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Weld
seam inspection
Zero-defect
production by checking of parts with a M2D laser scanner |
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Task
- Car headrest
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Car
headrests get their stability by a steel frame. These steel frames are
responsible for the security of the passengers. Therefore, during production,
high demands on seam weld quality are made.
Within the cycle time of 13 seconds, the round going and the lengthways
going seams have to be verified.
Two units, each with two laser scanners, perform this test request.
Defective parts are reported to PLC.
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| Solution |
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Rotative
seam
The welded parts are transported via stepper chain
to the checking station. At the rotation about 360° two M2D laser-scanners
read the left and the right weldseam. Afterwards the checking result is
displayed and reported to PLC.
The dimensional accuracy of the surface profile, scanned by M2D, is monitored
by the online computer. The measured values are compared to the stored
thresholds. On exceeding or falling below this values, an error is signaled.
In addition to the monitoring of the contour accuracy, major and minor
defects are analyzed. Modifications of the surface, like notches, pores
or holes are recognized reliably.
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Longitudinal
seam
The both lateral longitudinal seams of the workpiece,
are passed underneath the scanners by a slide. One seam is scanned on forward
motion, the other seam - after turning round the workpiece - on moving backwards.
In the meantime, the M2D laser scanner is generating a 3D picture of the
weldseam.
While system software is analyzing data, the part is already transported
to the next station. |
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| Result |
  
1. Picture NOK (welding defect, holes), 2. Picture NOK (welding
defect, slag / hole), 3. picture OK (perfect weldseam) |
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In
basic position, it´s simply displayed Ready - OK - NOK.
In detailed evaluation display, an analysis of error causes is possible.
With the recorded scans, the adjustments of the particular filters can
be tested and optimized. For each filter, the tolerance ranges are assignable.
Profiles of scans can be stored and displayed later on. All test results
are recorded with date and time in a log file.
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The
MEL i-Control is an ultra compact industrial
PC with additional interfaces for CAN-Bus and Profibus. With the bidirectional
communication, this PC is well equipped for automation business. The internal
processor prepares data in such way, that only control commands and results
have to be emitted and collected by interface.
The MEL software is able to operate without mouse and monitor. Of course,
you can use the peripheral devices for maintenance and parameter adjustments.
The PLC obtains messages and status signals of scanner evaluation by relay
card.
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For over 20 years, MEL is the
most innovative producer of intelligent sensors. Avail yourself of our
experience.
We cope with tasks of automation by using sensor technology and build
hard- and software as ideal solution. Alternatively, we deliver modular
solutions for integration into OEM projects.
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