Inspection - Import export

The LinearLevi-Inspectionmodule enables the inspection of substrates during the contactless transport. It is possible to check the quality of battery cells, foils, packaging, as well as wafers and chips without interrupting the transfer process. There is the opportunity to subsequently sort the substrates according to the inspection results. The application can be delivered in different versions. For example, combinations with the UltraLevi-Desk for contactless transport are possible. Features of the LinearLevi-Inspectionmodule: - Extendable - Various sizes - No particles due to no air turbulence - Double-sided inspection possible - High flatness, also for flexible substrates - Customizable according to customer specifications

Four QuellTech Q6 3D- laser scanners are installed, mutually displaced by an angle of 90°. In this configuration, they are able to monitor the complete surface of the cable running through. It is important that the test does not lower the production speed, therefore very high sampling rates are required, supported by convenient data processing. The measured position of a defect is recorded in cable direction.

Particular Challenges: In the course of the production, endless cables are running at a considerable speed, and supervision has to be carried out nearly under real-time conditions. The size of the objects to be determined, i.e. of the flaws to be discovered, is in the range of only some hundredths of a mm. Another difficulty is the fact that surfaces with very different reflectivity and roughness are involved. In order to be able to check the cables all around, several laser scanners must be in place, mounted at different angles, thus covering the entire range of 360°. Quelltech Solution: The solution consists in a configuration of four Q6 laser scanners, mutually displaced by 90°, so the entire surface of the cables is in the field of view. On the basis of the 100% inline inspection, the position of defects can precisely be determined, without losing too much time.

Particular Challenges: The seal surfaces in this case are made of very glossy metal, with the drawback of emitted reflections. This effect during an optical measurement must be eliminated. Furthermore, it is absolutely necessary to guide the laser scanner on a linear path over the surface, since fluctuations of distance may falsify the measurement result. QuellTech Solution: The Quelltech model Q5 disposes of an adequate resolution in X and Z direction and proves to be able to verify the planarity tolerances and to measure the size of defects. Meanwhile a precise rotary axle, used as guiding element, moves the scanner over the surface to be evaluated. Interfering artefacts caused by the glossy finish are suppressed by particular algorithms integrated within the software. As an encoder value is permanently supplied by the rotary axle, the position of each scanner profile within the point cloud can accurately be determined.

Plastic Mold Part (AC Controller) Inspection At this point the manufacturer is looking for scratches and chips and dimension specifications manually. In this respect manual inspection is not a repeatable or trustworthy method to guarantee steady quality of goods. It will be demanding for a human worker to detect this for a long period. QuellTech Solution Plastic Mold Parts are easily measurable materials for QuellTech scanners. Using the QuellTech Q4-120 Laser Line Scanner it is possible to obtain very precise reflection free 3D point clouds. A Software making necessary detections in 3D point clouds can effortlessly check dimensions and find scratches or any other defect which allows the manufacturer to automatically parse outparts that do not pass the tolerance levels.

Q6-Lasor sensor – High Speed, High Resolution – Q6 Sets New Standards for 2D / 3D Measurement: Resolution of up to 0.6 µm Profile speed of up to 25.000 profiles/s Measuring ranges between 2 mm and up to 370 mm available Laser wave lengths starting from UV via blue, red and green through to IR The Q6 laser sensor series has already proven its ability in numerous industrial applications demanding a high degree of precision and process stability at increased travel speed. For common environments, connection is established via GIGE interface and GeniCam. Integration with linear axes and robots is possible by means of encoder inputs and trigger option.

Initial Situation: Inspection of a laser weld seam for pores and geometrical anomalies The production of a client in automotive industry is subjected to extremely stringent quality requirements. This is valid particularly also for the precision of laser weld seam of fine mechanical work. 100% inline supervision is required for the following task: A laser weld beam (width ca. 200µm) has to be verified with respect to the presence of pores and geometrical anomalies. Camera inspection performed until now turned out to be not stable. Therefore the client is forced to implement an improved monitoring process. The challenge The resolution required amounts to 4µm. The high gloss finished material and glossy laser weld seam may give rise to reflections, and the space for installation is restricted. A low form factor for the monitoring equipment is imperative.

