Automotive parts defects detection using non-contact sensors

The automotive world is one of the largest developing markets in the world. This industry embraces new technologies both in-line and off-line quality control of production line. Automotive parts are scanned with a variety of metrology tools, different laser sensor technologies and using CMM, all using robots that works 24/7. In this blog I illustrate an in-line defect detection task, where speed is an important issue but exact part measurement is not. Scanning with an area scanner or a line sensor means that the manufacturer understands the trade-off between measurement speed and accuracy, naturally covering large areas in fast speed has accuracy limitation and such technologies will provide data that will range between several microns to tens of microns. Accuracy also determine by the motion system limitation and not only by the sensor. Whenever we want to have very high definition scan, getting the best resolution, we may use a point sensor. This will usually occur when scanning small items with complex geometries.

In this case below the automotive engine manufacturer wanted an in-line defect inspection system, achieving fast results, but was ready to compromise on 10-15 micron accuracy only. Using an Optimet CL-100 line sensor is a good solution for this application. The sensor is able to provide distinction between engine holes which has defects to those which doesn’t. In this case the scanning data was 100 lines/second & 20 kHz speed rate.  In another case a manufacturer in Taiwan used a point sensor attached to a periscope in order to inspect smaller and hidden holes which the standard line sensor can’t reach. By doing this he achieve accuracies of 1-6 microns only. However, this test is made off-line and requires more time. Again, Trade-off is the name of the game.

Contact us for more information on your particular application challenge.

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  • Fadi Kassem

    I work at GM. I have a supplier who produces SMC (Sheet molded compounds). They bond inner and outer using glue. In certain cases, they have slivers caused by the hardening glue. They are manually de-roping any excess glue. However, they do miss a few. They tend to cause a safety issue at the plant. Do you have a technology that can check for this type of defect online?

  • Sam

    Using non-contact laser sensors can provide the end users a variety of parameters to measure and characterize surface features such as flatness, roughness, and displacement. One dominant parameter end users want to measure is the thickness of metal, plastic, wood, and glass.

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