Photosensor ‘distances’ automotive manufacturer from rejects

When an automotive first-tier manufacturer of forged and machined components needed a distance measuring photoelectric sensor to ensure that the correct gear model is selected in an assembly, it turned to Contrinex.

The automotive industry is perhaps the largest user of automation because it provides efficiency and helps ensure the accuracy that is an essential part of the reliability we now expect from vehicles.

In this particular application, the manufacturer has a choice of two gears, which can both be fitted into the same location in the assembly. Therefore, it needed a reliable and ideally auditable method to ensure that the assembly contains the correct gear for the version being produced.

Utilising the fact that the height of the assembled component differs depending on which gear model has been mounted, automated identification of the assembly type is offered by using a distance measurement sensor. Because space is limited, a compact sensor with a long sensing range is required.

Contrinex’s DTL-C23PB diffuse laser distance measurement sensors offer an operating range of 20 to 100mm in a small 30 x 20 x 12mm sensor. Its compact size and IP67/IP69K-rated housing make it suitable for this industrial environment.

Whilst the DTR-C23PB sister sensors offer a longer 200mm sensing range, the DTL-C23PB was selected because it uses a laser light source which provides a small beam spot 1.5mm in diameter, which is ideal for accurately measuring the curved surface at the top of the assembly.

The sensor is part of a Poka-Yoke system which stops the production process if the incorrect gear assembly is presented to the gearbox, thus correct assembly is ensured for the manufacturer and in turn for their customer.