The new QuellTech Q5 Laser Scanner Series combines the advantages of small form factors with both high resolution and scan rate. The sensor disposes of different set-up possibilities with respect to the analysis algorithm. Measurement results are delivered via Ethernet, calibrated in the X / Z plane. Special adjustable algorithms can be selected, extremely useful particularly also for optically most demanding surfaces. Time-consuming calibration tasks for the user are no more required, as the calibration routine runs on board. High Scan Rate with up to 14,000 Profiles per Second Due to an appropriate limitation of the image range (AOI) in X and Z direction, the scan rate could considerably be increased. High resolution and detection frequency with up to 14.000 profiles and 28 Mio. points per second •X measuring range from 10 to 1022 mm •Z measuring range (height) from 5 to 878 mm •Laser wave length blue 405/450nm, red 650nm

Particular Challenge: For the assessment of rotating parts, numerous parameters have to be taken into consideration: Concentricity, radial run-out and axial run-out (i.e. wobble); furthermore thickness, diameter, planarity and the absence of surface defects had to be examined. The solution developed by QuellTech consists in a configuration of three Q6 Laser Laser Scanners.Each of the lateral surfaces is assigned to its own scanner. In order to enable the thickness precisely to be determined, both laser lines are mutually oriented in opposite direction. The third scanner inspects the outer circumference of the wheel, this way measuring diameter and radial run-out. All of these scanners are subject to encoder signals supplied by the rotary axis and synchronously triggered, so possible defects on the wheel can precisely be localized. The measurement takes place at a resolution of ca. 30 µm, and a cloud comprising several millions of points are obtained.

The QuellTech laser sensor family Q4 or Q5 used for these tasks is generally mounted on an arm of a rotational axis, to scan along the complete 360° angle of the internal surface in a sequence of strips. The Q4 sensors can also be used to control the weld seam tracking itself for rapid setup and ease of use. Even during a project, the range and scope of the Q Series sensor demonstrates the advantages of a modular system to quickly adapt to project needs, where the smallest system has provided fast analysis of pipes as small as 105mm. The low power, with standard communication protocols, enable battery powered systems to transmit wireless data to other systems for review and cloud back up.

Rotationally symmetrical driving gears in a line producing for automotive industry are mutually connected by electron beam welding. The camera inspection carried out until was not able to assess the quality of the weld seams at the required precision. Non-contact laser measurement system Particular Challenge: As the welding seams show a high reflectivity and are located at a position hard to access, inspection is difficult, all the more so as they dispose of a width of only 500µm. Therefore it is quite a challenge for the laser measurement system. The QuellTech solution: A QuellTech Laser Scanner Q4-5 with extremely small shape factor and high resolution proved to be perfectly suited for this application. In order to suppress reflections from elements in the surroundings, a particular algorithm has been integrated. Furthermore, this laser measurement system features a particularly adapted laser wavelength and an ultrafine laser line.

Within the frame of quality assurance, the forged pieces of this client have to be checked in an inline inspection with respect to several parameters: Inner and outer diameters, as well as the absence of surface defects have to be verified. Video of inline forgings inspection for dimensional accuracy and surface defects with QuellTech LaserScaner. Particular Challenges Manual inspection carried out until now turned out to be not reliable enough, particularly after an increase in production. The final rejection rate has seriously affected the productivity of the entire manufacturing process. A solution for a contactless inline inspection was needed. The QuellTech Solution A testing station including an index table has been designed. This configuration acts as a support for two QuellTech Q4-60 laser scanners, used for inspection of the parameters mentioned above.

Micro-Epsilon offers suitable accessories for TIM infrared cameras in order to expand their functionality and application possibilities. Interfaces, PCs, interchangeable lenses and protective housings allow for the thermal imaging camera to be adapted to the respective measurement task.

The MSC controllers are designed to be operated with LVDT and LDR measuring gauges and displacement sensors. Due to the robust and compact aluminum housing, the controllers are ideal for industrial measurement tasks. A large variety of compatible, inductive displacement sensors and gauges combined with an optimized price/performance ratio opens up multiple fields of applications in automation technology and machine building.

Our production facilities are fully up to date. Thanks to the adjustable design of our lines, we can easily implement special solutions. The 3D automatic optical inspection of SMD components combines 2D and 3D inspection at maximum speed. Some of our machines allow an inspection in 360 ° steps. Depending on the machine, excellent dynamic properties and the highest positioning speed can be achieved on the basis of linear drives.

