Sensor solutions for the automotive industry

Designing future-proof and efficient systems Page 6 – 7 Prepared for the car of the future Page 8 – 9 The press shop Page 10 – 17 The body shop Page 18 – 25 The paint shop Page 26 – 31 Powertrain – The combustion engine Page 32 – 37 Powertrain – The electric drive Page 38 – 43 The final assembly Page 44 – 49 Technical data Page 50 – 71

Yesterday. Today. Tomorrow. With curiosity and determination, we – the Sensor People – have been partners for technological milestones in industrial auto ation for more than 50 years. m The success of our customers is what drives us. Yesterday. Today. Tomorro

Designing future-proof and efficient systems Through innovative technologies, such as OPC UA, process and diagnostic data can be evaluated with a new level of quality. Processes can thereby be systematically optimized, machines constantly monitored and devices centrally and easily managed. Intelligent sensors are a fundamental element here: with the help of new communication technologies, the data from these sensors can be collected and evaluated across all levels of a production system. With our 1D and 2Dsensors, we already have OPCUAcertified sensors that are ideally suited for, among other...

el Process optimization Machine monitoring Device management Standardized communication enables analyses on the level of the individual device or of a local system. Moreover, through cloud communication, data can also be aggregated over multiple locations worldwide. Additional knowledge can thereby be gained and uniform analysis data made available securely.

Prepared for the car of the future The market for alternative drives is growing rapidly. An increasing number of models and equipment options require even more flexible production and an extensive quality management system. Our goal, as a partner for our customers, is to ensure your success in an industry that is ever evolving. The automotive industry in particular currently faces great challenges. Based on years of industry knowledge, we orient our product range toward current and future application solutions. Predictive maintenance and diagnostic possibilities for Industry 4.0 are as much in...

Flexible manufacturing and e-mobility The production processes in the press shop, paint shop and final assembly are becoming increasingly flexible. Different vehicle models and equipment options need to be taken into account in the process. Scalable manu facturing concepts that can be adapted to production capacities are called for here. The trend towards emission-free vehicles is also changing manufacturing processes. The complexity and the number of components in the powertrain is decreasing, and the production of batteries and battery packs is growing. Maximum system availability and certified...

The press shop Various body parts for the subsequent finished vehicles are produced from massive steel rolls, so-called coils. Whether for cutting the coils or punching, pressing and shaping the blanks: sensors accompany and safeguard all manufacturing steps, even under harsh environmental conditions. The applications are as diverse as our product range, which is tailored to these applications. Inductive and optical sensors check and monitor the presence and position of parts. Identification systems record data for the traceability of those parts. At the cutting systems, our sensors supply measurement...

1 Code reading on the steel coil 8 Presence control of the tool 2 Area guarding of the feeder 9 Position control of the pallet 3 Measuring the coil diameter 10 Monitoring of the stack height 11 Errorfree acceptance of the blanks 12 Presence control for controlling the gripper robot 6 Anteroom guarding on press lines 13 Code reading on the rack 7 Access guarding on press lines

Applications – The press shop Code reading on the steel coil Requirement: The relevant technical data, such as material and material thick ness, are encoded onto the coil. After removing the coils from the warehouse and before they are accepted into the cutting machine, this data must be recorded in order to ensure traceability over the entire process chain. Solution: The DCR 200i camerabased code readers read all common 1D and 2Dcodes, are easy to config ure, and, thanks to the various optics, are simple to install. In cases where the position of the 1Dcode on the coil can vary, the oscillating...

Applications – The press shop Loop control Requirement: In the cutting system, the cutting process must be decoupled from the belt transport. The sag of the loop is to be determined contactfree to communicate the necessary measurement values to the control for deter mining the hauloff speed. Solution: The sensors of the ODS10 / 110 and ODSL 96 series, which operate ac cording to the timeofflight measurement principle (TOF), offer measurement ranges of several meters. They feature a high resolution and a high level of reproducibility. The devices can be flexibly integrated via analog output, serial...

Applications – The press shop Anteroom guarding on press lines Requirement: Before the carriages move into the press, a check must be performed to ensure that no persons are in front of the gates. During entry, the area to the side of the carriages is to be secured to prevent persons from enter ing the press line alongside a carriage. Solution: With its configurable and switchable protective fields, the RSL 400 safety laser scanner secures the area in front of the respective door. With its large operating range of 8.25 m and two parallel pro tective functions, two entrance areas can be simultaneously...

Applications – The press shop Position control of the pallet Requirement: The cut, in some cases, already stamped blanks are fed for further processing by means of forklift trucks or automated guided vehicles. Before the parts can be accepted, a check must be performed to ensure that the pallet or load carrier has reached the transfer position. This is to occur contactlessly. Solution: The inductive switches of the IS 200 / 244 series offer high performance and large function reserve. Depending on the installation location and the required operating range, both cylindrical designs with triple...