Thousands of laser measuring sensors are being used in tire manufacturing to monitor dimensional quality
Application for process and final inspection.
The application ranges from the tire tread extrusion profile and the width measurement on the roller to the tire construction measurement inspection, the finished wheel positioning and the measurement of the material volume on the conveyor belt.
Almost all of these
The contact sensor is a single point sensor, a single point measurement on the surface of the rubber.
They have proven to be superior to conventional contact/mechanical followers and capacitive sensors.
As tire specifications become more stringent, tire manufacturers need faster, more complex, and accurate measuring and testing equipment, while on-and off-
By providing more information, higher data density sensors can detect local geometric changes that are often missed by single point sensors.
To meet these requirements, a new intelligent laser line sensor for digital imaging has been developed.
These sensors provide extremely high resolution.
The horizontal measurement line in a single frame scans a section profile of up to 150 points or profiles.
Laser line induction (figure 1)
Similar to point triangulation.
The main difference is that an extended laser beam with an optical element illuminates a line on a horizontal surface.
2D digital camera image detector is used to view line images at a standard frame rate of 30 frames per second, with a camera exposure time of 15 ms. [
Figure 1 slightly]
Main features include-the-
Field measurements of material geometry changes in multiple sizes increase operator control over greater throughput, reduce waste, and strengthen production controls for optimal uniformity and product quality.
The development of these laser line sensors called EyeCON is the result of recent advances in digital technology, image processing and laser line projection.
These new sensors process more data than many other scanning systems.
The main use of these sensors is in the preparation of the plant, such as tire tread extrusion width and profile monitoring, tire manufacturing and measurement of the calender rubber.
Small sensor package for the specifications of laser sensors (figure 2)
Includes laser for operating sensors, 2D camera detectors, imaging optics, and in-house processing.
Internal processing the engineering unit that converts the data to output, and also the ability to process the data internally.
In the manufacturing process of advanced imaging and enhanced quality control using the Descartes coordinate algorithm, laser lines, optics, and 2D camera detectors are calibrated together.
3D data can be obtained when the encoder is applied to moving materials and used for calculation. [
The sensor is packaged in a rugged ip65/ Nf4 industrial housing for maximum accuracy and is ideal for a wide range of applications.
For maximum reliability and stability, the sensor does not use an internal moving mirror and can work at a temperature of 0 [degrees]C to 50[degrees]C (32[degrees]F to 122[degrees]F).
Size 359x70x70mm (14. 13 x 2. 75 x 2. 75 in. ).
Total depth of view/measurement (DOV)
287mm of the sensor (11. 3 in. ). Field of view (FOV)
Measurement is 104mm (4. 09 in. )
At close to 179mm (7. 04 in. )at the far end. Accuracy is [+ or -]0.
1% of the measured distance with a resolution of 0. 01 mm (0. 0004 in. ).
Eyes of laser line sensor-
The safe visible laser is Grade II for laser safety, simplifying the installation requirements.
In the past, IIIb laser sensors needed to fully collect enough data for many applications.
The IIIb class sensors have much more stringent requirements for laser safety, increasing system costs and complexity.
The laser line sensor has two connectors, a power connector for powering the sensor and an Ethernet connector for communicating with the sensor, located on the sensor housing.
The Ethernet connection of the sensor allows for use in any standard PC environment and runs on Windows 95 or later.
Maximum power of 8 to 32 v dc @ 10w is required.
Diagnostic software packages with sensors allow measurement and image snapshots to be taken in order to monitor the system during installation, normal production and failure
In order to obtain the best quality control and greater uniformity.
For full quality verification, it is easy to install at any line location.
Sensor with point
The line sensor based on the point triangle measurement has been very successful in the tire measurement because it provides a very high data rate (16 to 32 kHz)
, For analog and digital output with simple interfaces and resolutions as low as 25 microns.
In contrast, the laser line sensor obtains data at multiple surface points, and the data accumulation speed is slow.
Choosing the best sensor for a given application depends on specific performance requirements.
An important factor to consider is data density.
This is directly related to the data rate or frame rate of the sensor.
The choice of sensor types depends on the application and the ability of the data analysis software.
If reliable inspection of tires without limiting productivity requires high sensors to measure data rates, it is recommended that laser line sensors not only collect data at high speed, but also communicate effectively with PC or other equipment.
The new laser line sensor series is equipped with Ethernet connections.
In the past, most point sensor implementation passed the data through the simulation method, which made the data affected by noise in the factory environment.
Recently, point sensors have been developed with high-speed flow RS-
The 422 capability enables them to transmit digital measurement data at a speed of 460 kbps.
In tire monitoring applications, smart sensors that have applications inside most sensors are "smart sensors" that are used to control the software and hardware that the sensors run inside the sensor head.
These software functions include converting measurement data into engineering units (digital output)
, Automatic gain control to ensure that the data is accurate even if the surface reflectivity of the object changes rapidly, and in some cases, low-pass filtering and analog-to-digital conversion.
Sensor operating parameters for specific types of applications are also stored in the sensor head.
The latest developments in intelligent sensor technology have expanded the processing capabilities inside the sensor to allow additional processing capabilities (
Generated by sensor manufacturer, system integrator or end user)
Resides in the sensor head along with the sensor operation software.
Recently, with the introduction of new intelligent sensor technology, single point sensor (
Application software inside
By eliminating the need for external controllers, the sensor data collection and control software functions are integrated in the sensor head to achieve high efficiency and reduce system costs (
PC, PLC or other equipment).
The technology also simplifies software programming and sensor control.
This intelligent sensor technology runs application-specific analysis software inside the sensor housing and can also be used with updated laser line sensors.
The implementation example application of laser line sensing is mainly in the preparation of the factory.
They range from tire tread extrusion width measurement and profile, width measurement on roller, lateral and radial runout of uncured tire, tire construction measurement inspection, completion of wheel positioning and measurement of on conveyor belt volume of material.
The thickness profile/edge tracking laser line sensor is ideal for thickness profile and edge tracking.
For tread profiles, the laser line sensor eliminates the lateral scanning frame of smaller parts and enhances data collection during scanning to achieve higher automation intelligence and control.
Wire sensors are also useful for customers to replace expensive "smart cameras" with complex lighting packages and high engineering costs ".
Single sensor (figure 3)
Thickness profile data and edge position tracking can be provided.
The main advantage is that the sensor does not need a light strip or reflective strip under the network, and due to the accumulation of dirt, the accuracy will be reduced over time.
The sensor is located above the material and is not affected by debris falling from the line. [
Figure 3 slightly]
Width measurement using two sensors (figure 4)
Contour analysis is allowed at the edge of the material to achieve optimal quality control. [
Figure 4 slightly]
Conclusion of In-
In the rubber and tire industries, laser sensors are used in process and finished product applications to enhance competitive power by increasing productivity.
The new laser line sensor provides higher density data to provide a high level of quality, productivity and safety, and provides immediate measurement data to meet the exact requirements of customers and improve manufacturing quality and productivity.