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SENSOR PRODUCTS |
Quality control
directly in the production process
Is Top-Product quality your competitive advantage? Do you need fully automatic
quality assurance integrated directly in the production line? Does 100 percent
control of components during the production process make your product even more
reliable?
Inspection systems from plasmo integrated in the production line ensure for the
best quality currently possible in industrial production, in real-time. While
predominantly camera-based solutions are used in the pre- as well as post-weld
sector, the sensor-based solutions have become generally accepted for
Inline-inspection. The benefits of sensor-based solutions:
- Fast processing speed. The results are provided in real-time.
- They work contact-free and offer a high degree of robustness.
- The small amount of integration work. The installation of its own station in
the production process is not necessary.
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| processobserver classic
Process monitoring during laser welding,
drilling and cutting |
- Online process monitoring during the laser material processing (welding,
cutting, drilling, soldering)
- Defects not visible to the naked eye can be detected
- Automatic quality assurance in real-time
- Error evaluation during the machining process
- Detection of defects such as pores/seam narrowing, spitting/welding
splashes, changes in the welding depth, insufficient connection and
contaminants
- Documentation and storage of the measurement data according to ISO
9001/2
Functioning principle of the plasmo powerobserver:
The monitoring takes place through observation of process light occurring during
the machining process in the visible and invisible (NIR) range. Fast signal or
RISC processors ensure for the online classification and error evaluation
directly during the machining process. The visualization and parameterization is
carried out by an industrial PC. The plasmo processobserver classic quickly and
reliably detects irregularities and defects, such as welding interruptions,
pores (even in the interior of the material), etc.
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| processobserver advanced
Process monitoring and/or power measurement in
one device |
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Two independent channels for process monitoring and/or power measurement in
one device
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Automatic process monitoring system integrated in the production process
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Defects are detected in real-time; the analysis is non-contact and
non-destructive
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Documentation and storage of the measurement data according to ISO 9001/2
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The statistical long-term evaluation of the data is an effective means for
process optimization
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Online process monitoring during the laser material processing (welding,
cutting, drilling, soldering)
- Defects not visible to the naked eye can be detected
Functioning principle of the plasmo processobserver advanced:
The process light is transmitted to a RISC processor (Power PC) by means of an
optical fiber via an optical adapter, a fiber mounting or an integrated fiber in
a machining head. The digitized and conditioned signal is analyzed and evaluated
by the RISC processor. The result is indicated in real-time at the end of the
weld by an IO/NIO-evaluation (IO = In Order; NIO = Not In Order) on the front
display and at one of the digital PLC outputs. In addition, the recorded signal
data are forwarded to a higher-level workstation for visualization over the
RS232 or Ethernet interface. For the workstation there are parameterization
tools available as well as visualization software (online/offline). Besides a
statistics module for short-term and long-term evaluation, there are other
helpful software tools available.
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| powerobserver
Fast and intelligent laser power measurement |
- Newly developed measuring device for laser power measurement
- Fast power measurement of approx. 1 - 2 sec.
- Accuracy of 3% relative to the maximum measuring range
Functioning principle of the plasmo powerobserver
The measuring device is calibrated at works and is supplied with a test
certificate. Documentation of your laser power - without reducing the
productivity of the plant. This is enabled by the innovative implementation of
the calorimeter principle: The specification about the laser power is not
achieved via the stable state of equilibrium, rather via the time-resolved
measurement of the rise in temperature.
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INDUSTRIAL IMAGE PROCESSING |
INNOVATION SOLVES
COMPLEX INSPECTION TASKS
Are you looking for solutions to complex inspection tasks in the manufacturing
industry? The plasmo engineers have developed an innovative approach for the
successful realization of industrial image processing projects, such as
- Measuring stones
- Measuring mirrors
- Detection of cracks
- Measuring of geometric forms
- Examination of weld and solder seams
- and many others
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profileobserver / profileobserver compact

Geometry measurement of weld
and solder seams
- Fast and precise geometry measurement of weld and solder seams
- Detects deviations from the admissible weld seam geometry with great
reliability and highest speed
- Detects e.g. seam cambering or concavity, edge notches, edge offset,
one-sided connection etc.
