MANUFACTURING TECHNOLOGY Mectron advances technology
On a recent trip to the US, Phil Matten met with Scott Corrunker, vice president of Mectron Engineering, to discuss technology developments that ensure Mectron’s high-speed inspection systems meet the needs of European fastener companies.
A
personal visit to Mectron underlines several things. First is the level of commitment invested in research and development. This is reflected not only in its technical facility but in the growth of highly qualified
personnel dedicated to Mectron’s future technologies. An example of this technical competence is the manufacturing
of Mectron’s own lasers in-house. Two recent developments in Mectron’s industry leading LSR-30 lasers emphasise the significance of that direct control. Mectron has introduced a patent pending design to both sender and receiver that angles the laser precisely to the pitch of the fastener thread, probing the thread root for defects more effectively than ever before. Combined with Mectron’s tilt laser array plate, which substantially increases detection in previous blind spots under the head, the result is superior accuracy and detection capabilities. At a practical level, design changes have also been implemented to the LSR-30 laser receiver to improve the ability to keep the laser lenses clean from today’s increased use of organic coatings and plating. This ensures the field of detectability is not compromised. These developments have already proven their worth in Mectron’s own contract sorting operation – delivering up to a 35% improvement in throughput and efficiency.
“This has been one of our biggest innovations over the last five years…”
These improvements are very significant for Mectron’s in-house
contract sorting facility, which has the capacity to process one million pieces per day for some of the most demanding US parts manufacturers. There can be no better proving ground for Mectron’s technical developments. The new modular design of Mectron’s Q-series ‘Flex’ machines
is also presenting major user benefits, permitting much easier upgrades and improvements in serviceability. Previously the base and tooling of Mectron’s two-laser system was different from the six or eight-laser system. The new design allows ‘two-laser’ machine owners to easily upgrade to six or eight-lasers. Just as importantly, the design facilitates the addition of eddy current detection, the tilt laser array plate, and/or CCD vision cameras
complete with Mectron’s LED light ring illumination. These changes provide the opportunity for a ‘two-laser’ machine owner to make the transition to total part inspection without having to purchase an entirely new system. Amongst an array of developments, Scott Corrunker singles
out two that are of major importance to Mectron customers. Mectron’s new laser length analyser has already made its mark, providing measurement of feature lengths, stack-up, head height and overall lengths. “Integrated with Mectron’s 360° laser array for diameters, the laser length analyser allows for complete multi-axis inspections,” explains Corrunker. Adding: “This has been one of our biggest innovations over the last five years, and is particularly important to some automotive applications.” Corrunker is also clearly excited by Mectron’s development
of rotational crack detection. In fact, evolution would probably be the better term as Mectron has been successfully operating high-speed crack detection in its own contract sorting operation for more than five years. “One of Europe’s leading fastener manufacturers, and a long standing Mectron customer, once described this area as ‘Mectron’s only black hole’,” reflects Corrunker. “So the release of this new system in conjunction with the best dimensional lasers in the market today means Mectron has set a new bar in complete inspection control to meet the high demands of the European fastener market.” Similar to Mectron’s other equipment, the Rotational Crack
Detection System is fed from custom-built vibratory systems that will orientate diverse configurations of fasteners. An independent, continuous rotation inspection disc provides a two-station dual channel eddy current instrument. Using one channel and a differential probe for crack detection and one channel with a differential coil for hardness detection that is proficient in multiple frequency testing, the operator is armed with the largest range of inductance when diagnosing today’s challenging metallurgical combinations. The two-stations allow 360° crack detection and hardness testing at speeds up to 200ppm. With existing eddy current systems on the market typically operating at 60ppm – 120ppm, that represents a major advancement in detection efficiency. This is particularly impressive when one factors in the level of detection capability, picking up hairline defects undetectable to camera systems. The new Rotational Crack Detection System can be integrated
to any existing Windows based Mectron system. It will make its first general appearance in the US market at the upcoming National Industrial Fastener & Mill Expo in Las Vegas, 22nd October 2014. Visitors to National Machinery’s 140th Anniversary Open House, 23rd – 25th
September 2014, will also have the
chance to learn more about it from Mectron representatives. The new system, together with all of Mectron’s developments and capabilities, will be features at the Fastener Fair in Stuttgart, Germany, 10th
– 12th March 2015.
www.mectron.net 100 Fastener + Fixing Magazine • Issue 89 September 2014 – 24th
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