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

Automotive development

Sensor systems in the car

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

Sensor technology applied

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

Brake disc concentricity

Brake discs are subject to the highest loads in use and are responsible for the safety of vehicles. For this reason alone, brake discs are thoroughly inspected on test benches. Brake discs are checked for various characteristics at a speed of approx. 2000 rpm on special testers. Capacitive sensors are used for checking the geometric characteristics such as concentricity, thickness and wear. As the deformations only occur in the range of hundredths of micrometres, only very precise sensors can be considered for this. The thermoMETER infrared sensors are used for examining the thermal characteristics of the brake disc. The absolute temperature can be monitored with these so that the thermal drift over a long period can be established.

Sensor technology applied

Brake disc temperature measurement for Formula Student

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

Sensor technology applied

Injector needle lifting

Combustion engines are a combination of many different technologies. Therefore, the precision of each individual one is responsible for the performance of the engine. The actual injected amount of fuel for Common Rail engines is controlled by the lift height and the lift duration of the jet needles of the injector. Temperatures up to 150 °C, pressures up to 2000 bar and an electromagnetically sensitive environment make measurement evaluation difficult. The NLS miniature sensor of the eddyNCDT product group measures the needle movement at the tip of the injector where influences due to bending or compression of the needle do not even occur.

Sensor technology applied

Monitoring the commutator in electric motors

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

Sensor technology applied

Pistons

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

Sensor technology applied

Piston – Top Dead Center

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

Sensor technology applied

Piston Secondary Movement and Piston Ring Position

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

Sensor technology applied

Piston ring- and piston secondary movement

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

Sensor technology applied

Piston secondary movement

Among other things, the lateral movement of the piston in the cylinder is crucial for the service life of engines. Miniature eddy current sensors for this are integrated in the piston which measure onto the cylinder wall. If the distance is too large or too small, the piston has too much play or continuous lubrication cannot be ensured. The sensor cables are routed out of the engine along the connecting rod over a rocker in the gearbox.

Sensor technology applied

Image processing system for the detection of markings

In order to increase the process reliability in the final assembly of cars it is necessary make a reliable differentiation between the wheel and spare wheel on different types of vehicle once the tire has been fitted to the rim. For this purpose line markings are applied to the sides of the tire. They must be reliably and fully automatically detected when all components (tire,rim, transport belt) are optically similar (matt black).

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

Clutch wear in racing cars

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

Sensor technology applied

In-line inspection of the rubber on windshield wiper blades

A faultless surface is indispensable for the functionality of wiper blades. Therefore, wiper blades are inspected by the measuring system after the extrusion in the endless state. In doing so, two scan CONTROL 2800 sensors are used. The inspection is performed above and below the material.

Sensor technology applied

Lubrication gap

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

Sensor technology applied

Turbochargers

Apart from the angle of the guide vanes, the speed of the vanes on the turbine wheel is important for the performance of the turbocharger. The rotation of the vanes is measured on the face side for this. Due to increasing material stresses and speeds besides aluminum, titanium vanes are now being used, which presents a challenge in terms of measurement technology. Titanium is a very poor electrical conductor. Therefore, eddy current sensors cannot be used easily on titanium. With varying speeds from 200 to 400,000 rpm, it is extremely difficult to measure these precisely. However, using special linearization and an advanced electronics system, Micro-Epsilon is able to precisely measure this speed on aluminum and titan vanes over the whole speed range.

Sensor technology applied

Measurement of valve movement

In order to optimize engine power, fuel consumption and valve lifetime, it is important to measure the exact valve movement in the running internal combustion engine. Using eddy-current displacement sensors it is possible to acquire the position of intake and exhaust valves. This can occur both in towing and in normal powered modes. Different measurement arrangements are practicable for these two modes of operation.

Sensor technology applied

Valve lift measurement in the MultiAir cylinder

The MultiAir cylinder procedure patented by FIAT / Schaeffler controls individual valves independently of the camshaft. An electro-hydraulic control system provides fully variable valve control.

Therefore, the stroke and the opening/closing times of the inlet valve are freely controllable. This reduces fuel consumption and CO2 emissions with a simultaneous increase in engine performance and torque.

During the end-of-line inspection of the MultiAir components, a test bench simulates the conditions inside the engine. Eddy current sensors from Micro-Epsilon measure the exact valve lift.

Sensor technology applied

Valve lift sensor

Controlling the valves of combustion engines using electromagnetic actuators is a current objective of many engine developers. This technology makes possible potential fuel consumption savings of 8% - 9%. Sensors for checking the movement are necessary in the course of electromagnetic valve control. The valve lift sensor of the VIP series makes this possible without contact, with high resolution, linearity and excellent temperature stability. The sensor operates without permanent magnets and is thus not influenced by neighboring devices or components.

