Thickness of plate, sheet, foil, rubber, insulation, layer, board
Thickness measurement using displacement sensors is a wide application area. Basically there are distinctions between non-destructive/destructive, non-contact/with contact and one-side/two-sided thickness measurement. The Micro-Epsilon measuring techniques for thickness measurement are all emission-free whereby no emissions regulations of any kind have to be complied with.
Thickness measurements must be performed both with contacting as well as with non-contact sensors whereby non-contact measuring techniques show advantages with regard to accuracy and measuring speed.
There is also a distinction between one-sided and two-sided thickness measurement. Two-sided thickness measurements are carried out with at least one pair of sensors which are installed together on one axis. This pair of sensors measures the target synchronously. The difference between the measurement results (C-A-B) produces the thickness of the measuring object.
One-sided thickness measurements must only be performed with non-contact sensors. In doing so, the target is only measured with one sensor and either only a part of the target thickness (e.g. layer thickness) or the complete measuring object thickness is measured. Thickness measurements are mainly used in process control and quality assurance, e.g. for the control of extrusion systems or 100% checking of tube diameters.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Non-contact thickness measurement of aluminum
For the prompt detection of incorrect thickness on aluminum strip, patented laser triangulation sensors are employed as a modern alternative solution to isotope measurement systems. To save costs the places on the strip which are outside the permissible thickness tolerance are not provided with a foodstuffs-compatible coating and so the strip can be recycled without problem in production. At the point of measurement the sensors are mounted opposite one another, above and below the passing aluminum strip. Irrespective of the exact height position of the strip, the exact material thickness is obtained by a simple distance signal coupling, F=Ref. - (A + B), of both sensors.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Aluminum thickness
It is important to know the thickness of the plates for the manufacture of aluminum plates. The non-contact profile measuring system measures the profile of the plates using a capacitive sensor. At the same time, the width of the plate is determined during the measurement. The reversing rolling stand and the following roller stands can be better adjusted using the data obtained. The system is integrated in the existing roller track. Installed directly before the cropping shear where the plate is stationary for the cut, the production process is not impaired.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Thickness measurement of battery separators
In the production of battery separators the in-line monitoring of the profile thickness is an important measurement task within the framework of quality assurance. A measurement system with high spatial resolution and a high sampling rate is needed for the determination of the profile structure. This task represents one of the classical fields of application for the laser-based triangulation sensor in the Series ILD 2000. The battery separator is manufactured in an extrusion process. For the thickness measurement the optical sensors are mounted on a welded C-frame. This traverses on air bearings without making physical contact on a hard rock base. In this way the vibration of the top belt is minimized and a precise measurement facilitated.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Blown film thickness
The thickness of blown films is an important aspect in terms of constant quality in blown film production. Partially strong thickness tolerances can occur for the production in doing so. The blown film system from Micro-Epsilon measures the profile of the film with or without contact directly after the extrusion nozzle. Located on a reversing frame, the system continuously traverses the film tube and provides the data to the host system for controlling the extrusion nozzle.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Sheet thickness
It is often the case for sheet machining that sheets must be transported individually in machines. Therefore, it is essential that only one sheet gets into the machine. If two sheets are on top of each other, the process will be halted. This task is resolved in a simple way using thickness measurement. If the current measured value is different from the thickness of one sheet, an error is detected. The measurement is independent of the absolute position of the sheet in the measuring gap. Depending on the requirement, laser, optical, capacitive or eddy current sensors can be used for this.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Measure Disc Thickness Variation (DTV) on brake discs
Measuring the deformation of brake discs under load while braking is an ideal task for the optoNCDT 1700BL. Due to the short wavelength of the blue-violet laser used, the light emitted from the red-hot brake does not dazzle the sensor, as the 600-nm wavelength is a long way off the 405-nm wavelength of the blue-violet laser and is effectively blocked by the high quality interference filters employed.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
One-sided thickness measurement of container glass
In container glass production, wall thickness and roundness of the bottles are crucial quality features. This is why these parameters must be 100 % inspected. Any faulty containers are immediately rejected and returned to the glass melt. Due to high processing speeds and in order to prevent the bottles from being damaged, a fast, non-contact measurement procedure is required. The confocal chromatic confocalDT 2422 dual-channel measurement system combined with the IFS2406-10 sensor from Micro-Epsilon are ideally suited to this measurement task.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Thickness measurement of mineral cotton
Mineral cotton is often used for heating insulation of buildings. However, as well as the homogenous material structure, thickness is also a critical factor in ensuring the right insulation characteristics. In the production two optoNCDT 1700 laser sensors with an integrated controller and air purge system for protecting the optics are therefore required for quality control.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Processing measurement data for thickness measurements
