SERVICE SPECIALIST
FOR INDUSTRIAL COMPUTERTOMOGRAPHY

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.