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27.09.2018

EMG SOLIDⓇ IR: tailor-made solutions

Worldwide first: Oil layer measurement on individual sheets in the automotive pressing process

In the car body and parts manufacturing industry, the pressing process poses ever increasing challenges to the control of the process itself and the reduction of scrap. Steel grades with high strength values (e.g. AHSS) and low thicknesses react sensitively to the slightest disturbances in the pressing process. In addition to the roughness and tensile strength of the processed material, the exact oiling of the metal plates to be formed plays a decisive role in the quality and yield of the press line.

Advanced automobile manufacturers and press line operators not only check the oiling of the strip to be processed before the stamping process, but instead or additionally apply a tailor-made oiling to the stamped metal sheets. The target oil layer thickness varies across the blanked sheet area and can, for example, be lower at edges or cut-outs than on the rest of the plate.

Exactly this requirement was approached to EMG Automation (Beijing) Ltd. by an Asian press line operator. The aim was to measure the applied oil layer in longitudinal stripes on individual sheets, which are transported to the press in a fast cycle (2 m/s) via a conveyor belt. With regard to surfaces, oil types and space conditions, this task could be very well realized by the infrared spectroscopic oil layer measuring system EMG SOLIDⓇ IR. Completely new, however, were the requirements regarding the measurement of the oil film in individual stripes on the blanks.

EMG and EMG Beijing were also able to solve these requirements in close cooperation with the user. Two traversing infrared measuring heads are now being used on this line to check the incoming sheet from above (i.e. on one side). From these measurements, a flat image of the blanked sheet is then successively assembled.

The picture shows the installation situation on the left side. The sheets are coming out of the oiler [1], are moved over the circulating conveyor belt [2] under the EMG SOLIDⓇ IR measuring heads [3] and finally moved by a robot arm [4] (covered in the picture) into the press (or sorted out).

On the right side of the picture, the graphical user interface of the spot oiling can be seen at the top and the results of the oil layer measurement on the individual stripes at the bottom. By moving the mouse (red arrow) on the screen with the measurement results (bottom right), the user can directly read the oil layer in any stripe on the sheets and, in an emergency, derive measures for direct intervention in the production. 

Compared to a measurement on endless strips or coils, this system required extensive adaptations and special solutions on the software side, as well as additional sensors [5] for determining the edge of the conveyor belt. The programming work was mainly carried out by EMG Beijing with expert support from EMG Germany. 

The result of this innovative project is the world's first oil layer measurement on single metal sheets behind a spot lubricator, which allows the oiling result to be monitored online and resolved into longitudinal stripes. 

Have you become curious? Would you like to know more about EMG SOLIDⓇ IR and its possible applications on continuous production lines or press lines?

Then please download the short overview of EMG SOLID® IR or watch the video on oil layer measurement with EMG SOLID® technologies.

Please also contact our responsible sales manager Mr. Karl-Heinz Fröhning (karl-heinz.froehning@emg-automation.com), our international sales organization or directly our product manager Mr. Timo Gemmer (timo.gemmer@emg-automation.com).