One method of measuring thickness is to calculate values from two opposing distance sensors. With up to six inputs, the CSP2008 universal controller allows synchronous recording of measured values from optical sensors: A pair of sensors is connected directly to the controller, another pair is connected via the EtherCAT fieldbus coupler and an integrated extension terminal. Two analog sensors measure the width of the material. These sensors are connected via a dual-channel analog input terminal. After the sensors have recorded their values, the CSP2008 calculates material thickness and width. Three switching inputs are used to set masters as per a calibration standard.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Thickness measurement of black rubber belts
Rubber mats for the structure sealing must exhibit a specified thickness for durability and tear resistance. The thickness of the films is measured directly after the extrusion. The optoNCDT 1700 sensors used measure the distance to the rubber despite bad reflectivity. The thickness is determined from the sensor signal and the distance to a reference roller. The user thus recognizes already starting deviations from the target thickness.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Thickness and volume measurement of potato slices
When producing potato crisps, factors such as consistency, quality and taste depend to a significant degree on the thickness of the potato slices used. Depending on the process parameters and the condition of the tools used, the thickness of the cut slices changes slowly but steadily during the production time. This is why it is important to continuously monitor the thickness during production by using the scanCONTROL 2950-50BL sensor. The sensor projects a laser line onto a conveyor belt, which continuously guides sample slices along it.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Display glass / flat glass thickness
A special measuring system has been developed for the quality control of display glass. The glass pane is placed on a measuring table by a robot. A measuring arm with several confocal sensors traverses the glass pane there. If any thickness discrepancies are found, the pane is marked as NOK and rejected. The scanCONTROL laser scanner simultaneously circumnavigates the edges and checks these for defects and dimensions. After the check has been completed successfully, the pane is lifted back into the production process and the next measurement is started.
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
|
|
__________________________________________________________________________________________________________ |
Flat film thickness
The thickness of manufactured films is frequently a decisive quality criteria in production. Specially developed thickness measurement systems are used as early as possible in the production for the check of the thickness. Dual sensors consisting of two sensors with different measuring principles measure the thickness across the complete width of the film from one side without contact. A thickness profile of the flat film is thus produced using which the production systems can be regulated extremely precisely. The dual sensors are compiled differently depending on the type of film.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Flat glass thickness
A special measuring system has been developed for the quality control of display glass. The glass pane is placed on a measuring table by a robot. A measuring arm with several confocal sensors traverses the glass pane there. If any thickness discrepancies are found, the pane is marked as NOK and rejected. The scanCONTROL laser scanner simultaneously circumnavigates the edges and checks these for defects and dimensions. After the check has been completed successfully, the pane is lifted back into the production process and the next measurement is started.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Non-contacting online layer-thickness measurement of foils
In foil production online process monitoring guarantees constant product quality. MICRO-EPSILON’s KS5 combination sensor measures the layer thickness on foils in a non-contact and thus non-wearing process.
|
|
__________________________________________________________________________________________________________ |
Yarn thickness
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.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Glass thickness
A special measuring system has been developed for the quality control of glass. The glass pane is placed on a measuring table by a robot. A measuring arm with several confocal sensors traverses the glass pane there. If any thickness discrepancies are found, the pane is marked as NOK and rejected. The scanCONTROL laser scanner simultaneously circumnavigates the edges and checks these for defects and dimensions. After the check has been completed successfully, the pane is lifted back into the production process and the next measurement is started.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Thickness measurement of glass
The specification of the thickness of glass panes is an optimization process between a required mechanical strength and efficient use of materials. In the manufacturing process the glass thickness is measured and the conformance to prescribed tolerances is monitored. The measurement is carried out with displacement sensors working on the eddy-current principle. Here, the sensor hovers over the glass surface and measures through the glass to a metal plate situated behind it. The values can be read off directly on the device; an analog output voltage facilitates further evaluation.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Inner liner thickness measurement
Inner liners are used in every tire to prevent the air from escaping. As the inner liner is a characteristic relevant to safety of every tire, there are high requirements for compliance with the target data. An important criterion is the layer thickness. The system for measuring the thickness of inner liners operates without contact and wear-free. The inner liner is routed through the measuring system immediately after the calender roller. A measuring head traverses above the surface. An eddy current sensor measures the distance to the reference roller while an optical micrometer measures the distance to the rubber surface. The system can be integrated in the heating circuit of the calender roller for better temperature compensation.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Thickness measurement system for partially transparent insulation panels