The FTS 8101.EC O-frame is based on the combisensor principle equipped with non-contact capacitive sensors. The distance between sensor and film is measured with the capacitive sensor. The eddy-current sensors ensures the thickness signal by a reference measurement to a second target. The system can be integrated in the flat layer section.

For the production of reeled resistors or sheet goods on roller head installations the thickness measurement is an essential factor for controlling and monitoring the production process. Applying systems of the RTP series, the profile thickness can be measured in various accuracy classes, thickness ranges and material widths.

The RTP 8301.CT is based on laser triangulation sensors and therefore ensures the measurement being independently from material constants. The system is designed as O-frame, both sensors detect the thickness according to the differential method. In order to ensure highest precision, the laser beams of the sensors are accurately adjusted during the production process using optoelectronic tools which have been specially developed. The system is ideal for monitoring high-dynamically processes due to its high measuring rate. The O-frame mechanics of the system dispose of a compensation frame which does not vary with temperature and which is used in order to avoid temperature fluctuations of the measuring frame using further sensors. The profilometer corresponds to the TIP 8301.CT regarding its functionality. However, it has a different operators´ frontend and evaluation functions.

The system RTP 8301.EO operates according to a combination principle consisting of a thru-beam sensor, an eddy current sensor and a measuring roller. The eddy current sensor and the thru-beam sensor are applied on an innovative measuring clamp. Since the sensor measures the distance from the clamp to the roller, the lower side of the material is detected. As the sensor performance is specially aligned with the measuring task a huge measuring gap is possible while offering highest precision. The thru-beam sensor detects the upper side of the material. The thickness of the target is the difference between the two signals. The measuring clamp is equipped with a pneumatically cleaning mechanism and therefore ideal for the application in harsh environment. The profilometer corresponds to the TIP 8301 regarding its functionality. However, it has a different operators´ frontend and evaluation functions.

For the production of reeled resistors or sheet goods in calenders the thickness measurement is a vital factor for controlling and monitoring the production process. By applying systems of the RTP series, the profile thickness can be measured in various accuracy classes, thickness ranges and material widths.

The idiamCONTROL sensor system precisely measures the inner diameter of bore holes such as in extruders in order to determine the wear. The idiamCONTROL is guided into the bore hole and determines the bore hole diameter while being pulled out. Wear-based tolerance violations are automatically displayed and can be output via USB.

The FTS 8102.EC C-frame is based on the combisensor principle equipped with non-contact capacitive sensors. The distance between sensor and film is measured with the capacitive sensor. The eddy-current sensors ensures the thickness signal by a reference measurement to a second target. The system is designed as a C-frame and can be used as a traversing unit by using the linear axis.

The BTS 8101.EO O-frame is based on the combisensor principle. The system is equipped with a non-contact capacitive sensors and a Thrubeam sensor which are integrated in a traversing frame. The eddy current sensor measures the reference distance to the measurement roll‘s metal surface. The distance from the film surface is measured by the Thrubeam sensor. Together with the reference signal the film thickness is calculated. This combisensor principle allows extreme precise measurements.

The systems of the FTS familiy offer thickness measurements with extreme stability and accuracy. Applying them in extrusion lines provides reliable measurement results in high precision and thus creates the basis for controlling the production process and eventually the quality achieved.

The systems of the FTS familiy series offer thickness measurements with extreme stability and accuracy. Applying them in thermoformed flat film lines provides reliable measurement results in high precision and thus creates the basis for controlling the production process and eventually the quality achieved.

Gauges and inspection systems from Micro-Epsilon are used in the plastics processing industry in order to ensure efficient production.

The system TCC 8303.I marks the running surface which is output after the extruder, inspects the colour lines for their completeness and measures the width of the running strip.

Monitoring tire geometry i.e. the measurement of radial or lateral unbalance as well as side wall detection for bulges, constrictions, dents etc., is one of the most important inspections at the end of the production process. The TGI 8302.LLT system can be easily integrated while offering precise measuring results.

The dimensionCONTROL TWI 7303.I tire width inspection system is designed for profile width measurement in extrusion lines. This measuring system is based on camera vision technology involving two cameras inside one measurement box. These cameras are angle mounted to each other and operate according to stereo vision technology which enables high precision measurements in the whole calibration range.