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Die-cast Machines

Processing Machines
Washers
Heat Treating
Machine Presses
Welders
Plastic Moulding Machines
Assembly
Innspection

Automotive Process Applications by Machine

Automotive Process
Applications by Machine

4
3
1

Die-cast Machines

Washers

Processing Machines

Die-cast products

Welders

Machine Presses

Pressed products

Plastic Moulding

Plastic Moulding Machines

Heat Treating

Automotive Process Applications by Machine

Die-cast Machines
Intrusion prevention
Detecting part seating in the de-burring process

Processing Machines
Detecting broken cutting tools
Thread detection

4
Assembly

Inspection

Assembly/Inspection
Parts
feeder

Shaft
assembly

O-ring
assembly

Transportation

Application of
adhesive agent

Packing label
machine

Gear
assembly

Inspection
machine

P14

Assembly
Detecting loose O-rings
Detecting the application of liquid adhesive
Assembly check of injector
Traceability for the assembly process

P12

Plastic Moulding Machines


Traceability of plastic products
Eliminating static for moulding machines
Detecting moulding failures
Confirming part removal

P10

Welders
Detecting multipul feeding
Measuring the amount of subduction for resistance welding
Safety detection for welders
Positional control of welding beads

P8

Machine Presses
Detecting workpiece seating
Measuring dimensions after forging
Detecting the entry of an operator
Confirming part ejection

P6

Heat Treating
Heat resistant fibre optics
Lasers that are resistant to colour change
Environment resistant sensors
Detecting and preventing falling targets

P5

Washers
Detecting targets within a washer
Detecting fluid levels in a parts washer
Detecting the entry of an operator
Detecting targets with mounting restrictions

P4

P16

Inspection
Inspection of motor core thickness
Measurement of groove depth after machining
Inspection of instrument panel
Detecting the presence of foam materials

P18

Automotive Process Applications by Machine

Die-cast Machines

Intrusion prevention
Recommended sensor

SL-VHM Series

[ REASON ]
With die-cast machines, there are many cases when workers must enter
the equipment area for mould replacement and maintenance. This
creates an increased need for the installation of safety light curtains.
Furthermore, when there is a high frequency of workers coming into
contact with the curtains, the risk of workers hitting or breaking the
sensors is increased. By using the SL-VHM Series, these concerns are
eliminated with reliable Type 4 protection and an ultra tough design.

Detecting part seating in the de-burring process


Recommended sensor

LV-N11N + LV-S62

[ REASON ]
In the de-burring process, the part must be securely fixed. The LV-S62
can be used for detection of improperly seated parts. If the part fixturing
is large, it is often tough to align the optical axis of a conventional
sensor. The LV-S62 provides a wide, 10mm, visible beam along with a
dual display amplifier. Aligning the beam spot on the reflector and
monitoring the received light intensity values on the amplifier allow
optimum alignment to be easily achieved.

Automotive Process Applications by Machine

Processing Machines

Detecting broken cutting tools


Recommended sensor

PX-10C + PX-H71TZ

[ REASON ]
A photoelectric sensor can be used to check for broken cutting
tools. With conventional contact methods, maintenance was
required due to wear, but with the PX, which has no moving parts or
areas of contact, the sensor can be used maintenance-free for a
long period of time. In addition, because the PX has an IP68g
enclosure rating, there is no need to worry about water or oil
entering the device and causing it to fail.

Thread detection
Recommended sensor

LV-N11N + LV-NH32

[ REASON ]
While conventional sensors have trouble detecting the presence of
threads, the LV-NH32 can easily detect the difference between a tapped
and untapped hole. With an unthreaded hole, sensor light is trapped
and is not returned, but with a threaded hole, much of the light is
reflected back to the sensor. Furthermore, because the LV-NH32 has an
adjustable beam spot diameter, it can be changed according to the size
of the hole and threads, producing extremely stable detection.

Automotive Process Applications by Machine

Washers

KEYENCE Technical Column about the PX Series

Why the PX Series is effective in wet processes:


1. Reduces the probability of malfunction by separating the transmitter and receiver
Current problems
1 Light is diffracted when

a water droplet attaches


to the sensor face.

NG

2 Influence from the back-

ground is directly received.

NG

3 Influence from

water droplets in the


environment.