In the manufacturing of plastic panels, thickness profile measurements must be carried out due to the necessary quality assurance. For this purpose two laseroptical displacement sensors are mounted on a traversing device, one underneath and one above the panel which passes along a defined path. The preprogrammed measuring points are sampled consecutively. Irrespective of the exact height position of the panels, the accurate material thickness is obtained by simple coupling of the synchronously measured distance values from both sensors. The output of the desired measurement log is realized with the aid of a PC system in the fully automatic sequence of the profile measurement table.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Thickness Measurement on the Calender
Rubber-coated textile and metal fabrics form the basis of tire manufacture. The rubber is applied to the fabric by calender rolling which demands a uniform layer thickness for the manufacture of high quality tires. The strength and the dimensional conformity of the tire directly depend on the coating process.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Active compensation for movements in the measurement process
Harsh industrial environments place high demands on optical displacement sensors – precise measurements must still take place despite dust and high processing speeds. The optoNCDT 1700 and optoNCDT 2300 series of laser sensors have been mastering 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. Examples include folds in a belt.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Thickness measurement of dies
When optical data carriers are produced, the data are initially transferred to a master. Depending on the number of copies, different dies made of nickel are produced from the master by galvanization. These dies must show a thickness of 297 µm ± 3 µm for faultless production. It is checked several times during the galvanization that this dimension is complied with. The company ISEDD GmbH from Bielefeld has developed a measuring device for this which enables fast and accurate inspections of the dies. Capacitive sensors from Micro-Epsilon are used for the thickness measurement.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Thickness measurement using displacement sensors
Thickness measurement using displacement sensors is a wide application area. Basically there are distinctions between non-destructive/destructive, non-contact/with contact and one-side/two-sided thickness measurement. The Micro-Epsilon measuring techniques for thickness measurement are all emission-free whereby no emissions regulations of any kind have to be complied with. Thickness measurements must be performed both with contacting as well as with non-contact sensors whereby non-contact measuring techniques show advantages as regards accuracy and measuring speed. There is also a distinction between one-sided and two-sided thickness measurement. Two-sided thickness measurements are carried out with at least one pair of sensors which are installed together on one axis. This pair of sensors measures the target synchronously. The difference between the measurement results (C-A-B) produces the thickness of the measuring object. One-sided thickness measurements must only be performed with non-contact sensors. In doing so, the target is only measured with one sensor and either only a part of the target thickness (e.g. layer thickness) or the complete measuring object thickness is measured. Thickness measurements are mainly used in process control and quality assurance, e.g. for the control of extrusion systems or 100% checking of tube diameters.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Thickness measurement of rubber film
Precise thickness specifications are assigned for the manufacture of rubber film which is rolled using calender rollers. Random-sample manual measurements, as previously carried out, are no longer sufficient for today’s demands on quality assurance. Consequently, a system with three fixed tracks has been adapted for in-line inspection of the thickness. For each track an eddy current sensor of Type U6 is built into a jockey follower system which measures against an stainless steel roller. Controllers of the range multiNCDT series 100 are employed for the evaluation electronics. The stainless steel roller represents the reference system for the measurement.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Oil film thickness
The oil film thickness for combustion engines describes the gap and thus the quantity of oil between piston and cylinder wall. Thus it is sometimes a determining factor for smooth operation and durability. As the oil film can only be integrated and really measured in the firing condition, it is extremely difficult to manufacture sensors for these environmental conditions and then also find space for them. Specially miniaturized eddy current sensors from Micro-Epsilon are capable for this. The smallest with only 2.4 mm external diameter is integrated directly into the cylinder wall and ground to its shape. There, it measures the distance from sensor to piston or the space available for the engine oil for lubrication in every stroke.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Double-sheet detection before pressing
To prevent damage, laser-based optical displacement sensors are employed in front of the inlet for profiled sheets in presses to enable the detection of double sheets. The sensors are mounted opposite one another, above and below the passing sheets. Irrespective of the actual position of the sheets, the material thickness is obtained by simple coupling of the distance signals from both sensors. For adjustment a master sheet for each type of sheet is inserted into the measuring gap and the resulting signal set to zero. The zero value is monitored within a tolerance. The sensors are operated in special protective housings because of the harsh ambient.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Reliable quality control in the rolling mill
One of the profile rolling mills processes profile steel in reversing operation. The rod center is then measured and evaluated using a optoNCDT 1700-750BL.