Sensor technology applied

Oil film thickness measurement in an internal combustion engine

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

Sensor technology applied

Displacement/timing measurement in the common rail injector

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

Sensor technology applied

Examination of the oscillation behavior of toothed-belt camshaft drives

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

Sensor technology applied

Low cost sensors for cylinder applications

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

Sensor technology applied

Cylinder breathing of the cylinder head gasket

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

Sensor technology applied

Measurement and automation technology

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

Bore hole depth

It is essential to measure in bore holes for some applications. In doing so, the depth or the wall structure of a bore hole can usually be measured. Only confocal axial or radial miniature sensors with 4 mm external diameter are suitable for this. Triangulation sensors would not provide any measurement results due to the shadowing of the laser in bore holes. The target material is not important for confocal sensors.

Sensor technology applied

Inspection of sockets

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

Sensor technology applied

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

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

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 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 measurement of LED panels (RGB)

When RGB LED panels are produced, the challenge is to create a uniform, completely homogenous surface. Therefore, a diffuser layer is used, which enables a regular scattering of the otherwise point-shaped LED light. In order to avoid defects in the material and during production, the inline colorCONTROL ACS7000 color measurement system is used with the ACS3-TR receiver unit. Errors can therefore be recognized during the production process itself rather than the previous method of manual final inspection, which is no longer necessary.

Sensor technology applied

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

Measurement of large geometries with precision machines

Measuring complex part geometries is a task for the scanCONTROL laser scanner. Laser scanners are used in the precision machines of EHR in order to perform a component inspection at high resolution and without contact. The special feature is that using a scanner, not only is an inspection possible from the outside but also from the inside.

Sensor technology applied

Overhead conveyor distance

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

Sensor technology applied

Optical sensors in side trimming systems of saw mills

The tree trunk cut into planks in saw mills still shows the wane of the original tree on the edges. In order to achieve an optimum cutting width and thus a maximum yield here, laser triangulation sensors are installed every 30 to 50 cm which measure the transverse section of the plank in the flow path. The maximum width of the plank is calculated using special software.

Sensor technology applied

Measurement system for the flat setting on carding machines

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

Sensor technology applied

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

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

Bearing shell surface

Sliding bearings are used in combustion engines for the crankshaft and camshaft. The bearing shells are often composed of three layers whereby the inner layer is only metalized or sputtered. If there are residues on the bearing shell, the inner layer has too little purchase and flakes off. The system from Micro-Epsilon checks all bearing shells at the end of the production for a faultless condition of the surface. A BV camera records an image of each shell which is evaluated afterwards completely automatically. If necessary, the system also takes over the selection afterwards depending on the measurement result.

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

Measuring of the haptic contact temperature

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

Sensor technology applied

Measurement of the zinc strip color in the production plant

In the production of high-quality material strips and boards made out of titanium zinc, the surfaces receive specific treatment. Therefore, the coloring of the zinc products is already determined during the production process.

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

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

Automatic test station for heat exchangers

Heat exchangers in plant and machinery serve as heat transfer mechanisms between different material flows. To maximise the heat-emitting area, they are designed using multiple plates. Respectively one connecting flange for the material-conveying cables is welded or soldered onto the last plate. The position and the flatness of the flanges have to fulfil highest requirements so that these can be connected  at  the  desired  point.

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

Vibration test of wet razor

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

Sensor technology applied

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

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

Welded sheets on gas valves

For automatic welding processes, the quality of the weld is often dependent on how precisely the welding head is positioned for the seam place. If the positioning is checked by a measurement system before the welding, unnecessary rejection can be prevented right from the start. The elster company uses the scanCONTROL 2810 profile sensor for this. The position of the scanner to the valve is initially measured eight times before the welding process. The laser welding head is positioned to the seam based on these data.

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

Conveying technology

Lift platform - automotive

Short cycle times for the assembly are extremely important in automobile production. In order to design the optimum ergonomics for the worker, the vehicles are transported along the production line on ...

Sensor technology applied

Lift platform – lift height

Side supports against tipping over are installed for lift trucks and lift work platforms. The crane or the platform can only be put into operation when the supports are completely extended so that there ...

Sensor technology applied

Lift height for two-column lifts

There is no connection between the columns for modern two-column lifts. Nevertheless, the lift height must be changed synchronously. Draw-wire sensors are being used more and more often for the reliable ...

Sensor technology applied

Crane support distance

A truck-mounted crane is frequently the better solution in many cases where loads have to be lifted. As a mobile solution, safety also plays an important role here. Therefore a load torque limiter controls ...

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 ...

Sensor technology applied

Rack control unit - lift height

The frequently used automatic rack control units make modern warehousing much easier. These units must automatically travel long distances and position the products with millimetre precision at the end. ...

Sensor technology applied

Forklift lifting height

A large part of internal transportation is performed by forklifts. The risk of tipping the forklift when products are lifted is high. Therefore, the permitted speed has been restricted with limit switches. ...

Sensor technology applied

Synchronized lifting system lift height

Mobile lifting jacks are being used more and more often for commercial and railed vehicles. The lifting jacks for commercial vehicles are often designed as column lifts. In contrast, railed vehicles are ...

Sensor technology applied

Precision synchronized lifting system

Synchronized lifting systems enable the raising and lowering of heavy loads controlled for distance and force or the controlled forward feed of large components. To achieve this, eight or more cylinders ...

Sensor technology applied