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Challenge / Problem
It's crucial to keep the thickness of the flexible shingle sheet within tolerance before the cutting stage in production.
Manual sampling inspection did not show deviations in dynamics. This led to defects, overuse of raw materials, and the risk of unstable product output.
Solution
We implemented a non-contact thickness measurement system based on our own DT-5 laser triangulation sensors.
The sensors work in pairs and continuously measure the thickness of the moving sheet right on the line.
The operator sees real-time values and trends, and the production team gets a tool for fast response to deviations.
Key Features:
- Material control at line speeds up to 150 m/min
- Measurement accuracy up to 0.1 mm
- Reliable with rough and complex surfaces
- Data refresh rate up to 500 Hz
- Dustproof IP65 housing and optional air purging for the control area
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Results
- Over 15% defect reduction thanks to instant thickness deviation detection
- Up to 7% raw material savings by maintaining thickness within tolerance
- 24/7 continuous control with no line stops and no manual checks
- Lower logistics costs by producing closer to the lower tolerance bound without quality loss
- Prevents defective shipments at the pre-cutting and packing stage
Technical Details:
- The system uses pairs of laser triangulation sensors, installed opposite each other.
- Thickness is calculated as the difference in distance between the upper and lower sensor, taking into account their known base distance.
- An air supply can be used for more stable measurements in dusty zones.
- Processing is performed in a control cabinet based on an industrial PC with Kvantron software.
- A patent for the thickness measurement system was registered under: RU 114362 U1.
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