Chemical industry, process automation

Automatic height adjustment for material analysis

Laser-induced breakdown spectroscopy (LIBS) performs precise analysis of the atomic composition of different materials. The measurement objects involved are mostly mineral or metallic parts whose surfaces have different gloss levels and which are sometimes extremely tilted.

SECOPTA analytics GmbH uses the ILD1320-100 sensors from Micro-Epsilon in this application to automatically readjust the height of the LIBS sensor head. Particularly with metal samples whose surfaces have different textures such as oxidized spots, the ILD1320 with the ATC feature is a reliable sensor.

Sensor technology applied

On-line inspection of sealing compound in covering lid

After injection of the sealing compound in the covering lid, curing takes place in the tunnel furnace. Here, fault points and faulty thicknesses of compound must be acquired and faulty lids must be sorted out in the production process. A laser-based optical displacement measurement system samples the compound surface of the rotating lid for a quality inspection. The monitoring of the thickness contour within the permissible tolerance limits and the sorting of the faulty lids occurs with the aid of the PLC that is employed.

Sensor technology applied

Extruder bore diameter

The idiamCONTROL system has been developed for checking the wear of extruder bores. The measuring cylinder is inserted in the case bore and pushed as far as the upper end. During retraction of the cylinder, several capacitive sensors measure the case diameter on several tracks. Specially for double worm extruders, the measuring cylinder has two metal pins which run along the saddle of both bores and in this way prevent rotation of the cylinder.

Sensor technology applied

Absolute and continuous filling-level measurement

Continuous acquisition of the level must be ensured for high precision monitoring of filling levels. These requirements can be obtained with a MICROEPSILON vipSENSOR element whereby the actual sensor is integrated into a specified housing. The specified length of immersed tube can be optimally used as the measurement range due to the compact design and the very short installed length of the sensor element. This ensures a highly accurate, continuous filling level measurement from completely filled to completely empty.

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

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

Filling level

A filling level measurement situation can arise with a liquid substance as well as with dry, bulky goods. The precise measurement of liquid levels is difficult to achieve, nevertheless, the confocal measuring technique is a suitable solution for this problem. Light is also reflected on the surface of liquids and thus provides a reliable result. Filling levels of dry bulk materials are easier to measure due to the surfaces. The ILR Time-of-Flight sensors are suitable for deep containers. Laser sensors from the optoNCDT group are available for shorter sections.

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

Construction industry, building materials

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

Automatic height adjustment for material analysis

Laser-induced breakdown spectroscopy (LIBS) performs precise analysis of the atomic composition of different materials. The measurement objects involved are mostly mineral or metallic parts whose surfaces have different gloss levels and which are sometimes extremely tilted.

SECOPTA analytics GmbH uses the ILD1320-100 sensors from Micro-Epsilon in this application to automatically readjust the height of the LIBS sensor head. Particularly with metal samples whose surfaces have different textures such as oxidized spots, the ILD1320 with the ATC feature is a reliable sensor.

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

Determination of the thermal conductivity of building materials

An important criterion for the quality of porous concrete is the thermal conductivity. It varies in the final product due to quality differences in the raw materials used (including sand and natural lime). An internal determination of the thermal conductivity using a double-plate device as in DIN 52612 Part 1 immediately after production enables a substantially faster reaction in comparison to the previous external testing of samples. The double-plate device available to the user was equipped with a computer system with application-specific evaluation software. The software was developed with the modular software toolbox ICONNECT.

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

Lift height measurement for maintenance work on bridges

In certain cases for maintenance work on bridges, the bridge must be raised, for example to replace the supports. Heavy-duty jacks are used for this. The distance at each jack is measured with a draw-wire sensor so that the jacks operate completely in synchronization.

Sensor technology applied

3D inspection and surface assessment of roof tiles

The production of roof tiles places high demands on measurement and testing methods for ensuring constant high product quality. In the DASTOKON semi-automatic measurement and test system and in the BSPK pilot plant a laser triangulation sensor of the Series ILD 1800 is used for the 3D inspection and for surface assessment.

Sensor technology applied

Defect recognition on worktops

Kitchen worktops are now made from a variety of materials, e.g. natural or artificial stone, solid wood and laminate (e.g. HPL). All these materials offer benefits and have special characteristics. However, a defect-free surface finish and perfect edges are critical production factors. The example above is a so-called laminate worktop with a stone decor. As the cutting edge of this top is rough and unclear, it is covered with sidebars. Foreign bodies, uneven distribution of the adhesive or unevenness when closing may produce open joints between the top material and the sidebars. The scanCONTROL 2910-25 laser profile scanner is used to inspect if any open joints are present.

Sensor technology applied

In-line detection of protective film on PVC window frames

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

Sensor technology applied

Color detection of kitchen fronts

Kitchens are available in many different colors. In order to guarantee that the customer receives the desired color, the colorSENSOR OT-3-MA-30-16 inspects the color of the kitchen fronts in the painting plant.