Sensor technology applied
Blue Laser triangulation sensor - optoNCDT 1700BL
|
|
__________________________________________________________________________________________________________ |
Thickness monitoring in straightening factories
Optical laser displacement sensors are employed in front of the inlet for panels on straightening machines to prevent damage to the machine. The sensors enable the detection of double sheets and an accurate acquisition of upright edges.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Layer thickness measurement (non contacting)
Layer thickness measurement belongs to the group of one-sided, non-contact thickness measurement. Basically, only the layer thickness of electrical insulators can be measured for opaque objects. An eddy current sensor penetrates the insulating layer without damage and measures the distance to a layer underneath it. At the same time, a second sensor, a laser triangulator measures the insulating layer. The layer thickness is obtained by offsetting both signals. This method of measuring with two sensors using different principles is called the dual sensor technique by Micro-Epsilon. A second possibility is the layer thickness measurement of transparent materials using confocal measurement technology. The emitted white light penetrates the measuring object and provides a peak in the signal graph at every material transition. For example, the film thickness between two glass panes can be easily measured in this way.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Measurement of sprayed skin thickness
Sprayed skins for vehicle instruments and controls and for airbag cladding are sprayed using a robot-guided nozzle. The thickness of the sprayed skin is inspected during the spraying process. An eddy current sensor measures the distance to the nickel-coated spray mould. The eddy current sensor has an opening in the center through which the laser sensor measures the distance to the sprayed part. When subtracted, both signals provide the thickness of the applied sprayed skin.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Measurement of flat washers
These days, flat washers are an auxiliary material used in almost every industry. In most cases, the washers consist of different alloys and are required in all sizes and thicknesses, which means the demands on the manufacturers are particularly high. In order to supply the customer with a correctly sorted, high quality product, the thickness and diameter are inspected before the washers are packed. This inspection is carried out using a scanCONTROL 2910-50 laser scanner.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Windscreen thickness
Using a film between several glass panes, laminated safety glass prevents dangerous shards flying around in the case of breakage. The adhesive film is clamped during the production. In doing so, it is important that the film shows the correct thickness in order to be able to ensure the required safety. Thickness can be measured on one side using the optoNCDT2401 confocal system. The light from the sensor penetrates the glass and displays the thickness of the film in the pane.
Sensor technology applied
|
|
|
|
|
Dimensions, tolerances, sorting, part recognition
Dimensions usually designate the significant linear dimensions of an object. Dimensions can be measured in different ways. Under certain circumstances, one sensor can measure the complete dimensions for small objects. Image processing systems, laser profile sensors and ThruBeam micrometers are particularly capable of detecting complete dimensions. For larger measuring objects, the measurement can be performed using sensors which move along one edge of the target and thus measure the object dimensions. One alternative to this is that the dimension is measured with a static sensor and moving measuring objects as is typically the case for assembly lines.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Aluminum rim dimension
Maximum quality is required for the production of aluminum rims so that the necessary smooth running is achieved in the subsequent use. In contrast to tactile methods, laser scanners from the Micro Epsilon scanCONTROL series are used for this. These sensors inspect the rims for all geometric defects in an integrated tester. Therefore, a 100% in-line quality control is achieved.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Web-edge detection in the calender of a paper machine
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.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Measuring the height of concrete blocks
For the final inspection during the production of concrete blocks, a special test bench records the height of the blocks over a number of tracks. On each track, an optoNCDT 1700 laser sensor measure vertically on the conveyor belt. The blocks on the conveyor belt run through the sensor's laser beam.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Sheet edge measurement prior to laser welding
The company „Paul von der Bank“ in Hilden (Germany) develops and manufactures modular-designed robotic welding cells and fully automatic production and processing lines. To ensure high production quality of longitudinally welded pipes, the following factors must be considered: Besides sheet edge length, the exact edge position must be known, it must be guaranteed that sheet edges are aligned perfectly to each other.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Thickness and volume measurement of potato slices
When producing potato crisps, factors such as consistency, quality and taste depend to a significant degree on the thickness of the potato slices used. Depending on the process parameters and the condition of the tools used, the thickness of the cut slices changes slowly but steadily during the production time. This is why it is important to continuously monitor the thickness during production by using the scanCONTROL 2950-50BL sensor. The sensor projects a laser line onto a conveyor belt, which continuously guides sample slices along it.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Digital 3D measurement of complex parts and shapes
Mabotic devepols and manufactures various designs of digital scanning units. scanCONTROL laser scanner are often used for digitization of parts. The scanner projects a laser line onto the object being measured and records the profile of the line. When the scanner is mounted on a linear axis and the scanner traverses over the measurement target, a 3D image of the target can be generated.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Dimension inspection of cylindrical objects
The CD Express measuring instrument developed by a British company measures circumference, diameter and ovality of cylindrically shaped objects. The measuring objects are inserted in the measuring device and the measurement starts automatically. An optical micrometer from the optoCONTROL 2500 series operates in the measuring device. The software has been customised for this application so that the optoCONTROL now takes over the complete control of the measuring device.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Liquid level in falling film reactors
In falling film reactors used by the chemicals industry, the geometrical dimensions of the reactor metal sheet are measured using confocal sensors. The filling level of the liquid is also measured during this test. The channels have dimensions of 200µm depth and a width of 400µm. The advantages of using a compact beam path are fully exploited in this application example.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Thermal milling spindles
Accuracies of a few micrometres must increasingly more often be achieved for the parts machining using machine tools. In doing so, the heat development during the machining and in the tool holder is not insignificant. The thermal expansion of the spindle during the machining can affect the precision so much that the workpiece no longer meets the requirements. The SGS system developed by Micro-Epsilon is used for compensating for the expansion of the tool spindle. The expansion of the spindle is measured using the eddy current based system and in this way precise workpiece machining is made possible.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Inline burr measurement on sheet edges in body manufacture
In order to avoid corrosion, continuous and error-free corrosion protection is a critical factor in the painting process. As the thickness of the applied painting on burrs can only be determined under challenging limitations, it is a decisive advantage that the burrs are recognized early in the production process before the corrosion protection and other paint layers are applied.
