A new and automated control system can monitor the spray quality in gluing and coating processes in-line and in real time using a laser, high-precision optics and artificial intelligence (AI). It is an alternative to visual quality control that is quicker, consistently accurate and more economical in the long term.
Anyone who has used an adhesive spray process in production is well aware of its downsides. Defects in the bonds are either spotted too far down the line or not at all, despite complex technology and visual inspections. As a consequence, many defective parts are produced which must be disposed of at great expense or undergo time-intensive reworking. In the worst case scenario, it is the customer who discovers the defect, which can increase follow-up costs even more or lead to claims for damages.
AOM-Systems says it has now developed a new and automated control system ("SpraySpy Process Line") that monitors the glue application in-line and in real time using a laser, high-performance optics and sophisticated physics. "The innovative laser-based SpraySpy technology allows us to measure the droplets during the adhesive spray process. The procedure is based on the light scattering of moving particles. The technology is used for quality control in gluing processes and for the monitoring of tricky production processes in surface engineering," explains Meiko Hecker, Sales Manager at AOM-Systems.
Detecting contaminated nozzles in the blink of an eye
The system can measure size, speed and the number of droplets, all within a split second. With the help of algorithms, these measurements are used to generate data that delivers valuable production information to the plant operators and quality managers. This might include whether the coating meets the quality specifications or whether a production stage is running positively or negatively. This should enable defects in the spaying medium or faults in the spraying hardware and contaminants in the plant to be detected early on.
The system is already being put to practical use
The SpraySpy is being put to practical use by a manufacturer of airbag components that has switched to using adhesive spray in its manufacturing process. It requires a very precise amount of adhesive to be applied, often with high edge definition and without overspray. If the given amount of adhesive is not applied or is applied inconsistently – due to a contaminated air cap diverting the direction of the spray jet, for instance – then the product quality is inadequate. The SpraySpy technology is used for monitoring the coating in place of manual visual final inspection. This means that deviations can be detected that are too subtle for even experienced inspectors to spot during visual defect inspection. This example shows how the system brings objectivity to a subjective monitoring process.