Close tolerance measurements on all injection mouldings ensure perfect connectors
16 July 2003Manufacturing / Production Technology, Hardware & Services
To ensure that only acceptable tolerance connector mouldings are produced in its factory, Erni uses a 3D measuring instrument especially developed by C E Johanssen of Sweden in conjunction with Optical Gaging Products of Rochester, USA.
Measurements are made by means of an optical CID (charge injection device) area array transistorised camera that has an image field capable of registering more than 60 000 pixels. Analysis of picture information is done by a microprocessor that also controls the camera functions. Maximum bandwidth errors are: 0,005 mm for the X-Y axis, and 0,012 mm for the Z axis.
Lighting via collimation lenses ensures a sharp picture that clearly highlights any undulations and pores in the mouldings being measured. Four-quadrant light sources using fresnel lenses and fibre-optics are used to measure individual planes. All imperfections are measured, recorded and subsequently used as a basis to modify the moulding tools. Only when 100% perfect mouldings are produced from a particular tool is this then finished and released for production purposes.
The drawing dimensions are programmed into the system whereafter the instrument is completely automatic. Two levels of measurements are performed:
* Every dimension is measured before a new tool with one or more cavities is released for production. The same applies as soon as any repairs or changes are made to tools.
* A reduced number of dimensions are measured from each production batch, particularly the dimensions that are influenced by tool erosion (caused by glass fibres mainly), by injection pressure, or by temperature tolerances.
All these dimensions are saved to disk and used to track production data on a continuous basis. Initially over 400 measurements are taken on a 96-way connector moulding to ensure that it is perfect.
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