How SDC Ensured ±0.00015” Precision with Automated Measurement

Customer Overview

• Industry: Consumer Appliance Manufacturing
• Company Size: Large Manufacturer
• Production Focus: Precision components for food blenders
• Challenge: Ensuring in-line measurement and quality control for high-tolerance grinding operations

 

Technology

• Custom V-Belt Conveyor – Provides controlled part movement for precise measurement.
• Air Knife Cleaning System – Removes bulk contaminants before measurement.
• Absorbent Media Cleaning System – Eliminates residual cutting fluid for accurate readings.
• Keyence LS-9030 Laser Micrometer – Measures part diameters with sub-micron accuracy.
• Position Tracking System – Ensures each part is measured and sorted correctly.
• Allen-Bradley PLC & 7” Touchscreen HMI – Controls automation and provides operator interface.
• Dual Reject Air Blow-Off System – Directs non-conforming parts into separate bins.

 

The Challenge

A leading manufacturer of consumer food blender components needed an automated quality control solution to monitor part dimensions in real-time immediately following a grinding operation.

The company’s primary challenge was maintaining ultra-tight tolerances of ±0.00015” on critical part diameters. This level of precision required highly accurate measurement and immediate sorting of defective parts to prevent faulty components from progressing in production.

Key Challenges:

• Manual inspection was impractical – Operator inspection couldn’t reliably detect micron-level variations.
• Contaminants affected measurements – Residual cutting fluid skewed measurement accuracy.
• Defective parts needed instant removal – Non-conforming parts had to be sorted without slowing down production.

To meet these challenges, SDC engineered an automated in-line measuring system that integrated high-precision laser measurement, part cleaning, and automatic rejection of out-of-spec components.

 

Our Custom Solution

SDC designed a fully automated quality control system that:

• Cleans each part to remove contaminants before measurement.
• Measures part diameters in real-time using a laser micrometer.
• Tracks each part’s position to ensure accurate sorting.
• Automatically separates pass/fail parts using high-speed air jets.

 

Breaking Down the Automation Process

1. Precision Part Cleaning

Before measurement, each part passes through a dual-stage cleaning system:

• Air Knife Cleaning – High-pressure air removes loose contaminants and debris.
• Absorbent Media Cleaning – Removes residual cutting fluids that could interfere with laser measurement.

2. Real-Time Laser Measurement

• Parts move along a custom V-belt conveyor to ensure proper alignment for measurement.
• The Keyence LS-9030 Laser Micrometer measures part diameters to within ±0.00015”.
• The PLC system records and compares each measurement against pre-set tolerance limits.

3. Position Tracking & Sorting

• Each part is tracked throughout the conveyor system to ensure accurate sorting.
• The PLC determines pass/fail status based on real-time measurement data.
• Two air blow-off reject stations automatically separate non-conforming parts into dedicated bins.

4. Automated Sorting & Rejection

• Pass Parts: Continue down the production line for assembly.
• Fail Parts: Ejected via air jets into reject bins for review and rework.

 

Implementation & Results

Through rigorous design, testing, and integration, SDC delivered an automated in-line measuring system that significantly improved production efficiency and quality control.

Throughput Efficiency: Accurately measures 20 parts per minute without slowing production.
Precision & Consistency: Laser micrometry ensures 99.9% measurement accuracy.

Reduced Defects: Instant rejection prevents out-of-spec parts from reaching assembly.
Labor Reduction: Eliminates the need for manual inspection, cutting operational costs.
Real-Time Monitoring: The HMI interface allows operators to track quality trends.

The customer eliminated costly defects and improved overall production yield, leading to increased efficiency and repeatability.

 

Why Choose SDC for Automated Quality Control?

Expertise in High-Precision Measurement

SDC specializes in designing custom automated inspection and measurement systems for industries that demand ultra-tight tolerances. Our solutions:

• Improve accuracy and repeatability for critical components.
• Eliminate human error through real-time automated quality control.
• Reduce scrap and rework costs by instantly removing defective parts.
• Integrate seamlessly with existing production lines for minimal disruption.

Custom Quality Control Solutions for Every Industry

We help manufacturers automate precision measurement for:

• Medical Devices – Microscopic measurement for ultra-small components.
• Aerospace Parts – Ensuring compliance with aerospace-grade tolerances.
• Automotive Components – Real-time measurement for engine and drivetrain parts.
• Consumer Goods – Automated inspection for high-volume production.

By leveraging cutting-edge laser measurement, vision inspection, and automated sorting, SDC helps manufacturers achieve zero-defect production.