In contrast to fixed solutions that enable a random test, Micro-Epsilon offers its scanCONTROL 2910-10/BL Plug & Play system which provides the required precision with its high point resolution of approx. 8µm along the laser line in order to recognize burrs reliably even during inline measurements.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Vibration measurement on carbon brushes
Many direct current electric motors operate with carbon brushes for the current transmission. optoNCDT laser sensors are used to monitor the vibration during operation. They measure the carbon brushes without contact and also measure high speeds of the motor due to their high cut-off frequency.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Coordinate measurement machine
Coordinate measurement machines are used for measuring many different components. Different scanners and measuring equipment measure the surface of the component in three dimensions. Laser line scanners from the scanCONTROL 2800 and 2700 series are ideally suited for this purpose. They measure the actual surface of the component without contact and with micrometre precision according to the triangulation principle.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Coordinate measuring machine
Coordinate measurement machines from Zeiss have been known for decades for the highest quality, precision and reliability. Also the mobile measurement machine, ScanMax fulfills these criteria, in part due to the application of inductive displacement sensors from Micro-Epsilon.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Sorting crabs
Crabs are sorted by size in a sorting system. Thereby, the crabs are transported using a vibrating unit on a roller which has a clearance between 20 mm and 40 mm. For checking the clearance, an induSENSOR series LVP is used which measures the changing clearance and shows it on a digital display. The sensor is designed in stainless steel for the food industry.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Measuring the base height of filters in the automotive industry
In automotive filter production, faultless workmanship is essential for the proper functioning of the filter. In addition, the specified height of the filter is also critical in order to prevent any damage occurring to the periphery of the filter during assembly. In cooperation with special purpose machine builder Limberger GmbH and the Signum image processing specialists, scanCONTROL laser profile scanners were integrated to a filter test machine.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Automated board measurements in wood production
Electronic Wood Systems GmbH (EWS) has launched the "dimension scan"a new approach to the automated measurement of finished boards. The market leader in measurement systems for the wood processing industry, based in the German town of Hamelin, EWS developed this innovative solution for the inline quality control of chipboards, MDF and HDF boards.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Profile measurement of mounted tram rails
Modern operating conditions for trams lead to increased wear of the wheels and rail. In order to document the wear of the rail, our customer has developed a measurement system that detects, automatically evaluates and analyzes this data. scanCONTROL laser profile scanners record the profile of the rail.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Fluid level measurement of aluminum pig irons
A German manufacturer of prestressed concrete products uses a number of 3D measurement systems by InSystems Automation with optical sensors made by Micro-Epsilon for quality control of railway sleepers. The systems include a portal station that is fitted to a forming station above the conveyor technology. Two scanCONTROL LLT2800-100 laser profile sensors travel along the portal axes and scan the sleepers from above.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Reliable quality control in the rolling mill
One of the profile rolling mills processes profile steel in reversing operation. The rod center is then measured and evaluated using a optoNCDT 1700-750BL.
