Optimize Adhesive Application Processes with IR Pyrometer Technology
Challenges in Detecting Small Glue Points Enhancing Quality Control in High-Speed Production
Challenge
In high-speed adhesive applications, accurately detecting tiny glue droplets on various substrates is difficult due to material variability, rapid dispensing speeds, and the need for real-time quality control without slowing down production.
Solution
By integrating a compact, fast-response infrared pyrometer directly into the dispensing head, manufacturers can verify adhesive droplet presence in real time, enabling consistent quality control across diverse substrates and ultra-fast processes.
Benefits
- Ensures reliable glue detection even during ultra-fast dispensing operations
- Minimizes defective products by enabling immediate corrective actions
- Reduces material waste through accurate droplet verification
- Maintains high production speed without compromising on quality control
- Integrates seamlessly into existing automation systems with minimal disruption
Challenges in High-Speed Adhesive Applications
In the manufacturing industry, particularly in high-speed processes, the precise application and monitoring of adhesive materials are vital. Manufacturers often face the challenge of accurately detecting very small glue points on various substrates, such as cardboard, plastic components, or carbon parts. These substrates differ in material properties, which complicates the detection process. For instance, in applications involving high-frequency dispensing heads operating at high despensing speed, ensuring that each adhesive droplet adheres correctly to the target area is crucial for maintaining product integrity. The absence of reliable detection methods has historically led to incomplete bonding, product defects, and increased production costs.
The motivation for integrating precise temperature measurement into adhesive application processes stems from the necessity of real-time quality control. Monitoring the temperature of the adhesive immediately after application provides manufacturers with critical information about whether a glue droplet has been deposited correctly. This need for instant verification is especially pronounced in ultra-fast processes, where the margin for error is minimal. However, the actual temperature of the adhesive is less important than the ability to confirm the presence of the droplet. This is where advanced infrared technology, such as that provided by Optris, becomes essential, offering a solution that ensures both speed and accuracy in detecting adhesive points.
Efficient and Fast Adhesive Application Monitoring Requires Customized Optris Pyrometer
To address these challenges, Optris develops specialized infrared cameras and pyrometers that cater specifically to the needs of high-speed manufacturing environments. For example, in collaboration with a manufacturer well known for its adhesive dispensing systems, Optris uses a specially configured CT 3ML infrared pyrometer. This device handles the rapid pace required in such applications, with a response time as quick as 1 millisecond, enabling real-time detection of adhesive droplets.
The CT 3ML pyrometer is customized to meet the customer’s specific needs. Unlike standard models, this version of the CT 3ML operates without the usual electronics box, allowing for easier integration into the manufacturing setup. The pyrometer, featuring a compact sensing head with a diameter of just 14 mm and a length of 28 mm, is strategically mounted directly onto the adhesive dispensing head, where it detects the thermal signature of the adhesive as it exits the nozzle. This setup ensures that any deviations in adhesive application are immediately identified, providing a reliable and efficient method for quality control.
Operating at a short wavelength of 2.3 micrometers, the CT 3ML pyrometer is ideal for detecting minute thermal variations associated with adhesive droplets, especially in materials with unknown emissivity. The device offers a temperature measuring range from 50 °C to 400 °C (122 °F to 752 °F), making it suitable for a wide variety of adhesive applications. By outputting a 0–10-volt signal based on the detected temperature, the system clearly indicates whether a glue droplet is present. This rapid response is crucial for maintaining the high speeds required in modern manufacturing processes, ensuring that quality control does not slow down production.
The integration of the CT 3ML into existing systems is both efficient and non-disruptive. Its design allows it to operate in ambient temperatures up to 85 °C (185 °F) without cooling, making it suitable for demanding environments. The pyrometer’s compatibility with standard industrial automation systems, such as PLCs, means it can be seamlessly incorporated into broader process control systems. This flexibility makes the Optris solution particularly appealing for manufacturers looking to enhance their adhesive application processes without extensive modifications to their current operations.
Reducing Defects and Boosting Efficiency: Optris CT 3ML Pyrometer in Ultra-Fast Manufacturing
Adopting Optris infrared technology in the manufacturer’s adhesive application process has led to significant improvements in product quality and operational efficiency. The CT 3ML pyrometer special provides real-time, accurate detection of glue droplets, even in ultra-high-speed processes, thereby reducing the incidence of defective products. This capability ensures that each adhesive point is correctly applied and enables quick adjustments during production, minimizing waste and enhancing overall efficiency.
One of the most notable benefits of using Optris infrared technology is the immediate feedback loop it provides for monitoring adhesive application in real time. This allows manufacturers to detect and correct errors on the fly, reducing the likelihood of defects and ensuring a higher standard of product quality. Furthermore, the ease of integrating Optris pyrometers into existing production lines minimizes downtime and disruption, making the transition to this advanced technology smooth and cost-effective.
Manufacturers choose Optris not only for the performance of its infrared measurement solutions, but also for its unwavering commitment to meeting the specific requirements of high-speed manufacturing processes. The CT 3ML pyrometer special offering is a prime example of Optris’ ability to deliver customized solutions that meet the unique challenges of manufacturers like this application. This commitment to precision, reliability and customer support makes Optris an ideal partner for companies looking to optimize their adhesive application or similar processes.
In summary, the Optris CT 3ML pyrometer offers unparalleled speed, accuracy, and ease of integration, making it indispensable for manufacturers of high-speed adhesive applications.
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Talk to us about your IR Temperature Measurement Requirements
There are over 300 different pyrometer variants to choose from in the Optris infrared pyrometer portfolio each optimized for material, spot size, distance from the target, and environmental conditions. Fortunately, there is a trained engineer to phone or chat with to guide you through the process of choosing the perfect infrared sensor for your application.
The same support is available for the extensive IR camera product line.
