Kistler presents new solutions for process and quality control

There will also be customisable combinations of automation and inspection solutions, precisely controllable assembly systems for highly complex processes and technical innovations for fastening technology.

Solutions for quality assurance and process control not only differ significantly from industry to industry, but also between manufacturers within the same industry. Depending on the production process and the part to be inspected, they have to adapt their quality and process control precisely to the complex requirements of the industry and the customer. To this end, Kistler combines expertise from measuring, testing and automation under one roof and presents new automated and modular solutions for precisely coordinated quality monitoring and assurance at Control 2024.

Multicapture device: 360-degree inspection of lateral surfaces in a single pass in the KVC 821

At its booth, Kistler will show the new Multicapture Device in the KVC 821 optical quality inspection system for the first time. Thanks to eight mirrors arranged in a circle, the camera station captures the entire lateral surface of the test part. Deformations such as scratches or dents are thus detected without the parts having to be mechanically rotated. This means that parts with high-quality requirements can be inspected in a single pass, allowing cycle times of up to 400 parts per minute.

Kistler generates high-resolution test images with one camera per mirror to ensure that even the smallest defects are visible, and identifies them with their own image processing software KiVision. With the help of algorithms based on artificial intelligence, the software also detects previously unknown anomalies. Kistler will demonstrate how different requirements in optical quality assurance can be handled by showcasing its complete imaging portfolio. The KVC 821 can be equipped with 2D, 2.5D as well as 3D inspection methods.

Custom-automated assembly

The Smart Single Station from Kistler makes detailed quality inspections and precisely controlled assembly processes possible including thermal bonding during the production of components for axial flux or other electric drives for high torques. The Smart Single Station can be automated in varying degrees.

To this end, Kistler experts develop individual concepts tailored to the component, the cycle times, the production process or the manufacturer's testing requirements. From manually assembled stand-alone solutions to robot-supported systems, a broad range of solutions is available.

The Smart Single Station implements automatic 100% quality inspections or spot checks based on core technologies from Kistler: the entire range of sensors and electronics for pressure, force, acceleration, and torque measurement technology can be used in addition to the optical testing technology including the KiVision image processing software.

Fastening technology

At Control, Kistler also presents two new solutions for fastening technology: the cerTEST inspection system and the caliTEST-B calibration device offer easy, standard-compliant testing and calibration of torque tools, as required by the automotive and aviation industries or in the construction sector.

cerTEST allows mobile testing in a range from 0.2 to 500 Nm with up to four integrated fastening simulators. Torque tools like cordless, rotary, and impulse screwdrivers can be tested in accordance with standards such as VDI/VDE 2645 Sheet 2, VDI/VDE 2647 or DIN EN ISO 5393, even directly in the assembly line.

With caliTEST-B, Kistler displays a calibration device for torque wrenches or tools with an effective length of up to 1320 mm. Thanks to individually usable sensors, these can be calibrated in a range between 0.2 and 1,000 Nm in accordance with DIN EN ISO 6789. The user-friendly CEUS software guides users step by step through the measurement on both devices, it saves different measurement settings and histories and it automatically creates test reports.