Stamping press lines are used to produce various body parts on a broad range of car models. As plants prepare to produce parts for a different vehicle, dies have to be exchanged regularly. Due to the multitude of body parts and vehicle types, managing the different dies is a complex task encompassing logistical and quality issues. Recognizing these issues and keeping track of the production data of the dies at the same time is key for efficient production of quality products.

Product Application: Displacement Measurement of Press Machine Mold

Correct alignment of press dies is critical to preventing defective molds. Occasional misalignment of molds results in defective parts. To prevent this misalignment, the displacement value of the mold must be measured to control the condition of forming, within a tolerance of +/-50 µm and a resolution of +/-5 µm.

Measuring the distance between the upper and lower dog with two laser displacement sensor heads and a multi-controller prevents damage to the mold.

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• Measurement Sensors >> Displacement

Although more and more body parts are glued together, welding is still an important bonding method. For both techniques, proper parameter setting is essential. Even the smallest deviation can lead to problems in later steps of the production process. Measuring the setup of body parts and controlling the glue or welding beads will not only result in the correct dimensions of the body work but also in the stiffness that is required for modern automobiles.

Product Application: Foundry Equipment Diagnosis System

One of Japan's largest automobile manufacturers wanted to improve their factory maintenance procedures to reduce lost production time through breakdown in the assembly line and consequently unscheduled repairs. The maintenance policy at that time was to react to breakdowns.

Omron designed a cost effective turn key solution diagnostic system based on analysis of data collected from production line machines via vibration sensors. The data was used to show tendencies and allowed the maintenance department to define when machinery was found to be in a 'danger zone'. Once identified, additional diagnostics allowed them to plan and organize work more efficiently.

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• Programmable Controllers >> Mid-Size PLCs

Different cars are painted through the automated paint shop. Statistically, there is no chance of producing two identical cars in a row. In the automated paint shop, it is essential to recognize the body and determine which color it has to be painted.

Product Application: Production ID System for the Painting Process

Identifying the type of car is critical as there are several essential parameters in the painting process. A system is needed to tag the process parameters, and it must be resistant to harsh temperature and chemical conditions in the production process.

An RFID system is easy to set up and ideal for this application as it features high resistance tags for harsh conditions.

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• RFID for Manufacturing >> High Speed & Temperature

The powertrain is as important to car production as the movement is to a watch. Without it everything stops. All the mechanical parts have to fit together to ensure reliability for the lifespan of the car.

Product Application: Gearbox Housing Inspection

After the gearbox leaves the workshop for assembly it is possible that screw threads may be missing or that a broken tool or metal chips remain in the holes.

Before the gearbox is sent to assembly, it is sent through a vision system for inspection. An array of cameras inspects all screw threads around the gearbox housing by counting the edges inside of each hole. This assures presence of the screw threads and conformity (no chips).

By detecting quality issues before assembly, this preventive inspection system keeps the production line moving and eliminates the need for costly manual assembly rework.

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• Vision Sensing >> General Inspection Controllers

As in the Paint Shop, it is statistically impossible to have two identical cars in a row in the assembly process. In order to build an automobile, parts from several suppliers, internally and externally, are accumulated simultaneously at the production line. Recognition of the car and the separate parts is essential for an efficient assembly system. Errors made at this final stage are highly visible, so automated quality control and identification systems help the production line deliver the highest quality.

Product Application: Airbag Label Inspection

Because car seats are handled in pairs, it is important that each seat is covered with the correct material so the airbag label is always on the outer side of the seat.

To make sure that the seats are manufactured correctly, a vision system with two cameras makes it possible to detect the presence of the airbag label on the outside of the seats.

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• Vision Sensing >> Date/Lot Code Controllers

Parts and subsystems manufactured by automotive Tier One suppliers undergo a multitude of processes before being assembled and then are delivered and become part of the next step in the car manufacturing process. The output from a supplier has a major impact on the rest of the production process. It is essential that proper quality control is maintained in these parts so that higher efficiencies and lower costs can be realized in the next phase.

Product Application: Eccentricity Measurement of Disk Plate

The brake disk has many features that require tight control. It's faces should be parallel to one another and parallel to the wheel face mount as well as having no extreme changes in thickness variation. Brake surfaces should also be flat and square to the axis of the disk's rotation to a specified tolerance (Tolerance: +/-40 µm; Resolution: +/-10 µm). Measuring the eccentricity of the disk with a contact sensor occasionally damaged the surface, causing the part to be rejected.

In order to continuously monitor product quality without affecting productivity, the use of a laser displacement sensor along with a sensor head and controller provides a more reliable system. To measure the eccentricity, the disk is set up in the turntable and the sensor is mounted at the upper point. The eccentricity data is continuously checked with the logging function of a "Smart Monitor".

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• Measurement Sensors >> Displacement

Automobile electronics are constantly advancing, and electronic antennas on cars are an example of this. One of the market leaders in this technology is the company, BOSCH Telecom GmbH in Berlin.

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