Laser triangulation makes complex mechanical measurements unnecessary: assembly of high-speed doors

Case study: Blumenbecker equips its automation technology with ATLAS sensors by LAP

Integrated ATLAS sensor by LAP

With the ATLAS laser sensor by LAP, the concentricity of pipes can be measured during the last processing step of welding on the flange which saves time and money. The user does not have to wait until the weld seams have cooled to perform mechanical measurements. The Czech automation professionals at Blumenbecker in Prague have recently been using this timesaving laser system by LAP with made-in-Germany technology. The laser measuring sensors are employed in a pipe welding system made by Blumenbecker for the high-speed door manufacture Efaflex.

Efaflex which is headquartered in Bruckberg uses the PLC system developed by Blumenbecker to weld connecting flanges onto pipes. The Czech plant in Opařany, Efaflex is using LAP laser sensors to measure the concentricity and concentricity of the tubes online, thus ensuring proper tip-speed and quality of door systems. For the tubes are a critical element of high-speed doors, because the high-speed system rolls up the door panel around the tubes. And speeds them up up to four meters per second. If the tube differs minimally from the the specified tolerances, the entire reeling and thus the longevity of the system is compromised.

Ensure quality with LAP sensors and save time and money
If the pipes do not lie within the tolerances, they mustn't be used in the further assembly process. The solution that Blumenbecker developed for the gate manufacturer, Efaflex, allows this decision to be made during the welding process. There is no remeasuring involved.

Contact-free measuring dispenses with mechanical handling
The advantages of contact-free measurement are obvious. Pipes can be measured directly during the welding process without having to wait for the parts to cool. This is not possible with mechanical measuring. Either time is lost waiting for the fresh weld seam cool, or the measuring equipment is subject to mechanical stress. This necessarily causes expensive wear of the measuring equipment.

By measuring the pipes online, that is, during the production process, Efaflex ensures that the manufactured pipes have a high, standardised level of quality. Thus saving its customer time and expense.

“Of course we are delighted to help Blumenbecker assist Efaflex with production,” says Steffen Gärtner, a member of the General Industries sales team at LAP. “The feedback that Blumenbecker has received from its end customers about our sensors’ measuring precision has been completely positive. In addition, we are quite proud that high-tech professionals such as Blumenbecker and Efaflex put their trust in our system solutions.”

The ATLAS measuring sensor by LAP measures more precisely than the competition
Automation specialist Blumenbecker performed a series of test measurements with laser measuring systems by other manufacturers while developing a welding machine for Efaflex. “The results are clearly in favour of LAP. Compared with highly precise mechanical measurements, the measuring system of one competitor deviated by 0.1 to 0.3 mm, and the measuring system of another competitor deviated by as much as 0.2 to 0.5 mm,” explains Pavel Rotter from the design office at Blumenbecker in the town of Olmütz in the Czech Republic. “The measuring system with the integrated ATLAS sensors by the laser specialists at LAP performed best with a deviation of only 0.05 mm and was therefore approved for our project. Efaflex that bought our welding machine is quite satisfied with the results and has resolved to continue working with LAP sensors in the future.”

As big as a pack of cigarettes: ATLAS with new technology

In the second quarter of 2012, LAP engineers revised the ATLAS sensors and completely revitalised their capabilities. The measuring experts at LAP narrowed repetitive accuracy to within a micrometre and reduced measuring inaccuracies to a maximum of 2 micrometres. LAP enclosed the ATLAS laser sensor with these outstanding capabilities in an extremely compact casing. The outer diameter of this universal sensor is 80 x 65 x 33 mm, about twice as thick as a box of cigarettes. This allows the LAP sensor to be installed in small nooks of production machines with only a slight amount of available space.

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Your Press Contact

    Thomas Armbruster

    Tel.: +49 (0)4131 951195
    Fax: +49 (0)4131 951196

    LAP GmbH
    Laser Applikationen
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    21337 Lüneburg

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