Non-destructive inspection Example: connector housing

The connector housing to be inspected is combined with other components to form a plug over the course of the production process. This plug is ultimately integrated into machines and systems. Defects in the connector housing which are only identified in later process steps can lead to high additional costs. Thus quality defects in the plastic casting should be identified as quickly as possible and with 100% reliability.

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Success Story
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ZEISS CT solutions for plastic casting in volume production
ZEISS VoluMax Computed tomography system
ZEISS VoluMax
ZEISS CALYPSO
ZEISS REVERSE ENGINEERING
Success:
  • Verification of a quality feature on the basis of a single scan
  • Non-destructive 3D inspection of concealed structures
  • Operator influence avoided
  • Visualizing the captured data in chronological order
  • Data can be accessed in realtime and at any time

Inspection in Volume Production with Large Quantities

Characteristics

Defects which can occur in the plastic casting and must be inspected are:

  • cavities
  • deformations
  • deviating dimensions and wall thicknesses
  • burrs
The 3D dimensional stability can be ideally inspected using ZEISS CALYPSO CT.
The 3D dimensional stability can be ideally inspected using ZEISS CALYPSO CT.

Standard inspection methods

Standard, non-destructive inspection methods such as visual inspections or gage testing only enable particular aspects of the total quality to be monitored. In order to achieve an overall picture of the object, multiple processes must be combined and the results merged. Materialography is adestructive inspection process which provides information about the interior structures. However, it requires a lot of time and effort, making it unsuitable for regular inspections.

The benefit: ZEISS VoluMax

With the ZEISS VoluMax, all required quality features can be checked on the basis of just a single scan. As a single procedure, computed tomography enables destruction-free 3D inspection of hidden structures. This largely prevents subjective evaluations or operator influences. A particular strength of the ZEISS VoluMax is the dimensional analysis. The entire component can be compared in terms of its dimensional stability using CAD data or a reference section. Deviations are, for example, comprehensively displayed using color-coding.

Inspection of pores using VGStudio Max
Inspection of pores using VGStudio Max
Virtual component cross-section using VGStudio Max
Virtual component cross-section using VGStudio Max

Inspection in practice

Generally a shot of injection molded parts is taken from each injection molding machine during every shift and inspected using the CT machine. In special cases, multiple random samples are taken each shift. The components are recognized automatically, and prepared inspection programs perform an automated analysis. The number of cavities in the component can be read so that a detected defect can easily be attributed to an injection mold and a manufacturing cluster. Based on the inspection results, the operators decide to what extent components in the shift are approved for additional processing.

Quality data management using ZEISS PiWeb software

ZEISS VoluMax automatically generates a large quantity of valuable quality data which can be documented using ZEISS PiWeb software, made available anywhere in the world and evaluated.For example: ZEISS PiWeb offers the option of visualizing the captured datain chronological order. Gradual changes in quality, e.g. because of wear, can be made visible and monitored. ZEISS PiWeb is also an ideal solution for the automatic and professional documentation of quality data. Stored centrally, these data can be accessed via a secure internet connection in realtime and at any time, further processed and analyzed in relation to other data.

The ZEISS PiWeb report shows which cavity is defective.
The ZEISS PiWeb report shows which cavity is defective.