Sensor technology applied
Blue Laser triangulation sensor - optoNCDT 1700BL
|
|
__________________________________________________________________________________________________________ |
Tire measurement
A 100% quality control is indispensable in tire production for vehicles. Tires without defects make an important contribution to vehicle safety. Measurement by laser scanner in contrast to point laser sensors or capacitive sensors is new for quality controls of the tires. Laser scanners inspect the surface of the tires for production defects within one second. The dimensions, size and lettering of the tires can be checked at the same time.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Calibrating robot axes
Industrial robots have become indispensable in modern production facilities due to their reliability and speed. During set up and also at regular intervals within the scope of quality assurance, the robot axes must be adjusted. Here, electronic adjustment probes have long substituted mechanical probes. The measurement probes mounted on the robot axes and acquire the zero point during the axis rotation using a probe tip. The integral electronics evaluate the probe signal and supplies a switching signal to the robot controller.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Draw-wire displacement sensors take measurements in pipe trade
In the piping industry orders are placed for fixed lengths of a certain type of pipe. The available pipes with different lengths are transported from the stores to a measurement table to process the order. Here, pipes are inserted one after the other and the partial lengths summed up using a rugged draw-wire displacement sensor. The movable stop on the table is linked to a sensor wire extension pretensioned by a springdriven motor. The draw-wire extension in the dirty section guarantees a clean wire intake in the sensor and a long service life.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Monitoring the thermal expansion of pipelines
Pipelines in power stations are stressed to their limits by pressure and temperature. These loads result in movements of the pipes which can be up to 1 metre. Constant supports compensate for the movements and show the displacement on a scale. wireSENSORs are used to notify the measurement results to a control desk. The long service life of the sensors is particularly important.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
High precision pipe measurement
High precision pipe measurement Pipes, fittings and sleeves are inspected using random sampling for their dimensional accuracy in a special system. Sensors of the optoNCDT 1700 series rotate mounted on a plate. The laser beam is deflected by 90° by an adjustable mirror for the measurement. The system produces a detailed thickness profile of the target using the difference method.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Damage prevention during production of locking cylinder
The company Aumat (Germany) develops and produces complex production systems for locking cylinders. In order to prevent any damage occurring, the operator must feed the correct blank into the production programme of the control system. This safety measure requires that a high number of components are detected and identified clearly and reliably in terms of both length and color.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Cutting edge measurement
Carbide specialist company Ceratizit uses a semi-automatic measuring machine for production control. This device checks cutting plates for dimensional stability. The cutting plates are moved horizontally for each linear axis and pass through the light beam of the optoCONTROL 2500 through-beam sensor. The edge of the cutting plate is measured exactly as a result of this movement.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Dimensional accuracy of sectional doors
With sectional doors for parquet or laminate flooring, key and slot joints for individual sections are applied. However, these sections are opened and closed frequently. To enable a robust but permanent flexible key and slot joint, specified dimensions are critical and must be adhered to. This is particularly important in the case of significant temperature differences or inaccurate dimensions, where the door could be locked or positioned incorrectly. The measurement of the key and slot joint is therefore critical in ensuring the correct manufacturing dimensions.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
High precision measurement of special profile sections in the production line
In the factory research department a fully automatic system for optical geometry measurement has been developed, constructed and integrated into a production line for lift profile rail sections. The system acquires the deviation of±0.2mmfrom straightness in both axes, the length of the section and the thickness of the rail web to ± 0.02 mm in two tracks.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Spindle growth
Spindles of machine tools are subjected to high mechanical load. This load results in thermal expansion of the spindles. The associated change in length causes a certain positioning error for the work to be performed. The SSW sensor is directly integrated in the spindle and measures the thermal expansion there of the tool holder without contact. The miniaturized eddy current sensor can also be used again immediately after a tool change. The measured value is transmitted to the CNC controller as a set offset.
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
|
|
__________________________________________________________________________________________________________ |
An automatic measurement system ensures the production quality of tablets
High performance pill presses are fitted with quickly interchangeable matrix disk units in order to minimize cleaning and setting up times when employing press tools. In automated production a high level of precision is required to ensure the quality of each individual pill. In production up to 47 stamp pairs pass through the press station in a circular arrangement and, due to their high production rate, are subject to a certain amount of wear. Here, an automatic system for the stamp measurement can ensure the optimum press quality.
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
|
|
__________________________________________________________________________________________________________ |
Monitoring embossment depth
Embossed serial numbers enable worldwide unambiguous identification of, for example, car body shells. For increased safety measures (e.g. in case of theft), car body IDs are punched into the vehicle frame. Therefore, the depth of the embossment is a critical factor.
This is why embossing machines operate using optoNCDT 1420 laser triangulation sensors from Micro-Epsilon. These determine the precise distance between the embossing tool and the component. Based on these distance values, the tool can be positioned correctly. After the embossment is finished, the sensor measures the profile of the embossment and ensures that all characters are embossed to the required depth.