Set in a Vformation

OK

2
Detection
range

NG
Receiver

Transmitter

1 Because the transmitter and receiver have been angled away


from each other, light is not diffracted.
2 Light hitting the background does not enter the receiver.
3 Does not see water droplets outside of the detection range.

2. Prevents chemical solutions from entering inside with its backfilled


epoxy resin design
Transparent epoxy resin is used to completely vacuum fill the case, heightening
the contact between cables and the lens and preventing the entry of liquid into the
internal circuitry, thus achieving a highly protected device.

Automotive Process Applications by Machine

Washers

Detecting targets within a washer


Recommended sensor

LV-21A + LV-H62F

[ REASON ]
With an IP67 enclosure rated sensor, there is no need to
worry about it being affected by washing liquid. By utilising
the LV-H62F laser sensor, it is possible to install the sensor
from a remote distance. In addition, with a reflector-type
sensor, installation is made easy as you only need to install
a reflector opposite the sensor head.

Detecting fluid levels in a parts washer


Recommended sensor

FS-N11N + FU-95S

[ REASON ]
Detection is possible without making contact with the liquid.
Though bubbles entering the pipes are unavoidable, the 16
linked optical axes of the FU-95S average out its effect,
thereby reducing the possibility of a detection error.

Detecting the entry of an operator


Recommended sensor

SL-VHM Series

[ REASON ]
In many processes that involve placement or removal of a
product, safety sensors are mounted from above or below
the perimeter to remain out of the way. However,
conventional sensors in this orientation often break due to
falling parts or washing liquid. The SL-VHM Series is both
slim, heavy duty and durable. It can withstand impact as
well as water with its IP67 enclosure rated body.

Detecting targets with mounting restrictions


Recommended sensor

PX-10C + PX-H71

[ REASON ]
Offers a method that can stably detect the target when only
reflective types can be used in the washer. Conventional
reflective sensors are influenced by the background of the
washer. By setting the thrubeam PX up in V-formation, it is
possible to detect the target without detecting the
background or washing liquid.

Automotive Process Applications by Machine

Heat Treating

KEYENCE Technical Column about the GV Series

The secret to detection reliability

Glass
Near

Far

Near

Angle

The angle between the receiver and the


transmitter doesn't change when the
target tilts.

Angle

The angle doesn't change through the


glass.

Far

Near

Far

Angle

The angle doesn't change when the


target's colour changes.

The GV uses triangulation to obtain the position of a target within a certain range. Laser light strikes a target
and is reflected back through lenses onto the GV CMOS receiver. The GV records the pixel position of the
received laser spot and converts the data into a relative measurement. Therefore, stable detection can be
achieved in the following:
(1) tilted position of the target;
(2) target detection through glass;
(3) detection of targets with frequently changing colours;

Automotive Process Applications by Machine

Heat Treating

Heat resistant fibre optics


Recommended sensor

FS-N11N + FU-84C

[ REASON ]
Heat-treating furnaces have extremely high temperatures
and easily break conventional sensors when they are used
in this environment. For cases like this, select one of our 17
different types of heat resistant fibre optic sensors that are
made to withstand a variety of high temperature ranges.

Lasers that are resistant to colour change


Recommended sensor

GV-21 + GV-H1000

[ REASON ]
There are many cases where the colour or surface
conditions vary for targets that come out of a heat-treating
furnace. The GV is a distance-based sensor that is
unaffected by colour or surface condition. By utilising a GV
in this type of situation, stable detection is possible
regardless of target colour.

Environment resistant sensors


Recommended sensor

PX-10C + PX-H71

[ REASON ]
Using ultra-high power, the PX performs stable detection
even in harsh environments that would typically cause
detection errors and temporary breakdowns with a
conventional sensor. In addition, the PX provides a
maintenance prediction alarm that further eliminates the
potential for temporary breakdowns.

Detecting and preventing falling targets


Recommended sensor

LV-21A + LV-H67

[ REASON ]
This sensor can stably detect at an ultra long range of 50 m.
When at this distance, it is generally very difficult to align the
optical axis. Since the LV-H67 is a retro-reflective type
sensor, installation is easy because it only requires that a
reflector be placed in the area that the laser hits. This
configuration allows long-range detection of reflective or
even mirrored targets before they fall off the line.

10

Automotive Process Applications by Machine

Machine Presses

KEYENCE Technical Column about the SL-V Series

Easy Troubleshooting
The status of the safety
light curtain can be
easily determined by the
easy-to-see LED indicators.

