Visualized measurement deviation
SYSTEM / APPLICATION
ZEISS COMET LƎD
Injection molding / module assembly
EMKA-Plast GmbH, Hille, Germany
The eastern Westphalian company EMKA-Plast GmbH has been designing, producing, and assembling plastic items and modules in Hille in the Minden-Lübbecke administrative district for 20 years. In the meantime, the company, with its 25 employees, works for a large number of internationally active companies from a wide variety of industries.
Seventeen injection molding machines are used in Hille to process the many customer orders. Around the clock. They use pressure to press liquid plastic into injection molding tools, which respectively determine the shape and the surface quality of the parts to be produced. Although injection molding is a common process today, the production process is nonetheless in no sense trivial, considering the strict quality specifications of customers. Especially when, as is usual in Hille, insert parts are inserted into the injection molding tool, which EMKA-Plast usually produces itself, and sprayed with plastic. The inserts are usually threaded sockets, contacts, plates, or coils. The spraying of other components such as magnets or PCBs is also possible in Hille.
In order to assure the quality of its broad product portfolio, the medium-sized company works with a 3D measuring machine that measures optically and tactilely. However, that takes time. Especially when parts with 200 or more specifications need to be tested. The manufacturer of plastic parts therefore searched for a digitizing system that enabled a rapid nominal/actual comparison. The system especially needed to be suitable for initial sampling reports. Also of great importance to the business management was that handling be simple and that the training of employees require no more than a week.
SOLUTION AND PRODUCT
The fringe projection sensor of Carl Zeiss Optotechnik GmbH scored points both with the business management and with the employees in Quality Assurance, who in the meantime use the system on a daily basis. Especially the results, which are very precise in comparison to other 3D digitizing methods, and the impressive speed in comparison with tactile measuring processes were immediately convincing.
The innovative ZEISS COMET sensor for 3D data recording is based on fringe projection and blue LED technology. It projects blue LED light in a fringe pattern onto the object to be measured. This pattern is specifically distorted by the geometry of the respective component and recorded by a camera. Software uses triangulation calculations to establish a relationship between the individual camera pixel and a point on the work piece. The point cloud created in this way is then transformed into the so-called triangular network in the Stl format, with which a 3D model can be generated. This is then drawn upon for the nominal/actual comparison with the 3D-CAD model.
RESULT / BENEFIT FOR THE CUSTOMER
Five days were enough to introduce the fringe projection or the system from ZEISS at the manufacturer of plastic parts. During this time, one employee of ZEISS Optotechnik trained two EMKA-Plast employees on location in Hille. For the person responsible for quality, "the week was more than enough" to be able to use the ZEISS COMET LƎD safely for a variety of tasks.” This is because, thanks to the excellent data quality, the application range is also broad for the manufacturer of injection molding parts.
According to EMKA-Plast, "the system utilizes all of its strengths”, especially for the creation of initial sample test reports. In addition to the considerable time savings in their own company, the company emphasizes another advantage: Thanks to the colored representation of the nominal/actual comparison, customers can now see at a glance whether all specifications are within tolerances. "That clearly involves less effort and time than working through sometimes endless table columns full of actual and nominal data."
ADVANTAGES / STATEMENT
- "Although concrete figures for a before-after comparison are missing, it goes without saying that the use of the ZEISS COMET system saves EMKA-Plast an unbelievable amount of time in the creation of initial sample test reports."
- "Customers also profit from the use of the ZEISS COMET system. This is because, thanks to the colored nominal/actual comparisons, the initial sample test reports can now be read more easily and quickly, which also reduces the time required by the customer."
- "The handling of the ZEISS COMET system is extremely simple. It can be safely operated after only a few days."
Quality testing, EMKA-Plast GmbH