SERVICE SPECIALIST FOR INDUSTRIAL COMPUTED TOMOGRAPHY

Assembly and joint control

Even if individual components appear to meet specifications, not everything always works as planned after the individual parts have been assembled. Collisions may occur or certain performance parameters may be missed. In such cases, the cause is often invisible from the outside. A look inside can pinpoint the cause. Industrial computed tomography makes this possible for you! 

After mounting, industrial CT can be used to observe the behavior of an assembly in various states. It is possible with ease to detect defects that occur during assembly.

If a problem occurs, the entire production batch could be affected. Disassembling everything is not an economical option. In these circumstances, a quick CT scan can provide a remedy. Our years of experience enable us to achieve a high degree of automation in assembly and joint inspection, which allows us to offer cost-effective solutions. If such problems, or similar ones, are of practical relevance to you, then you will certainly be interested in the following case studies.

Montagekontrolle und Fügekontrolle - Animation

Assembly and joining control using practical examples

Pumps

Montagekontrolle bei einer Pumpe - fehlerfrei

Error-free

Montagekontrolle bei einer Pumpe - fehlendes Teil

Error-prone

Challenge:

A pump about the size of a palm contains control electronics that are inserted completely as a circuit board by a robot. This is fastened by several pins that are firmly connected to the housing. The circuit board is pressed in via corresponding holes. The pins spread slightly and everything is fine. Normally!  Due to minimal tolerances and equally small positioning errors, it can occasionally happen that a pin is not hit correctly during assembly and is bent over instead. However, the press-in pressure remains constant, so that the assembly monitoring provided does not indicate an error in this case. 

Possible consequences:

After installation in the vehicle, an affected pump initially works perfectly. However, after driving a few kilometers or sometimes several hundred kilometers, a short circuit occurs between the circuit board and the housing. This can be caused, for example, by a violent impact when driving over a bump in the road. The result is that the pump fails and the vehicle comes to a standstill.

Resulting consequences for the manufacturer:
The pumps currently produced and not yet installed are not released by the customer without proof that they are free of defects. The only remedy is an 8D report or similar to release the current batch and find out how the problem can be effectively excluded in the future. 

Advantages of CT testing:

X-rays can be used to identify the problem, but the manufacturer does not have an automated, reliable process either for loading the X-ray machine or for evaluating the images. In contrast, Microvista's sophisticated software toolbox in combination with a fast CT scan allows the complete analysis of 100 pumps per hour and is up and running after a short preparation time.

Valve

Montagekontrolle eines Ventils - Dichtung nicht verbogen

Gasket fits correctly

Montagekontrolle eines Ventils - Dichtung verbogen

Seal sits incorrectly

Challenge:

When mounting a valve for opening and closing the cooling circuit in the vehicle, a shaft with a lever must be inserted. This lever is engaged by an actuator that acts as a final control element. Seals are pre-mounted in the valve to prevent coolant from escaping in the shaft area. When the shaft is pushed in, slight pressure is exerted on these seals. In rare cases, this can cause the seal to be squeezed, so that the seal lips no longer fit properly against the housing. The manufacturing process is therefore not 100% controlled. 

Possible consequences:

Coolant leaks out after several actuations. The effect, which is very slight at first, intensifies with further functional strokes, so that eventually recognizable puddles of coolant form under the vehicle. Although the problem occurs extremely rarely, it cannot be completely avoided by the production department.

Advantages of CT testing:

Microvista's automated processes can provide a cost-effective and fast 100% inspection. With this solution, there is no need for costly and lengthy design rework including new injection molds, iterations as well as sampling processes. Instead, the economic efficiency of production is ensured by a highly automated and effective design of the inspection process. In the case described here, all parts of a container (30 pieces) were digitized in one step and then evaluated using artificial intelligence. The valve manufacturer is satisfied with this solution and his customer is happy. The archiving of all analysis data can be seen as a small positive side effect. If field failures occur years later, this enables the manufacturer to prove that it has delivered quality parts to the assembly line.

What are the options for a CT inspection? 

Fast industrial CT analysis is available from Microvista at an excellent price-performance ratio. The unit costs for assembly and joint inspection shown in the examples should give you a basic idea of the price. Due to the fact that the challenges our customers face are usually very different, we create an individual offer for everyone.

Serienprüfung oder Bemusterung

Price examples for analyses with industrial computed tomography

Rapid industrial CT analysis is available from Microvista at an excellent price-performance ratio. The unit costs for assembly and joint inspection shown in the examples are intended to give you a basic idea of the price. Due to the fact that the challenges our customers face are usually very different, we create an individual offer for everyone.

Quantity Water pumps Valve
Checking of 4 soldered joints for correct geometry of the joining zone Examination for squeezing of a gasket in the assembled state
100 46,50 €/piece 25,00 €/piece
500 19,00 €/piece 13,00 €/piece
1000 11,00 €/piece 4,90 €/piece
Notice:
In each case, the complete parts logistics including the traceability of all inspection results as well as the fully automated evaluation including the result documents are covered.