During startup

Verify alarm details


Wrong
wiring

Misaligned
beam
axes

Red
flashing
lights

Off or solid
red light
(part or all)

There is an error due to incorrect


wiring or similar problems.

LED bar
indicator
Indicator No.
(Either transmitter or
receiver) and the error

1 and 2
3
1 and 3
2 and 3
4
1 and 4

The beam axes are misaligned.

OSSD error
EDM error
Communication error
Receiver error
Transmitter error
Interlock error
System error

Receiver

Easy Alignment
With the HighlyVisible Indicators,
beam axis alignment
can be performed in
just three steps.

STEP 1

Align the top row

The top indicators light up red


when the top beam axis is aligned.

STEP 2

Align the bottom row

All of the indicators light up red


when the top and bottom beam
axes are aligned.

STEP 3
All of the indicators change to green
when all of the beam axes are aligned.

Fine-tune

Automotive Process Applications by Machine

11

Machine Presses

Detecting workpiece seating


Recommended sensor

LV-N11N + LV-S62

[ REASON ]
Verify proper workpiece seating during part transfer.
Because the optical axis is 10 mm wide, it is possible to
identify a raised area anywhere on the target. By detecting
improperly seated parts, damage to costly workpieces is
prevented.

Measuring dimensions after forging


Recommended sensor

GT2 Series

[ REASON ]
Uses a contact-type sensor to measure the dimensions of
components after forging. Because the GT2 Series keeps
track of the absolute position and retains the zero point
position, there is no need to worry about the stroke speed
or to align the master when restarting after a malfunction or
any other time when the device is restarted.

Detecting the entry of an operator


Recommended sensor

SL-V Series

[ REASON ]
Visible LED indicators enables easy installation and easy
troubleshooting. The SL-V can be connected with one
another up to 3 units in line, which allows various patterns
of arrangement, such as a U-shape or L-shape, easily with
less wiring.

Confirming part ejection


Recommended sensor

FS-N11N + FU-E40

[ REASON ]
The 40mm wide area allows parts to be detected, even if
position varies. When using the edge detection mode, the
influence of dust and dirt buildup is greatly reduced.

12

Automotive Process Applications by Machine

Welders

KEYENCE Technical Column about the SL-VHM Series

Impact Resistant Structure


1 The internal circuit is not fixed to the outer frame.

Heavy Duty, Waterproof type


SL-VHM NEW

This design prevents external stress from transmitting to


the circuit through the outer frame.

46.5
mm

2 The SL-VHM Series conforms to IP67 standards due to its


enhanced rubber gasket on the surface lens.
40 mm

With conventional models, additional housing must be used


for protection, but the SL-VHM series provides a tough, slim
structure without the need for additional protection.
[First in its class]
IP67 without any additional accessories

No misalignment from impact

Tough brackets ensure that the optical


axes do not become misaligned if struck.

No damage from impact

This model can be used where


workpieces often strike the unit.

No damage when wet

The SL-VFM/VHM Series conforms to IP65


and IP67 standards.

Automotive Process Applications by Machine

13
Welders

Detecting multiple feeds


Recommended sensor

GV-21P + GV-H45

[ REASON ]
Detection is possible when the targets are fed together more
or less than necessary. This is because detection is done
based on height, which allows for reliable inspections without
being affected by the surface conditions (colours and glares)
of the targets. In addition, since the GV Series has the area
detection mode, it is possible to deal with any inspections with
one output even when there are a lot of targets or few targets.

Measuring the amount of subduction for resistance welding


Recommended sensor

GT2 Series

[ REASON ]
Use a contact-type sensor to measure the amount of
subduction for resistance welding. With its long, 20 million
cycle lifespan, it is possible to reduce maintenance costs
and time required for replacement.

Safety detection for welders


Recommended sensor

SL-VHM Series

[ REASON ]
In the vicinity of the loader and unloader for a welder,
targets pass at an extremely high frequency and we have
heard that the targets will often end up colliding with and
breaking the light curtian. To deal with this issue, we
suggest the SL-VHM. The emitter and receiver portions
have been made into concave shapes to prevent target
collision, allowing for worry free use.

Positional control of welding beads


Recommended sensor

IL Series

[ REASON ]
Through external calculations of height data from the
sensor, the device detects the position of the weld seam.
Welding accuracy can be improved via measurement
data feedback to the welder.

