can be found from the sum of the two distances.

Sensor technology applied

Pistons

Combustion engines must withstand maximum loads during a long service life. In order to deal with this requirement, eddy current sensors from the eddyNCDT series are installed in the engine for many different measurements. As the smallest eddy current sensors in the world, these sensors can be used in the fuelled condition. Examples of measurement already being carried out are: valve lift, needle lift, breathing of the cylinder head, lubrication gap on the cylinder, oil film thickness, crankshaft concentricity, crankshaft axial movement and piston secondary movement.

Sensor technology applied

Piston – Top Dead Center

The Top Dead Center of the cylinder movement is measured for adjustment of the precise ignition point in engine development. In doing so, a miniature eddy current sensor is integrated in the cylinder head cover. From this position, it precisely measures when the piston is at the smallest distance from the sensor. The ignition is optimum at precisely this time. Earlier or later ignition would reduce the efficiency of the engine. This measurement is only possible in towing operation.

Sensor technology applied

Piston Secondary Movement and Piston Ring Position

To improve the construction of internal combustion engines and damage analyzes, it is neccessary to measure the thermal and mechanical loads in the engine. Two important variables here are the transverse movement of the piston (secondary movement) and the position and deformation of the piston rings during the individual operating strokes. The measurements must be made under operating conditions in order to provide reliable results. To do this, the engine is run on the bench either in test mode or normal operating mode.

Sensor technology applied

Piston secondary movement

To improve the construction of internal combustion engines and damage analyzes, it is neccessary to measure the thermal and mechanical loads in the engine. Two important variables here are the transverse movement of the piston (secondary movement) and the position and deformation of the piston rings during the individual operating strokes. The measurements must be made under operating conditions in order to provide reliable results. To do this, the engine is run on the bench either in test mode or normal operating mode.

Sensor technology applied

Air gap measurement in large electric motors

With very large electric motors (diameter larger than 10m) it is important for reasons of cost effectiveness and energy efficiency, to know the radial run out of the rotor from the stator inside the motor. These electric motors are intended for use in rock grinding mills for cement production or mining. Due to imbalances during operation, the rotor may touch the stator, which would cause much damage. This is why sensors are used to measure the distance between the stator and rotor and to monitor the so-called rotor gap whilst the motor is in operation. For this application, capacitive sensors with a measuring range of approx. 30mm are used.

Sensor technology applied

Inspecting gaps in car trims

In high quality vehicles, the trim typically consists not only of a single material (e.g. plastics) but many different bonded materials. This offers various design options but also many additional functions e.g. illumination using semi-transparent parts. Bonding or welding these elements requires precise handling, as parts that are only slightly misaligned can cause large deviations in the corresponding gap size. In order to meet the high requirements demanded by automotive manufacturers, it is necessary to inspect all trim prior to delivery and to rework any defective parts. And this is where the scanCONTROL 2910-25 laser scanner comes in.

Sensor technology applied

Detection of turbocharger rotor dynamics

In order to inspect the behavior of turbochargers during different stress states, eddy current displacement sensors are applied in turbocharger test benches. The miniature design of the sensors and their resistance to oil and high temperatures enable the precise detection of the lubricating gap of hydrodynamically stored rotor shafts.

Sensor technology applied

Lubrication gap

Sliding bearings are used for crankshaft bearings in the engine. A specific minimum distance is required so that the bearing operates as wear-free as possible. Miniature eddy current sensors are integrated in the bearing for this. They measure the distance through the bearing half-shell on the crankshaft. It can thus be established whether sufficient oil is lubricating the shaft in the bearing. If the film of oil breaks down, the distance to the shaft must be almost zero. This is because a certain minimum clearance from the bearing to the shaft is required due to the viscosity of the oil.

Sensor technology applied

Quality control of medical tablet stamps and dies

According to ISO 18084:2011, the press tools for the tablet production are subject to a continuous quality control. Due to complex geometry and a strongly reflecting surface, automatic inspection of stamps and dies has been difficult. Only the use of a confocal sensor (confocalDT 2451) and an optical micrometer (optoCONTROL 2600) together with a precise movement with 5 degrees of freedom enabled the development of »Ti-1«. Ti-1 is a complex measurement system equipped with a USB interface and special software for the geometric and visual inspection of tools.

Sensor technology applied

Weld seam inspection on pipes

A perfect weld seam is essential in a leak tight pipe. scanCONTROL laser scanners are therefore used during spiral welding to align the weld flanks. This results in a much more reliable welding process. The long base distance of 600mm and the protective housing for the sensor are also important here.

Sensor technology applied

Gap measurement in photovoltaic modules

The module is hermetically sealed using a vacuum during a new method for the production of photovoltaic modules. The correct distance between glass front and metal rear side is important for this vacuum. Therefore, the distance of the glass pane to the rear side is automatically measured from one side in the production using confocal sensors.

