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  • Inline Control
  • Telecentric Optics
  • Slit Gap

Rapid Filter Slot Gap Monitoring for NPK “Filter”

Challenge/Problem

When manufacturing slot filters, it is important to maintain the gap between the coils along the entire length of the product.

The challenge is complicated by the presence of coolant, vibrations, high temperatures, and humidity in the workshop. Without real-time monitoring, deviations are detected too late and require extra finishing checks.

Solution

We have implemented a real-time monitoring system that measures the slot gap directly during production.

The system uses an optical micrometer, telecentric optics, and a laser sensor to stabilize measurements.

If parameters go beyond tolerance, the system alerts the operator and can send a signal to the line controller for automatic correction.

Main Features:

  1. Slot gap control directly during production
  2. Works in tough environments: coolant, humidity, vibration, glare
  3. Real-time measurement results
  4. Statistics storage and automatic report generation
  5. Tool for localizing and analyzing non-compliance areas
Results
  • Automated control of critical parameter on the line
  • Reduced production setup and preparation time
  • Operators receive a deviation map for quick corrections
  • Increased measurement accuracy thanks to stable optics and algorithms
  • Avoided additional costs for separate finishing control

Technical Details:

  1. The system is based on an optical micrometer with an industrial CMOS sensor, a bi-telecentric lens, and backlight.
  2. A laser triangulation sensor tracks filter displacement and helps keep the measuring unit in position.
  3. When deviations are detected, the system generates a warning and, in one of the modes, sends a discrete signal to production equipment.

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