Sensors & Applications Automotive Production

Sensors for automotive production Today, sensors and measurement technology are indispensable for modern automotive engineering – especially in view of ever more stringent quality requirements. From the press shop to assembly and finishing, they ensure precise control of production processes, seamless monitoring of supplied parts and final quality control. Micro-Epsilon supplies innovative sensor solutions for measuring distances, gaps, colors, temperatures and surfaces in almost all process steps of vehicle production. Leading car manufacturers around the world trust in the precision, reliability...

optoNCDT »| ■ Laser triangulation sensors * with measuring ranges up to 1000 mm ■ Accurate measurement from a safe distance ■ High measuring rate for monitoring fast processes

Monitoring of the sheet metal feed during pressing During forming in the press shop, presence detection and the exact detection of the sheet position are crucial for an error-free production process. The optoNCDT 1420 laser sensors measure directly onto the sheet metal between the dies. In confined installation spaces, they achieve precise measurement results even with vibrations and shocks. Thanks to the compact laser beam, measurements can be taken directly between the two dies. Sensor: optoNCDT 1420 Monitoring of the embossing depth Chassis numbers are stamped into the vehicle frame in embossing...

scanCONTROL ■ Compact laser scanner with integrated controller ■ High profile frequency for dynamic measurements ■ Synchronizable for multi-scanner applications ■ Different measuring ranges ■ Compact design with integrated controller, ideal for robots and drag chains

Distance measurement for robot positioning During cockpit assembly, laser time-of-flight sensors determine the exact position at which the car body should stop. The distance sensors are suitable for measurement tasks in assembly lines due to their short response time and high signal stability. Sensor: optoNCDT ILR1040 Position detection of the car body For automated machining processes on car bodies, the exact position relative to the machining tool – e.g. for drilling, punching, or mounting assemblies – must be determined. Laser triangulation sensors are used for high-precision distance measurement...

■ Fast, precise and repeatable ■ Group-wide transferability to all models ■ High coverage on curved surfaces ■ Complete integration: Sensors, robotics and

Fully automatic surface inspection of bodyshells The surfaceCONTROL Automotive measuring system is used for fully automatic defect detection on bodyshells. This system uses the principle of fringe projection on diffusely reflective surfaces. A learning process is used to reliably detect local shape defects such as pressure points, cracks, etc., taking permissible deviations into account. Flexible cell configuration with complete integration The surfaceCONTROL systems consist of a sensor, robot, computer, and software and interface package. Different versions of the system are available depending...

■ Automatic surface inspection of painted car bodies ■ Ultra-high detection rate - regardless of the car body color ■ High positional accuracy of the defects ■ Measurement also on design edges and contrasting roofs

Surface inspection of painted car bodies reflectCONTROL Automotive is used for the fully automatic inspection of painted car bodies. The robot-assisted systems enable the detection, three-dimensional measurement and classification of typical paint defects such as inclusions, craters and running paint. They stand out thanks to their high precision paired with high repeatability and can be easily combined with automatic processing and marking systems. Automatic setup of all car body colors The reflectCONTROL inspection systems detect almost 100% of all relevant defects, regardless of the paint...

Gearbox & engine construction optoCONTROL 2700 Measuring ranges 10 / 40 mm Sampling rate 15 kHz for fast measurements Micrometer-precise measurement of diameters, gaps and segments

Presence check of bearing shells During connecting rod assembly, bearing shells are pressed into the bearing shell covers. Before the connecting rod is fitted, it is checked that the bearing shells are in the bearing shell cover. Optical micrometers from the optoCONTROL series, which measure the diameter of the bearing shell covers, are used for presence checks. Position monitoring during the marriage process Laser point sensors from the optoNCDT series monitor the "marriage" of body and engine. The device is equipped with laser triangulation sensors that monitor the distance between the car...

optoNCDT 1900 ■ High-performance laser displacement sensor for industry and automation ■ Measuring rate of 10 kHz for precise and fast measurements ■ Compact sensor design with integrated controller ■ Robust and durable design

Highly accurate cockpit positioning For fully automatic installation in the vehicle, the cockpit must be positioned precisely. For this purpose, a frame with two grippers is mounted on a robot arm. scanCONTROL profile sensors are also attached to this frame to monitor the centering of the cockpit. Thanks to surface compensation, the scanners can also be used with different reflections that occur due to the different paint finishes. Position detection of the car body For automated machining processes on car bodies, the exact position relative to the machining tool (drilling, punching, mounting...

surfaceCONTROL ■ Measurement & inspection of diffusely reflective targets ■ Continuous process monitoring ■ Detection of a wide range of shape defects ■ Clear definition of defect criteria in supplier relationships ■ Objective evaluation of deviations ■ Reduction of work steps, minimization of rework and scrap costs ■ Visual identification of defects on the component by reprojection

Defect detection on interior parts In addition to the stringent visual requirements, instrument panels must also meet functional and safety requirements. A laser is often used to weaken the area of the front passenger airbag in order to create a predetermined breaking seam that allows the airbag to open safely. This predetermined breaking seam can result in tiny sink marks that are visible under certain lighting conditions. surfaceCONTROL inspection systems are used to detect these defects. These enable the quick and objective assessment of surface deviations on both grained and smooth surfaces....