14

Automotive Process Applications by Machine

Plastic Moulding Machines

KEYENCE Technical Column about the FU-U Series

Test Report
FU-U

Flex Test (Typical)


90

90

TEST CONDITIONS
Installation conditions: Installation according to the schematic drawing
Angle: 90 to the left or right
Bend radius: 30 mm
Load: 20 g
Speed: 30 times/min. (1 time = left to right and back again)

Test piece

FU-48U, FU-49U, FU-58U, FU-59U, FU-69U, FU-70U, FU-79U (3 pcs each)

TEST RESULTS

Up to 30 million bends without breaking


Note: Changing the test conditions above will vary the resulting number of bends. For example, reducing the load and increasing
the bend radius will increase the bend life span.

Automotive Process Applications by Machine

15

Plastic Moulding Machines

Traceability of plastic products


Recommended sensor

SR-600 Series

[ REASON ]
DataMatrix codes are often used for product traceability.
Codes can be applied through the use of labels or direct
marking to the plastic part. Fusing a new optical design
with advanced decoding techniques, the SR-600 Series
reliably reads even challenging, low print contrast codes.

Eliminating static for moulding machines


Recommended sensor

SJ Series

[ REASON ]
Static elimination for moulded items prevents them from
being left in the mould, or getting dust on them. The SJ
Series has achieved the shortest static elimination time in
the world by automatically controlling the ion balance
according the static status. It does not require manual ion
balance adjustment.

Detecting moulding failures


Recommended sensor

CV Series

[ REASON ]
Various easy-to-use filters and inspection tools ensure
steady inspections such as appearance inspections for
cracks, marks, dirt or foreign objects, and dimension
inspection. It prevents defects from being sent to the next
process.

Confirming part removal


Recommended sensor

FS-N11N + FU-U Series

[ REASON ]
FU-U Series fibres can be directly attached to a robotic arm
to confirm part removal and the presence of inserts.
Because they can withstand 20 million bends, they can be
used over long periods of time without requiring
maintenance.

16

Automotive Process Applications by Machine

Assembly

KEYENCE Technical Column about the GT2 Series

High-Precision Contact Digital Sensor GT2 Series


New Technology
Scale Shot System

KEYENCE INTRODUCES NEW TECHNOLOGY


Worlds first, high-speed scale shot* system using a CMOS sensor that scans the absolute
value quartz scale incorporating different patterns depending on the position.

Transmitter
Absolute
value scale

* Shutter speed: Approx. 6 s, Shooting interval: 1 ms

ADVANTAGES OF THE CONVENTIONAL SCALE METHOD (PULSE COUNTING)

CMOS sensor

High accuracy throughout the entire measurement range


Good temperature characteristics
ADVANTAGES OF THE CONVENTIONAL TRANSFORMER METHOD
No tracking errors
Absolute position detection

Long Life
Detection Durability: 20 million times

Water Resistant Cable


IP67 Enclosure Rating

Withstands Continuous Bending


Flexible Free-cut Robot Cable
Withstands bending 20 million times without
breaking (Typical usage)
90
Load (W): 250 g
Bend radius: 50 mm
Bending rate: 30 times/
minute
(1 time includes left to right to
original position)
Free cut: can be cut to length

Strong
rubber

Linear ball
bearing used

FREE CUT
W

17

Automotive Process Applications by Machine

Assembly

Detecting loose O-rings


Recommended sensor

GT2 Series

[ REASON ]
Use a contact type sensor to differentiate loose O-rings
during assembly. With the GT2 Series, it is possible to
output the results of the performed calculation with the GT2
amplifier unit to a PLC, making it possible to significantly
reduce programming costs.

Detecting the application of liquid adhesive


Recommended sensor

GV-21 + GV-H130

[ REASON ]
When applying liquid adhesive, if too little or nothing has
been applied, it will have an adverse effect on product
quality. The GV Series is able to perform stable detection
on inconsistent surfaces, such as liquid adhesive, due to its
distance based detection operation.

Assembly check of injector


Recommended sensor

CV-5001 + CV-035C

[ REASON ]
Prevent mixing of certain types of product by checking
colours, dimensions and length that differ depending on
the type, as well as checking deviation of stickers, if any. In
the process where more than one point is checked at once,
vision sensors are the most suitable.