- Through high resolution the detection in the tenth of a millimeter range
possible at 6m/min. and above
- Also detects the dangerous pinholes or cracks, that are visible on the
surface
- With laser soldering also detects those pores, that have not been
reliably closed during painting
- Due to the high speed can be used parallel to the soldering robot
- Slim construction also enables the use for poorly accessible seams
This is how the plasmo profileobserver works...
The plasmo profileobserver series functions according to the principle of
laser triangulation.
The image is acquired by means of a High-Speed CMOS sensor at a speed of
max. 10,000 images/sec. The CMOS chip converts the recorded laser line
directly into height value 3D measured values. These are forwarded to an
industrial PC over an HSSI bus. In the industrial PC the evaluation of the
seam geometry takes place in real-time according to parameter-settable
quality characteristics.
At the end of a measuring cycle the result (IO = In Order/NIO = Not in
Order), type of defect and location of defect are shown on the monitor and
forwarded to the system PLC via a digital output or a bus system.
The software can be configured accordingly for the analysis of the
measurement data and for the control of the measuring sequence.
With the plasmo profileobserver with the same measuring speed not only the
height profile is recorded, but also a grayscale image. In the industrial PC
the gray value information is evaluated in addition to the 3D information
and additional quality characteristics are detected.
The plasmo profileobserver series functions according to the principle of
laser triangulation. The image is acquired by means of a High-Speed CMOS
sensor at a speed of max. 10,000 images/sec. The CMOS chip converts the
recorded laser line directly into height value 3D measured values. These are
forwarded to an industrial PC over an HSSI bus. In the industrial PC the
evaluation of the seam geometry takes place in real-time according to
parameter-settable quality characteristics.
At the end of a measuring cycle the result (IO = In Order/NIO = Not in
Order), type of defect and location of defect are shown on the monitor and
forwarded to the system PLC via a digital output or a bus system.
The software can be configured accordingly for the analysis of the
measurement data and for the control of the measuring sequence.
With the plasmo profileobserver with the same measuring speed not only the
height profile is recorded, but also a grayscale image. In the industrial PC
the gray value information is evaluated in addition to the 3D information
and additional quality characteristics are detected.
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mirror observer

Control of mirror surfaces
- Detects cosmetic defects such as minute scratches and inclusions
- Checks the degree of reflection and controls inhomogeneous reflection
- Control of mirror surfaces
- Acceptance of the necessary measuring tasks for the part handling
(automation)
Practice Report:
"Mirror, mirror on the wall…" - Quality control of reflecting, shining
surfaces
Surface inspection of shining, polished or reflecting surfaces places high
demands on the lighting equipment and the innovative power of companies.
Mostly it is necessary to design specific lighting to realise quality
inspection. For Magna in Ireland and in USA, plasmo developed an innovative
solution for measuring and quality inspection of electrochromatic interior
vehicle mirrors. Beyond the mirror inspection, this solution offers numerous
possible applications for quality control and measuring of reflecting,
shining surfaces in general such as in production processes of engine blocks
and cylinders, chromium steel kitchen appliances, glass surfaces, solar
panels, coils, etc. Details regarding this application example can be found
on our homepage under products/industrial image processing/mirror observer.
Brief report plasmo for Magna: Plus 40 per cent productivity
In the development of a solution for the measuring and quality inspection of
electrochromatic interior vehicle mirrors at Magna in Ireland and in USA the
plasmo "engineered solution" project approach proven over many years was
employed. Plasmo assumes all tasks from the definition of the inspection
task to operating the solution:
The first step was the Definition of the individual inspection or detection
tasks with an idea of what defect sizes have to be detected and which cycle
times have to be maintained - a process that took several months and was
conducted jointly with the customer.