Sensor technology applied

Color measurement of the floorboards

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

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

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

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

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

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

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

Measurement of the radial deviation of a cutter disk

Sensor technology applied

3D profile measurement of soil samples

German automation company Visutronik GmbH from Neubrandenburg, Germany has developed a laser scanningdevice to measure surface soil samples for subsequent geometric analysis: roughness, surface type expansion (e.g. earthworm courses), etc. The core of the measuring device is the scanCONTROL 2700-100 laser scanner.

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

Filling level

A filling level measurement situation can arise with a liquid substance as well as with dry, bulky goods. The precise measurement of liquid levels is difficult to achieve, nevertheless, the confocal measuring technique is a suitable solution for this problem. Light is also reflected on the surface of liquids and thus provides a reliable result. Filling levels of dry bulk materials are easier to measure due to the surfaces. The ILR Time-of-Flight sensors are suitable for deep containers. Laser sensors from the optoNCDT group are available for shorter sections.

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

Measurement of pre-stressed steel

An inspection system for incoming goods inspection has been developed for a manufacturer of pre-stressed concrete, which detects the profile depth of delivered batches and continuously records this information to a database.

Sensor technology applied

Non-contact roller measuring device

In the cement and mineral industry roller mills are used for fine grinding of the raw materials. During the milling process the rollers are subject to high wear, which strongly reduces the quality of milling at the edges of the rollers. With a laser-optical roller measuring device the necessary regrinding process can be initiated at the right time, and the success of such regrinding can be determined. A protective device with special damping elements and air nozzles protects the laser-optics sensor against vibrations, and keeps the optical system and the beam path free of dust.

Sensor technology applied

Flatness inspection on ceramic wall tiles

In the production of ceramic wall tiles or similar products, a one hundred percent quality inspection is essential. Three laser triangulation displacement sensors measure the deflection of tiles with an accuracy of 0.1 μm. Separate specification values can be entered for concave or convex deflections.

Sensor technology applied

Automotive test bench

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

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

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

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

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

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

Vehicle distance to the road surface

The tilting and the driving behavior are often examined in driving tests with automobiles. Optical laser sensors are ideally suitable for this. They are mounted outside on the body shell and measure the distance from there to the road surface. The high measuring rate ensures a sufficient signal for evaluation of the road position of the vehicle.

Sensor technology applied

System for testing the risk of creaking with combinations of materials

Ziegler Instruments in Mönchengladbach, Germany develops  and  manufactures  test  systems  that  are  able  to predict the risk of creaking noises due to stick-slip vibrations. In this way, the movement of different material combinations relative to each other - so-called „stick-slip“ - can be examined. For example, a passenger car driving for 100,000km can be simulated in the laboratory in just a few hours.

Sensor technology applied

Profile sensor for tire measurement on the test rig

Tire properties are crucial for safety, driving response and comfort in modern automobiles. To ensure constant quality at the highest level 100% inspection of tires is already required in production. Apart from dynamic stress tests, the acquisition of bulges, constrictions and impacts is of primary importance.

Sensor technology applied

Tester for (railway) wheel rim measurement

Testers are integrated in the track bed for the wear control of wheel rims on trains. The profile is checked during the passage of the train. Point-type and line-type lasers measure the diameter and the profile of the wheel. Thus, a precise statement of when the wheel must be reprofiled is possible. The measuring technology thereby is exposed to all weather influences.

Sensor technology applied

Tire surface

Three laser scanners from the scanCONTROL series measure the surface profile of tires. The turnkey tester is at the end of the production line where each tire is examined for dents and bulges. The tire is clamped and rotated by 360° within one second. Lettering and symbols are recognized by the software and not assessed as bulges. The process takes place completely automatically and makes a 100% check possible. The tire is reintroduced back into the production process after completion of the testing.

Sensor technology applied

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

Measuring vibrations on an engine manifold

Optimizing the processes within an internal combustion engine is becoming increasingly important in this day and age. A whole series of measurements is vital for engine management purposes. The temperature of the exhaust gas is one important source and is recorded using a thermocouple within the manifold. To check the way it is attached, it is necessary to examine the propensity to vibrate, as well as the mechanical rigidity of the structure. This is an application where the blue laser comes to the fore.

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.

Automotive production

Color recognition for seams in automotive interiors

A well-known German car manufacturer relies on poka-yoke mechanisms for assembling interior components. The poka-yoke process prevents product defects due to random human errors and ensures that all parts are assembled correctly. However, similar types of component often have different colored seams, which is why error prevention is critical. Previously, these checks were performed manually - experts inspected the seams visually. Micro-Epsilon’s colorSENSOR LT-3-HE color sensors are now used to automate this process and to make it more efficient.