Sensor technology applied

Gap detection on glass

Glass substrates are required for certain medical tests. During manufacture of silicon chips, the substrate is milled in a defined grid with a depth of 800µm. For separation, the substrate is broken at pre-defined breaking points in a breaker station. For this, the glass pane must be positioned precisely. An optoNCDT 1700 sensor is used here for gap measurement.

Sensor technology applied

Gap measurement of brake discs

In any type of vehicle, the braking system is one of the most important safety features. This is why high requirements are placed on all braking system components. When manufacturing brake discs, the different sizes must be strictly adhered to. One critical feature is the gap between the plates of the brake disc. Therefore, the gapCONTROL 2911-25 gap sensor is used.

Sensor technology applied

Closed-loop gap control in magnetic bearings

Sensor technology applied

Gap measurement of tripping pins

When triggering a switching operation in test equipment for camshafts, a tripping pin is moved at high speed. A gap measurement detects whether the tripping pin has been completely extended and if it has been triggered with the required speed. Evaluation of the displacement-time-signal determines all parameters reliably. The optoCONTROL 1200/90 optical micrometer carries out these measurements.

Sensor technology applied

Gap monitoring in car interiors

Car interiors present a number of gaps, for example, between the single cockpit elements such as the center console or door trim. From a technical point of view, it is often irrelevant if the width and height of a gap are constant. However, the interior is an area of the car that the customer sees first. The gapCONTROL profile scanner inspects the gaps of all parts in the car interior during final assembly.

Sensor technology applied

Gap and flushness measurement of car bodywork parts

The demands on car bodywork are increasing, not only from a technical viewpoint, but also with regards to the optical design. Therefore, a door that doesn’t close flush could fulfill the technical purpose but would be detected immediately by the eye of the prospective buyer. A bonnet/hood with different gap sizes on both sides is also a considerable flaw. The typical approach for measuring gaps is to use manual feeler gages, which is time-consuming and costly. This method is prone to error due to human factors, which is why the gapCONTROL gap sensor is used in modern production lines to inspect bodywork gaps quickly, reliably and consistently.

Sensor technology applied

Eddy current sensors in tribology testers

Eddy current sensors from Micro-Epsilon are used for various measurement tasks in tribology testers of the ITR in Clausthal. They withstand the harshest ambient conditions there as they measure directly on the shaft in the tester. A tester with water lubrication and a tester which examines plain bearings for the automotive industry have already been realized. The position of the test bearing case and the relative movement between the rotor and the test bearing is detected in the tester using eddy current sensors.

Sensor technology applied

Monitoring oil gaps in hydrostatic bearings

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.

Sensor technology applied

Distinction of brake discs

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.

Sensor technology applied

Oil film thickness measurement in an internal combustion engine

Included in the objectives of current engine development are minimization of pollutants and the reduction of oil consumption. In order to be able to take measures in achieving these objectives, then along with a number of other factors, it is very important to obtain knowledge of the behavior and the thickness of the oil film between the cylinder wall and piston or piston rings In this respect the upper third of the cylinder bore is of particular interest.

Sensor technology applied

Measuring glass cups

In the production of drinking glasses, the stem and cup are connected using a gas burner. In order to enable the precise connection of the glass stem and cup, the distance between stem and cup needs to be measured. Monitoring this gap size allows for feed rate control during production. An optoCONTROL optical micrometer measures this gap.

Sensor technology applied

Roller clearance

The distance of both rollers from each other or from the roller to the support surface is the crucial dimension for rolling processes for metals, plastics or other materials. In the case of sensitive processes and high material accuracies, the clearance must be checked constantly so that imminent rejection is avoided. The contacting inductive and the non-contact methods are suitable for this. In the case of contacting methods, the sensor is mounted on the outside on the roller guide. The change in clearance is transmitted to a plunger whose position change is measured by the inductive sensor. In the case of the non-contact method, the roller is between the transmitter and receiver of an optical micrometer. The emitted light curtain is partially covered by the roller. The remainder reaches the receiver through the gap. The gap can be calculated based on the light quantity measurement.

Sensor technology applied

Windscreen gap

The final appearance of a product plays a crucial role everywhere that panes are positioned automatically. Apart from the shape, stability, color etc., the final appearance is also dependent on the position of the glass in the frame. The pane must be inserted in as centerd a position as possible. A laser scanner also detects automatically for the insertion of the glass whether the gap is the same on all sides or not. If differences occur, the pane can still be moved somewhat. The extremely difficult conditions of the different reflection factors of glass and frame (metal, wood, plastic) do not affect the quality of the measured data.

Sensor technology applied

Cylinder breathing of the cylinder head gasket

Specially shaped eddy current sensors are integrated directly in the crankcase where they measure, for example, the expansion of the cylinder head gasket during the stroke. Pressures of up to 50 bar are produced for every ignition of a cylinder, which slightly raise a tightly bolted cylinder head. This movement is compensated for by the cylinder head gasket, which is why it is referred to as “cylinder head gasket breathing”. How far the cylinder head moves is measured by eddy current sensors. This data provides information about the durability of the gasket and save customers from fatal engine damage.