A challenge that cannot be underestimated: In the vehicle mirror production,
16 different mirror geometries with different glass thicknesses, clip and
sizes and band lengths are used. Production amounts to 2.5 million units per
year in 3-shift operation with a cycle time of 7 seconds. The solution for
quality assurance should not cost any additional time in the production
process.
The solution
Integrated in the production processes are now several intelligent camera
systems on two image processing stations with the customised plasmo software
solution which checks the self-dimming mirrors of various automobiles for
cosmetic defects among others.
In other words, surface defects on the mirrors such as scratches,
inclusions, etc. or the installation of the clips are checked. Since some
defects can only be checked during the dimming and/or brightening operation,
quality inspection also takes place here and during the fastening of the
clips through gluing (tightness of the glue bead and the closure). In
addition, the application of the absorber pads and the quality of the
packaging are also checked. Finally the laser engraving of the serial number
is also checked to guarantee complete component traceability.
The result
The plasmo solution allows Magna 40 per cent more productivity. Defective
components are directly separated during the production process. Through the
stored quality documentation the traceability of individual production parts
can be guaranteed even after years which for example brings huge cost
savings in the event of possible complaints, call-back campaigns.
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3D observer

Image processing system for robot workspaces
- Provides 3D laser measurement for robot workspaces of several cubic
meters
- Measures highly precisely those parts that the robot grips or singles
out and determines the gripping point
- Takes component tolerances into account
- Based on laser triangulation and is adjusted extremely accurately or
calibrated precisely to a camera pixel
- Is particularly temperature stable due to carbon fiber elements
- Due to a very high scanning rate achieves shortest possible cycle times
and therefore greatest possible
- integration into the automation process
- Enables the positioning of the camera several meters above the measuring
area and thus avoids possible collisions with the robot
- Offers high flexibility as regards the interface solutions to CAD data
- Has a freely scalable system, which enables an optimal adaptation of the
measuring space and working distance to the customer system
- Achieves - depending on the working range - absolute accuracies of less
than 0.5 mm
How the plasmo 3D observer works ...
From a comparison with the associated CAD data, the camera system detects
which parts are at which position. The data of the parts to be processed are
transferred via XML files (component geometry description). The image
processing system determines the gripping points based on the measured 3D
coordination. The transmission of the coordinates of the individual parts
then takes place (x-, y-, z-coordinates as well as rotating angle +/- 1 mm).
The camera is positioned 1.5 m above the measuring surface and achieves an
absolute accuracy of less than +/- 1 mm.
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positioncontroller
Efficient weld seam position finding and reliable
measurement
- Efficient weld seam position finding
- Gap dimension measurement
- Finds joint gap with great precision and high speed
- Accuracy in the 1/100 mm range
- Regulates the Actual-position of the welding tool
The plasmo position controller functions like this ...
As an integrated system based on intelligent camera technology, the plasmo
positioncontroller requires the possibility to inspect the welded seam after
welding. Further measurements can be integrated into this system, such as
e.g. edge offset, gap dimension or the position of the welded seam after
welding.
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| Plasmo services |
For every order,
every project, at plasmo a consultant is engaged, who is best suited based on
his experience, his specialist knowledge and his connections in the respective
field. Complex assignments are processed in a team of specialists.
Our great stock of experience, specialist knowledge and social competence is not
limited only to analysis and consultation. The strength of plasmo Consulting
lies in the realization of projects and «seeing them through» to the finish. The
needs and demands of the customer are always the central focus.
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| Offer Profile |
plasmo offers innovative solutions for automated quality assurance and
-control systems in the manufacturing industry.
Vehicles, aircraft, ships, turbines, furnaces, household appliances, windows and
steel construction are safer, because plasmo systems inspect the quality.
Depending on the requirement, sensor- or camera-based inspection procedures
provide the matching solutions for automated quality assurance. The plasmo
engineers develop, adapt and integrate these according to your needs and
objectives.
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