Sensor technology applied

Color measurement of liquid paint

Measuring the color of liquid paint is extremely complex. To date, paints have been typically applied on a test area first and then measured only after the drying process in order to achieve reliable measurement results. If the measurement results reveal that the paints are faulty, the paint con­tainers must be mixed again or even disposed of which partly involves long waiting times until a new measurement process can be started. In order to accelerate this process, Micro­Epsilon has developed a sys­tem that enables the measurement of liquid paint during the production process.

This application therefore includes the colorCONTROL ACS7000 color spectrometer for color measurements and the optoNCDT 1420­50 laser triangulation sensor for distance measurements. The latter is ideally sui­ted to this application due to its compact size and excellent performance. A linear unit offers automatic readjustments.

Sensor technology applied

Color and intensity tests of vehicle lights

At the end of their production process, vehicle lights must be 100% inspected. Color and intensity of the finished lights are the primary inspection criteria. Homogenous distribution of light should also be guaranteed with fluctuating LED batches. The LED colorCONTROL MFA Analyzer performs this color inspection. The lights are positioned via a corresponding form so that the optical fiber can test at different points simultaneously, which ensures that every single LED is controlled. State-of-the-art 3D printing technology enables the adaption to the vehicle light.

Sensor technology applied

Color comparison between parking sensor and body shell

Car attachments such as parking sensors are painted separately. However, during assembly there must be no difference in color between the parking sensor and the bumper, which means the two colors must be identical. The colorSENSOR LT-2-DU sensor from Micro-Epsilon enables a direct color comparison between the parking sensor and the rear bumper.

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

Adhesive beading check on border strip

Border strips are automatically adhered to glass by robots in vehicle production. This automatic process must be monitored as the application of uniform adhesive beading by the robot is not certain. The adhesive beading is checked immediately after the application by the same robot using a scanCONTROL 2810 for height, width and position.

Sensor technology applied

Robot positioning for application of seals

In order to permanently protect weld seams against the penetration of moisture, BMW AG’s Leipzig factory seals the weld seam on the roof rail. A robot automatically applies sealant at the position where the side frame  is joined to the roof panel. A laser sensor from Micro-Epsilon, which prepositions the robot using distance measurement, is used so that the robot knows exactly where each weld seam is located.

Sensor technology applied

Adhesive beading check

It is important during the gluing in of glass panes in automobile production that the adhesive beading shows a constant track. Therefore a robot arm tracks the adhesive beading track exactly with a scanCONTROL laser scanner. In doing so, the robot centers itself on the adhesive beading automatically due to the measured data. In doing so, the scanner measures the surface profile of the adhesive beading. The supplied software automatically detects whether the beading is too narrow, too wide or too flat.

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

Paintwork defects

The exterior appearance is an important factor for many surfaces. The reflectCONTROL inspection system is suitable for automatic defect inspection of reflecting surfaces. This system measures the quality of the surface without contact using light reflections and classifies the defects found. The system is particularly suitable for painted surfaces or smooth plastic. Different versions make possible adequate usage for automobile body shells or smaller elements.

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

Automatic positioning of synchronizer discs

Synchronizer discs are used as a synchronizer package in automatic transmissions. Behr Systems in Germany created a handling and processing plant for deburring the front side of the synchronizer discs using a laser. An essential part of this plant is the measurement technology, which guarantees the precise positioning of the synchronizer discs under the deburring laser.

Sensor technology applied

Stitching position of airbags

As interior parts, the covers must therefore harmonise with the overall appearance. The high aesthetic requirements placed on the cockpit, seats, interior trim and steering wheel are particularly important for this functional component. While assembly gaps cannot be measured prior to installation, like many other elements of a car, the airbag stitching can be inspected during production by using a scanCONTROL 2910-25 laser profile scanner. The scanner detects the contour of the stitching while being guided by a robot arm and evaluates several features synchronously.

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

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

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

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

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

Windscreen defects

During the production of windscreens, it can happen that the correct curvature of the windscreen has not been maintained or the fissures and cracks in the surface make the windscreen unusable. A system has been developed for this purpose which inspects the windscreens completely in-line for a surface free from defects. Several confocal sensors on a measuring beam measure the distance to the surface. Using the automatic centering function of the confocal sensors, they track the curvature of the surface precisely. The high resolution makes it possible to inspect the windscreen for cracks and fissures at the same time.

Windscreen profile

Flat glass for demanding industrial tasks is subjected to 100% testing after the production. Dimensional accuracy is important for industrial glass which is used for demanding technical tasks. Examples of such types of glass would be windscreens, display glass for LCD televisions or glass for the production of photovoltaic modules. Even a small deviation from the required geometry or thickness can drastically influence the later function of the glass. The glass profile measuring system uses confocal sensors. These operate with white light and precisely measure the profile of the pane and also an inner layer. A laser scanner is also used for determining the measurement.

Sensor technology applied