Sensor technology applied
|
|
|
|
|
Shipbuilding and railway technology
|
Sensors for displacement measurement are frequently used in both these areas. In doing so, the application area starts as early as the manufacture. For example, sensors from Micro-Epsilon are used for the quality inspection. In operation, they often provide the necessary safety such as, for example, the inclination of trains. Displacement sensors are also used during maintenance and repair.
|
Ovality inspection on brake pipes using vision4A
For the highly accurate measurement of the roundness of the ends of brake pipes in production with short cycle times, only a precise and versatile vision system is able to fulfill the required rapid data acquisition with the associated evaluation. In this regard the diameter measurement of individual pipes, as normally carried out in the industry through the center of the circle, is nowhere near sufficient. For reliable quality assessment the deviation of the actually existing circular geometry must be dimensionally acquired over the complete 360° circle.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Rail wear
Tram or train rails are subject to constant wear either due to corrosion or due to friction during use. Rails are checked for wear completely automatically using a system developed by Micro-Epsilon. A test car records the surface profile of the rail during the journey. The data obtained is compared with standard values and if a section is recognized as worn down, the system stores the track section for later maintenance. The profiles are measured using several line scanners of the type scanCONTROL 2800.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Profile measurement of mounted tram rails
Modern operating conditions for trams lead to increased wear of the wheels and rail. In order to document the wear of the rail, our customer has developed a measurement system that detects, automatically evaluates and analyzes this data. scanCONTROL laser profile scanners record the profile of the rail.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Fluid level measurement of aluminum pig irons
A German manufacturer of prestressed concrete products uses a number of 3D measurement systems by InSystems Automation with optical sensors made by Micro-Epsilon for quality control of railway sleepers. The systems include a portal station that is fitted to a forming station above the conveyor technology. Two scanCONTROL LLT2800-100 laser profile sensors travel along the portal axes and scan the sleepers from above.
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
|
|
__________________________________________________________________________________________________________ |
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
|
|
__________________________________________________________________________________________________________ |
Tracking control of gantry and overhead cranes
Rail-guiding elements (wheel flanges, guide pulleys) ensure that the crane stays on the rails. Due to uneven distribution of mass, track errors, rails offset and different driving speeds, the rail-guiding elements can mesh. The lateral forces arising from this can lead to noise, stress in the crane construction or wear of the wheels and rails. Machines of this type require considerable maintenance. In order to reduce the latter, so-called tracking controllers are used in order to ensure that the crane wheels are kept central to the rail track. In this case, a number of sensors keep the controller informed about the position and direction of the crane, as well as any deviations that occur.
Sensor technology applied
|
|
|
|
|
Paper and printing technology
|
An important requirement is that the production in paper and printing technology runs without errors. Small deviations from the specified dimensions quickly become apparent during the fast running processes. Precise displacement sensors from Micro-Epsilon avoid such types of situations. Temperature monitoring in this sector is a safety function. Preventive action in systems and machines can be taken before dangerous situations occur.
|
Web-edge detection in the calender of a paper machine
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.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Print head positioning using laser triangulation sensors
When printing on materials such as glass and ceramics, very fine detailed structures are generated, which requires precise positioning of the print head. This is why 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 sensor data is transferred via the RS422 interface to the control system. The data obtained enables the determination of the edges and the surface tilt and therefore the exact positioning of the print head.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Rebound behavior of the felt
In paper production the paper band is transported over a felt conveyer from the screen station to the pressing station. This felt removes the residual moisture from the paper. For water separation the felt passes a defined gap between the central and the suction roller. The wear and the rebound behavior of the felt determine the hygroscopy and are thus of decisive importance for the paper quality. Laser-optical position measuring systems monitor the wear at a guide roller. Measuring with two sensors compensates the ovality / stroke of the guide roller. The result of the measurement is the effective thickness of the felt. If the measured value falls below the specified limits of wear, the production can be stopped and the felt can be replaced. Because of the difficult environmental conditions the sensors are installed in a protective housing.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Thickness measurement using displacement sensors
Thickness measurement using displacement sensors is a wide application area. Basically there are distinctions between non-destructive/destructive, non-contact/with contact and one-side/two-sided thickness measurement. The Micro-Epsilon measuring techniques for thickness measurement are all emission-free whereby no emissions regulations of any kind have to be complied with. Thickness measurements must be performed both with contacting as well as with non-contact sensors whereby non-contact measuring techniques show advantages as regards accuracy and measuring speed. There is also a distinction between one-sided and two-sided thickness measurement. Two-sided thickness measurements are carried out with at least one pair of sensors which are installed together on one axis. This pair of sensors measures the target synchronously. The difference between the measurement results (C-A-B) produces the thickness of the measuring object. One-sided thickness measurements must only be performed with non-contact sensors. In doing so, the target is only measured with one sensor and either only a part of the target thickness (e.g. layer thickness) or the complete measuring object thickness is measured. Thickness measurements are mainly used in process control and quality assurance, e.g. for the control of extrusion systems or 100% checking of tube diameters.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Automatic paper roll control
In paper production the prepared paper pulp flows onto a conveyor belt of fine wire mesh at the so called "wet end". There most of the water is removed by means of a vacuum. The paper web is generated and is transported to the second station, the wet press rollers, which determine the paper web speed by means of a second drive unit. In order to avoid tears in the paper web a laser position measuring system is used here which measures the position of the paper web between the two stations. The analog output signal of the sensor is fed into a closed-loop control circuit which influences the motor speed at station 1 and thereby ensures that a specified setpoint distance value is maintained.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Paper fold recognition in printing machines
Possible folds produced in the paper web that remain unnoticed can have far-reaching consequences during processing and often lead to unusable printed products. Extreme differences in printing registration, i.e. inaccuracies when correlating overlapping colors may also occur. Another risk is that the paper web tears while going through the print machine. Any machine stoppages or changeovers can significantly increase printing costs. Non-contact, optical measurement technology is a suitable solution.