Traceability for the assembly process


Recommended sensor

SR-600 Series

[ REASON ]
DataMatrix codes are used in the management of
automotive ICs. Fusing a new optical design with
advanced decoding techniques, the SR-600 Series reliably
reads even the most challenging, poor contrast codes
marked on the IC or lead frame.

18

Automotive Process Applications by Machine

Inspection

KEYENCE Technical Column about the IL Series

CMOS Analogue Laser Sensor IL Series


High-Precision Head + Multi-Function Amplifier
[Newly developed LSGC included] + [All-in-one design]
The stable measurement of any given target is possible by
sensing the target surface and adjusting the 600,000 times
dynamic range. Furthermore, in order to further streamline
communication with process control systems we have installed
application specific functions into the compact amplifier.

Reduced power

Increased power

When the workpiece is highly


reflective

When the workpiece is dark

Reflection

Power

Multi-Function Amplifier

C A L C U L AT I O N F U N C T I O N
Addition Mode
Setting example 1
(thickness measurement)

Subtraction Mode
Setting example 2
(width measurement)

Setting example 1
(Measurement of height difference)

Setting example 2
(Measuring tilt)

19

Automotive Process Applications by Machine

Inspection

Inspection of motor core thickness


Recommended sensor

IL-1000 + IL-030

[ REASON ]
Non-contact inspection allows instant measurement and
recognition by the mm without stopping work by just having
the products pass through. The two-head structure with
calculation function enables thickness inspection.

Measurement of groove depth after machining


Recommended sensor

IG-1000 + IG-028

[ REASON ]
The multi-purpose CCD laser type, the IG Series measure
process grooves in interim inspections after mechanical
processing and model mixing inspection before assembly.
By connecting an amplifier, it measures the edge positions
of the top and bottom of the groove and calculates the
depth of the groove instantly.

Inspection of instrument panel


Recommended sensor

CV-5701 + CV-H500C

[ REASON ]
The high-resolution colour camera performs lighting
inspection, respective pattern display inspection for the
LED, and mounting inspection for buttons. It covers a wide
area while keeping the resolution. Glare coming from shiny
plastic surfaces is removed with filters.

Detecting the presence of foam materials


Recommended sensor

FS-N11N + FU-40

[ REASON ]
Conventionally, it is difficult to detect foam materials using
reflective type sensors, since they absorb light. The FU-40
is a fibre unit with a built-in lens that allows for stable
detection of foam materials due to its focused beam. The
FU-40 can also be recommended for many other
applications requiring a higher power, focused beam.

SENSOR LINE-UP
A U TOMO T IV E IN DU ST RY
The 3 votes of confidence we provide for the Automotive Industries
All catalogue products
available for immediate delivery

Complete Variety

A L L - P U R P OS E P ROD U C T S

A trial unit that allows testing


prior to purchase

AC C O R D IN G TO USE

Fibre Sensor Amplifier/


Fibre Unit
FS/FU Series

Type4
Safety Light Curtain
SL-V Series

CMOS Laser Sensor


GV Series

Ultra High-Speed/
Multi-Camera Image Sensor
CV-5000 Series

Digital Laser Sensor


LV Series

Heavy-Duty Photoelectric Sensor


PX Series

RGB Digital Fibreoptic Sensor


CZ-V20 Series

High-Speed/High-Accuracy
CCD Laser Displacement Sensor
LK-G Series

Self-Contained
Photoelectric Sensor
PZ-G Series

High-Precision Contact
Digital Sensor
GT2 Series

Multi-Purpose CCD
Laser Micrometre
IG Series

CMOS Analogue
Laser Sensor
IL Series

Multi Pressure Sensor


AP Series

Proximity Sensor
E (V.Z.M.) Series

Ultra Compact
2D Code Reader
SR-600 Series

High-Accuracy
2D Laser Displacement Sensor
LJ-G Series

Please visit:

www.keyence.com

SAFETY INFORMATION
Please read the instruction manual carefully in
order to safely operate any KEYENCE product.

KEYENCE GLOBAL HEADQUARTERS


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WW1-1031

The information in this publication is based on KEYENCEs internal research/evaluation at the time of release and is subject to change without notice.
Copyright (c) 2011 KEYENCE CORPORATION. All rights reserved.
Auto-WW-AG-E 1051-1 600965 Printed in Japan
*