Case Studies: 100% inspection

Background: A major automotive supplier was having trouble controlling the thickness of the sheet material they produced. Typically, thickness measurements were done manually with a hand caliper, at specified times throughout the production run. Looking for a better solution, this customer contacted KEYENCE for assistance. The Problem: It was determined that there were two major problems with the current method of measurement. - First, the measurements being done by hand were very inconsistent. The material being measured was not rigid, and thus the measurements varied as the amount of force applied to the micrometer by the operators changed. - Second, the process problems that caused the thickness variation occurred very quickly, and the current “spot checking” method uncovered the problem often times too late. Thousands of dollars worth of “out of spec” material had been produced, only to be scrapped. The Solution: After an initial consultation visit by KEYENCE factory-trained sales engineers, it was determined that KEYENCE's LK-G series CCD laser displacement sensor would be the best solution to the customer's problem. The LK-G series is a high accuracy, non-contact, laser triangulation displacement sensor with many features and benefits that would eliminate the customer's problems: - High accuracy measurement: +/- 10um linearity (with dual head LK-G37 configuration) - High speed measurement: Up to 50kHZ sampling, ensuring 100% inspection in real time - Multi-functional controller: Able to process and display data from two sensor heads, and output overall thickness - Non contact: Due to the non contact triangulation measurement principle, the product will not be deformed during measurement - High accuracy regardless of material color, texture, etc. - Multiple outputs: Digital, analog, serial, USB. Can be used for local alarm, and/or data collection purposes The LK-G Series detects the thickness of various sheet materials such as films, rubber sheets, or bonded textiles within a production line. The Results: Three months after the first system was installed, there were significant improvements in the scrap rate and defect rate. The cost savings on the scrap alone justified the purchase of the LK-G system within 4 months! In addition, the customer began collecting the thickness measurement data, and was able to correlate the thickness changes with other problems, earlier in the production process. The customer was so impressed with the KEYENCE thickness measurement system that they plan on implementing duplicate systems on their other 4 production lines within the next 2 years.   Request Now! CCD Laser Displacement Sensor Selection Guide (22 pages).		Case Studies Case Study Index Small Optical Sensor Solves Big Product Line Issues Non-contact Measurement Sensors Reduces Scrap, Provides 100% Inspection Contact Sensors Prevent Automobile Part Defects Cost Effective Stand-alone Terminals for Lower Costs Challenge of Developing a New Product in an Untested Field Metal Product Manufacturer Saves $100K USD

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	Please describe your application problem below.  What is your detect / measurement target?  Detection / measurement type.(Choose one from the list below) Eccenctricity Runout Thickness Outer_Diameter Warpage Inner_Diameter Distortion Others  Please check the item(s) you are interested in. Information only. Sales support. Price inquiry. Application assistance.  Material:(optional) Ex: Steel, plastic, rubber, etc.  Accuracy:(optional) Ex: High, Repeatabilitly  Speed:(optional) Ex: Char/sec, cycles, etc.  output Type:(optional) Ex: Digital, analogy, etc.		Optional Questions   Are you using a similar product(s)? Yes No   Any plans to purchase this product(s)? Within 1 month in 1-3 months 3 months or more   Any questions about the product(s)?   How did you find us? Select one Clicking Keyence e-News From a search engine From General Catalog From colleague From brochures/leaflets From magazine advertisement From Home page Other   Notes: [1] Your request has to be forwarded to the correct Keyence affiliate company or distributor responsible for your country / area. The question will then be given to the responsible engineer. Please be patient, we will try to respond to each and every request as soon as we can, however the response may not be immediate. [2] Questions will be answered by a Keyence staff member if you live in the following areas : U.S.A, United Kingdom, Germany, France, Japan, Singapore, Malaysia, Thailand & Taiwan. If you are outside of these areas your question may be forwarded to a Keyence distributor.
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