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
|
|
__________________________________________________________________________________________________________ |
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
|
|
__________________________________________________________________________________________________________ |
Layer thickness measurement (non contacting)
Layer thickness measurement belongs to the group of one-sided, non-contact thickness measurement. Basically, only the layer thickness of electrical insulators can be measured for opaque objects. An eddy current sensor penetrates the insulating layer without damage and measures the distance to a layer underneath it. At the same time, a second sensor, a laser triangulator measures the insulating layer. The layer thickness is obtained by offsetting both signals. This method of measuring with two sensors using different principles is called the dual sensor technique by Micro-Epsilon. A second possibility is the layer thickness measurement of transparent materials using confocal measurement technology. The emitted white light penetrates the measuring object and provides a peak in the signal graph at every material transition. For example, the film thickness between two glass panes can be easily measured in this way.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Measurement system for cut packaging pieces
Manufacturers in the packaging industry make high demands with regard to their production quality. For sampling inspection for example, the cut pieces of packaging are extracted from the production, placed in a measurement system and a nozzle system draws them down flat by suction. A non-contacting triangulation sensor scans the surface to measure the topography of the cardboard and to determine the line of the grooves, edges and the associated lengths to high accuracy.
Sensor technology applied
|
|
__________________________________________________________________________________________________________ |
Roller levitation height
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 lift of the upper roller 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 at the height of the lift. 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
|
|
__________________________________________________________________________________________________________ |
Roller runout
The runout of the roller is a crucial criterion for rolling processes of metals, plastics or other materials. An imbalance is even dangerous for rollers which have to rotate at high speeds. Therefore, the roundness of the roller must be measured before and also during the application. For all the following processes, a sensor measures the roller directly and establishes the ovality. The non-contact eddy current method is used for rollers made of polished metal. Capacitive or laser triangulation sensors are used for rollers made of other materials.
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
|
|
|
|
|
Defense & Security
|
There are many applications in the military and armaments area. Current equipment and vehicles usually show a high degree of electronics, automation and thus also sensors. Sensors from Micro-Epsilon are seldom used thereby in series production, but rather for the further development and research.
|
Thickness measurement using displacement sensors
Thickness measurement using displacement sensors is a wide application area. Basically there are distinctions between non-destructive/destructive, non-contact/with contact and one-side/two-sided thickness measurement. The Micro-Epsilon measuring techniques for thickness measurement are all emission-free whereby no emissions regulations of any kind have to be complied with. Thickness measurements must be performed both with contacting as well as with non-contact sensors whereby non-contact measuring techniques show advantages as regards accuracy and measuring speed. There is also a distinction between one-sided and two-sided thickness measurement. Two-sided thickness measurements are carried out with at least one pair of sensors which are installed together on one axis. This pair of sensors measures the target synchronously. The difference between the measurement results (C-A-B) produces the thickness of the measuring object. One-sided thickness measurements must only be performed with non-contact sensors. In doing so, the target is only measured with one sensor and either only a part of the target thickness (e.g. layer thickness) or the complete measuring object thickness is measured. Thickness measurements are mainly used in process control and quality assurance, e.g. for the control of extrusion systems or 100% checking of tube diameters.
Sensor technology applied
|
|
|
|
|
|
