Sensors & transducers
the separating point between the single stitches and outputs the evaluation directly as ‘O’ (NOK) or ‘1’ (OK) via its Ethernet interface. Beyond that, the height difference between two single stitches is directly inspected in order to recognise any faulty assemblies immediately.
Gap monitorinG in car interiors
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. scanCONTROL laser profile scanners from Micro-Epsilon are being used to detect the contour of the stitching while being guided by robot arms, evaluating several features synchronously. The laser scanner continuously inspects the distance between the stitching and
Car interiors present a number of gaps, for example, between the single cockpit elements such as the centre 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. Even minor faults can therefore catch the buyer's eye and negatively influence their purchasing decision. The gapCONTROL profile scanner inspects the gaps of all parts in the car interior during final assembly. Depending on the inspection situation, a single scanner
applied on a robot arm can measure different gaps in a static or dynamic mode; alternatively, a special frame on the robot arm is used that enables the scanner to detect a number of different gaps in the interior in static mode within fractions of a second. The sensor then evaluates the measurement values and sends a signal to the control system if the values measured lie within the tolerances defined by the customer.
robotic weld inspection systems
Laser profile sensors are also installed on a groundbreaking automatic weld inspection system that is specifically designed to inspect thin section steels and thin gauge welds on ships and other marine vessels. The system inspects the weld and classifies it by means of laser, ultrasound and electromagnetic methods. The system uses a crawling robot that deploys remote volumetric surface and visual inspection to verify the integrity of welds on the hull plates of ships during manufacture and in the servicing of shipping vessels. Micro-Epsilon’s scanCONTROL LLT 2700-100
laser profile sensor is an integral part of the measurement system, providing the laser profile data required to verify and analyse the quality of thin steel and welds.
Most of the inspection techniques used
today have proven to be disruptive to the manufacturing process and are far from cost effective. New generations of ships are being built from thinner section steels in order to lower the cost of build and ship operations and so typical assessment methods are not as effective as they were for thicker sections. Therefore, there is a genuine need for a more reliable, faster, cost effective and safer inspection technique. By combining ultrasonic phased array,
electromagnetic ACFM (Alternating Current Field Measurement) and laser optical methods, the robotic inspection system enables the detection and sizing of surface breaking and sub- surface flaws or defects. By developing laser-based tracking and a self-controlled robot, the system enables automatic inspection following the weld run. The scanCONTROL 2700-100 has proven to
be very reliable, providing very high resolution measurements that are required in order to successfully detect small weld defects, which can measure just a few millimetres in diameter, or even down to a few microns if the defect is a weld crack or notch. The scanCONTROL sensor outputs the
profile measurement data to the system’s robot control system for guidance purposes. This is very important too, as the robot needs to accurately follow the centre of the weld line at all times. The robot cannot be allowed to deviate from this centre line, otherwise the ultrasonic and ACFM inspection systems will not be effective.
inteGration service
Micro-Epsilon offers an integration service for complex or multiple laser sensor configurations. This includes on-site sensor set up, visualisation and data logging, as well as ongoing technical support. The service is available for both new applications and retrofits when a customer needs to expand an existing sensor/ measurement system.
Micro-Epsilon Instrumentation Monthly February 2019
www.micro-epsilon.co.uk 27
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