Sensors and process monitoring in production

Process monitoring of joining operations – 100 percent quality thanks to precision and reliability

Process monitoring and control of joining operations provide the essential bedrock for all successful industrial production operations – in sectors as varied as the automotive and consumer goods industries, medical technology, packaging and electronics. Dependable monitoring allowing early detection and filtering of faulty parts so as to avoid further unnecessary process steps, ensures 100 percent quality of the end products.

Assembly and testing

Piezoelectric sensors and process monitoring systems from Kistler make it easy to monitor and control the quality of simple or complex dynamic assembly processes. Both for manual or automated assembly. Faulty parts are identified immediately and filtered out directly during the assembly process to assure quality. Traceability of measurement data is always guaranteed. There is a variety of different sensors measuring force, pressure, or torque to monitor any process step during production.

Quality assurance for assembly – advantages of process monitoring systems from Kistler:

Suitable for dynamic processes
Up to 20 measurements per second
A large number of individually configurable measuring programs
Excellent flexibility
Easy to integrate into existing or new production lines
Traceable documentation of quality relevant production processes

Half-/fully automatic joining processes

Our monitoring systems for press-fit processes are used in combination with hydraulic, hydropneumatic, pneumatic or electrically powered press cylinders. With these systems, quality assurance based on force-displacement measurement can be integrated into the press fit process. Typical applications include press-fits for ball bearings as well as press-fitting gears onto drive shafts in transmissions. What's more, the process can be visualized and monitored with the help of professional monitoring systems. As well as direct mounting of the sensor technology in the press cylinder, options include indirect mounting on the C-frame or tool holder.

Quality assurance for press-fit processes – advantages of monitoring systems from Kistler:

Suitable for dynamic processes
Up to 20 measurements per second
Direct in-process measurement
Flexible retrofitting
Traceability of measurement data
100 percent control of the press-fitting process
Sensors with overload protection

Hand presses

Precise and reliable measuring technology is the key to comprehensive quality assurance for assembly, joining and testing processes using manual presses. We offer retrofittable solutions for monitoring processes on the manual press with the force sensor integrated into the tool holder of the manual press. Control tasks related to the manual press can also be accomplished. This approach makes the process on the manual press independent of the respective operator.

Quality assurance for manual presses – advantages of monitoring systems from Kistler:

Programmable step chains (sequences)
Wide measurement range
Flexible retrofitting
100 percent control of the press-fitting process
Sensors with overload protection

Clinching

The clinching process is used to produce a positive connection between two layers of sheet metal, and it requires no filler metals. Integrated force-displacement or force-time monitoring is implemented to guarantee comprehensive quality assurance for the clinching process. As an additional quality characteristic, the residual base thickness of the clinching point can be determined as well. As for all other process data, also here highly informative visualization and evaluation of this parameter is available.

Quality assurance for clinching processes – advantages of monitoring systems from Kistler: