QuellTech Industrial 3D Laser Scanner Applications
As the degree of automation in many processes continuously increases, corresponding quality control equipment must be highly automated as well. Numerous measuring principles are available on the markets. QuellTech focuses on 3D laser scanner measurement based on the triangulation method.
Compared to other measuring principles, which benefits offers QuellTech laser technology?
Precise non-contact 3D measurement achieves a resolution down to 1,5 µm
High measuring speed – up to 20 kHz
Good scalability when measuring large objects
Rugged design withstanding harsh environmental conditions like heat, extraneous light and vibration
Simple integration into continuous production processes (inline)
Tolerance with respect to changes in color and surface structure
No interruption of running process run during inline measurement
3D measurements also for glowing parts
A great variety of specialized solutions has been developed in close cooperation with the clientele, with increased efficiency and reliable quality control always in mind. Several practical examples are described in the following, which clearly demonstrate the resulting advantages for the production process.
Applications in industry
QuellTech OEM Laser Scanner Integration
In serial production by machines, important monitoring tasks can be automatically performed by QuellTech laser scanners. Measuring results transferred back to the machine control can be processed without delay, entailing an immediate reaction of the system. Based on the measuring data provided by the laser scanner, the production sequence can be modified already before rejects are produced.
Benefits of OEM Laser Scanner Integration:
Improved product quality directly on the spot, as rejects are prevented immediately
Preventive maintenance with respect to wear of machines and tools
Process supervision; machine parameters are controlled and adapted in time
For existing plants as well, retrofit with quality control is possible
Comprehensive technical support by QuellTech for hard- and software
Turnkey Solutions for Non-Contact 3D Measurements by Laser Scanner
Why does QuellTech offer Turnkey Solutions?
Parts manufacturers are normally not involved in development of the machines used for their process, but focus on the knowhow concerning the production process itself. For this reason, their possibilities for production and integration of an own measuring system are restricted. QuellTech supports these companies by offering a tailored turnkey solution, including measuring technology, software, handling technology, service and integration.
Laser Measuring Technology in Production of Electronic Assemblies
As delivery chains in Eastern Asia recently are exposed to various problems, many companies in Europe intend to relocate the production of electronics back to Europe. It is a matter of common knowledge however that corresponding restructuring makes good economic sense only in the presence of a high degree of automation. Manual process steps frequently are too expensive.
Nowadays a high degree of automation is usual even for small series in flexible production processes. This means that already at an early stage within the production chain, automatic inspection routines must be implemented, otherwise cost-intensive rework or even product recall may be the consequence.
The production process is subject to the following challenges:
Ongoing miniaturization of parts complicates more and more manual inspection in very fast production cycles.
High standards for tested parameters with respect to safety and fitness for purpose of the final product.
Frequent change of production features and small lot sizes require flexible inspection equipment.
Thanks to the fine resolution and the high testing speed of the QuellTech laser triangulation system, even smallest irregularities can be discovered at an early stage directly inside the production process. The 100% inline inspection enables concerned defective parts to be screened out automatically. Test criteria for the measuring task are specified within the QuellTech Vision Software, which controls and documents the application together with the laser scanner, within the frame of general quality control.
Laser Measuring Technology in Automotive Production
The automotive production nowadays normally splits among main manufacturers and a large quantity of suppliers on different levels. The quantity of parts produced by the automobile manufacturers themselves has continuously decreased. With growing complexity of vehicles, quality requirements for supplied parts have increased as well. A 100% quality inspection in many cases is mandatory and has to be documented by subcontractors.
Frequent inspection tasks encountered in the automotive sector:
Dimensional inspection for electro-mechanic components
Molded plastic parts in vehicle interior
For electric vehicles, battery cells and underbodies
Tests for tire production
Inspection of seal surfaces in the motor and adjacent components
During assembly of the vehicles at the site of the manufacturer, the following inspections may prove to be necessary:
Gap sizes and flaps of the bodyshell
Precise positioning for car windows installation
Roller hemming seal
Inspection of glue beads e.g. for roof installation
As QuellTech laser scanners are perfectly fit for these quality inspection tasks, they represent a powerful tool for avoiding the need for expensive product recalls.
For companies manufacturing metal components, inspection represents an essential step in the production. Whereas random sampling in some branches still seems to be sufficient, more and more manufacturers are facing the challenge of inline supervision of their production process. The following boundary conditions have to be observed:
Sheets are considerably varying in size. Up from a certain limit (ca. 1 m x 1m), inspection by manual radius gauge proves to be extremely time-consuming.
For cutting and bending of sheets, as well as for coating of metal components, edges have to be rounded off.
Due to the process speed, manual dimensional measurement of raw products (like slabs, continuous cast products, forgings and glowing parts) is hard to perform.
Efficiency for detection of finest defects on metal surfaces and for planarity measurement of rolls and sheets can only be ensured by inline procedures.
Non-Contact Inline Supervision of Welding Processes
Weld Gap Tracking and Correction of Path:
Automatic welding nowadays has to be optimized due to increased quality requirements like:
Perfect mutual connection of adjacent layers in multilayer passes
Correction with respect to thermal distortion (warping) of gap geometry
In multilayer configurations, sufficient strength must be ensured by an adequate overlap of adjacent layers. Furthermore, thermal distortion of the pre-programmed gap geometry, caused by intense heat supply, must be prevented or compensated for – otherwise the welding process may take place in wrong position.
Weld Seam Inspection:
The quality of a welding seam should not be affected by flaws like pores, welding spatters, cinder inclusions or excessive height. These defects, resulting from improper positioning, as well as poor performance of the seam itself can be checked inline before and during the process. The non-contact Quelltech procedure considerably saves time by combining two inspection processes, and can be carried out inline, i.e. in the course of the welding routine.
Quality Control for Production of Continuous Material
Production of continuous material relates to numerous products like cables, tubes, wire ropes and brake lines. Continuous dimensional control in many production plants has not yet been established, so defective material cannot be sorted out in time.
QuellTech has gained considerable experience in measuring continuous material.
We would be happy to carry out a first test measurement for you with your laser scanner applications, give you an assessment of the feasibility and provide you with technical and sales support in the further procedure.