Sensor technology applied

Inspection of sockets

There are many uses of sockets in the automotive area. The dimensionCONTROL system is used for the quality inspection of these parts. An optical micrometer at the machine entry checks the size of the sockets. Using different image processing systems, both front faces and the shoulder face are tested for breakouts, fissures etc.

Sensor technology applied

Diameter - radial/axial runout - measurement at disk motors

The production of disk motors has to meet the highest mechanical accuracy requirements. In order to ensure perfect functioning of the disk drives the drive units are measured and evaluated with respect to diameter, true running, and axial running. Since production specifications of < 5 μm have to be measured under nominal speed, a decision has been made to use the fast and high-resolution capaNCDT system. In this measurement two sensors with measurement range50 μm that are adapted to the flange geometry are of special importance.

Sensor technology applied

Monitoring the commutator in electric motors

The “eddyNCDT” system offers many advantages for the non-contact monitoring of the mechanical condition of the commutator in electric D.C. motors or generators. The system uses the eddy-current measuring principle, is not subject to wear and cannot affect or influence the commutator.

Sensor technology applied

Vibration displacement measurement in road tests

With cars, tests on the running gears form the basic requirements for driving safety. Here sensors are needed which can also withstand the high demands of road tests. As an example, draw-wire sensors are mounted in parallel to the shock absorbers for the vibration displacement measurement and the data is recorded for varying road-surface quality. The displacement signal obtained is differentiated to give the vibration velocity and vibration acceleration.

Sensor technology applied

Co-planarity of IC-pins

The term „co-planarity“ discribes the proper seating of the tips of fine-pitch device leads on the copper pads on a PCB prior to solder process. The coplanarity is a critical dimension for the quality of the soldered joints, because no reliable and correct soldering can be done if there is a gap between the lead and the pad. In state of the art automatic assembly machines the co-planarity of components is measured during the assembling process. The component to be measured is passed over a triangulation displacement sensor which has a laser beam that scans the row of pins.

Sensor technology applied

Deformation measurement on lightweight structures

Specially designed measurement systems, which record the surface contours without reactive effects on the lightweight structures, are employed for the examination of component deformations under load. To achieve this, two laser-based optical displacement measurement systems can be mounted on a movable subframe subdivided with nineteen fixed reference points.

Sensor technology applied

Measurement of the radial deviation on superconducting magnets

At the Institute for Solids and Materials Research (IWF) Dresden a motor with magnetic bearings has been developed using high temperature superconductors which can be employed for feed pumps for liquid nitrogen. The most important application of superconducting permanent magnets is the superconducting magnetic bearing. For the measurement of the radial deviation of these magnetic bearings, U1 eddy current sensors with special temperature compensation for -196 °C and 20 °C are used in the evacuated and cooled ambient.

Sensor technology applied

Measurement of the radial deviation of a cutter disk

Sensor technology applied

Vibration test of wet razor

Modern wet razors provide the function of supporting the shave using vibration. A functional test is performed at the end of production for these models. The razor is switched on and placed in the light band of the optoCONTROL optical micrometer. The laser micrometer measures the vibration amplitude and the frequency.

Sensor technology applied

Non-contact measurement of relay contact movement

Even the layman can detect wether a relay is energized or not. The question how on the other hand, is difficult to answer even for the expert. What he needs to know is the timing of certain specific parameters such as pick-up delay, armature play, armature displacement, armature bounce, contact displacement, final contact position and contact bounce. These parameters can be derived from the measured armature and contact movement. The relay characteristics must not be affected in any way by the measuring equipment in the event. The noncontact displacement measuring systems optoNCDT offer the ideal solution to this problem.

Sensor technology applied

Automatic inspection and repair of marine propellers

Deformed ship propellers are bent back to their original condition using special machines. Previously, this work was performed manually but today it has been replaced by automatic systems. The current shape of the propeller is measured and stored using an optoNCDT 1700 series laser sensor. The system then automatically recognizes which positions need focusing on. In doing this, the laser sensor measures the shiny surface of the propeller, which it is able to do extremely well by using  fast, real-time surface compensation (RTSC) exposure regulation.

Sensor technology applied

Examination of the oscillation behavior of toothed-belt camshaft drives

To examine the influence of various system and operating parameters on the dynamic behavior of multi-disk drives a belt oscillation test bench has been set up which simulates the toothed-belt drive system of a direct injection motor vehicle diesel engine. The periodically fluctuating shaft torques generate rotary oscillations in the toothed-belt drive, which lead to transverse belt oscillation. Five laser optical position measuring systems are arranged closely side by side, so that oscillations of higher order can also be measured safely.

Sensor technology applied