Perfect coating thickness through precise height measurement
Quality inspection of a material applied to film in the µm-range
The precise control of industrial processes is a key component of modern manufacturing technologies. Particularly in coating, the inspection of layer thickness and surface properties plays a crucial role. To ensure that materials applied to films precisely meet the required specifications, we rely on innovative sensor technology and a custom-developed software solution. Deviations in layer thickness are in the µm range, requiring extremely precise sensors to detect and eliminate defects. This not only ensures consistently high product quality but also reduces material waste and sustainably lowers production costs.
Challenge
A conductive material is applied to a coated film. This process marks the start of a long production chain leading to the final product. Early inspection after the initial coating ensures that defective parts are excluded from further processing and refinement. This precise elimination of defective parts reduces costs, eases the workload of subsequent processes, and minimizes additional personnel requirements.
The goal
In collaboration with our client, we defined the following objectives for our project:
- Develop and integrate a test stand into the processes that allows precise measurement regardless of the test piece geometry.
- Ensure the new solution enables flexible measurement without requiring a fixed arrangement of the measuring positions.
- Reduce the measurement time while maintaining consistent accuracy.
To meet these criteria and develop a customized solution for our client, we conducted a comprehensive feasibility study in our specially equipped test laboratory.
The solution
Our system utilizes white light interferometry, a non-contact optical measurement method for surface topology measurements.
To ensure precise measurements, even in the presence of vibrations in the laboratory environment, we have integrated a specialized damping technology. This technology prevents even the slightest vibrations, such as those caused by foot traffic, from affecting the measurement results.
The DMC code is captured by an automated reading system, enabling the analyzed data to be directly assigned to the corresponding workpiece code and stored. This allows for easy retrospective verification and the quick generation of quality analysis statistics.
Thanks to the high precision of our sensors, we have successfully measured and documented both the coating thickness of the applied material and the surface roughness with exceptional accuracy. This ensures that all relevant quality parameters are continuously monitored.
To securely fix the base film for measurement, we developed a special device that suctions the film in place during the process. This ensures precise and repeatable measurement results, even with challenging material properties.
This comprehensive solution not only meets all requirements but also optimizes the entire inspection process. The combination of advanced sensor technology, precise data capture, and stable measurement techniques results in a significant increase in efficiency and a reduction in scrap.
This is why Goldlücke is the ideal partner
- 20 years of expertise in industrial image processing and the development of customized test systems and processes
- Comprehensive solutions from a single source, perfectly tailored to specific customer requirements
- Possibility to conduct feasibility studies in our in-house development laboratory
- Proprietary software to ensure reliable data analysis and continuous process optimization
- Highly qualified team with in-depth knowledge in mechanical and plant engineering, computer science, and electrical engineering
Do you have any questions about our systems?
Do you need a turnkey solution tailored to your requirements? We would be happy to discuss your needs and design a customized test system together. Feel free to send us a message or give us a call.