Sensors and Their Roles in Car and Tire Manufacturing

The production of automotive parts is highly automated. There is an involvement of measurement technology in processing lines and robots in nearly every production process. The demand for production safety, process stability and quality requires the application of reliable and accurate measurement systems and sensors.

Mounting Windscreens

Today, a windscreen in the car is much more than a simple glass sheet, which keeps the driver safe from headwind. It plays key role in the car construction and helps resist shocks and high variations of temperature. Using the adhesive beading perfectly to the screen edges is a decisive process. Therefore, the laser profile scanner scanCONTROL measures position and height of the adhesive beading on the edges of the screen. A robot places the glass in front of the bodywork and after determining the position by light section sensors, the screen is placed centrally into the bodywork. This method is carried out in real time and incorporated in the regular automotive production process of less than one minute.

scanCONTROL laser profile scanners guarantee perfect application of adhesive beadings to the screen edges

scanCONTROL laser profile scanners guarantee perfect application of adhesive beadings to the screen edges

Gap and Flushness Measurement of Bodywork Parts

Single bodywork parts are fixed in a complete car in the assembling section, however, gap and flushness sizes between the single parts occurring from this process are not accepted by all customers. In order to avoid this situation, optical sensors of the gapCONTROL series are used in the gripper system of the seeing robots. These sensors control the mounting process for each single assembly in real time by examining if the gap and flushness sizes meet the requirements of manufacturers.

gapCONTROL measures gap and flushness of the bodywork parts

gapCONTROL measures gap and flushness of the bodywork parts

3D Surface Inspections – Structured Light Projection

Micro-Epsilon provides its surfaceCONTROL measurement system for detecting defect on diffuse reflective surfaces, for instance in automotive production. This measurement system uses structured light projection in order to detect and analyze local shape defects (bumps and dents) on surfaces that vary by micrometers from their target measurements. It also works reliably on textured surfaces, for example, interior automotive parts. The surfaceCONTROL measurement system provides a wide range of measurement areas from about 150 x 100 mm2 to 600 x 400 m2, and it takes very few seconds to obtain 3D data for a surface. Different evaluation methods are available depending on the nature of the shape deviations that are being examined. The 3D data can be used to analyze a flawless virtual cover, or a digital whetstone, like a whetstone in a press shop, can be used. These procedures provide repeatable and objective assessments of deviations from approximately 5 µm to 20 µm, depending on the surface.

The structured light projection method is suitable for surfaces that diffusely reflect at least portion of the light, including aluminum, steel, ceramics and plastics.

Automatic defect detection on interior car components

Automatic defect detection on interior car components

Non contact tire DOT code reading

Manufacturers are accountable for providing every tire with a DOT number, which is printed on the tire wall and define the type and size of the wire, factory, and the manufacturing week. Automatic mounting of tires on rims, transportation of fully assembled tires to the car mounting and the related documentation require automatic detection, and due to short cycle time, this detection is a technical challenge. Micro-Epsilon offers identityCONTROL TID 8303.I, a new system that detects the DOT number and tire type when the tire lies on the feed slide. This system functions according to the structured light protection. The Micro-Epsilon solution, unlike other traditional systems, does not require additional electro-mechanic components to turn or index the tires.

The identityCONTROL system is wear-free, cost-effective and easy to maintain. Customers can easily tech TID 8303.I new tire types and control the administration in a data base.

TID 8303.I identifies the DOT number on tires within the required cycle time

TID 8303.I identifies the DOT number on tires within the required cycle time

This information has been sourced, reviewed and adapted from materials provided by Micro Epsilon.

For more information on this source, please visit Micro Epsilon.

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