Special solutions: special machines and custom systems
As an industrial company, you need technical systems that do not yet exist on the market or that are not tailored to your prerequisites and requirements. It’s for this purpose that we develop and implement customised solutions – from hand-held measuring devices through to entire production lines.
We’ll support you in these fields of application, for example:
- Monitoring and testing your technical processes, e.g. in production
- Monitoring and checking the quality of your end products
- Monitoring and checking the quality of your suppliers’ products (incoming inspection)
- Optimisation and automation of your technical processes
- Final acceptance of individual technical systems
Why special solutions from Dimensionics?
Thanks to our many years of experience in the fields of measurement and testing technology as well as automation, we are able to analyse highly complex problems and develop solution concepts precisely for your requirements. Our systems are established at numerous companies in a wide range of industries.
Dimensionics stands for quality, and this is also reflected in our choice of components. We rely on sustainable components from established manufacturers and benefit from long-standing co-operations.
We work closely with our customers in developing new systems: You know your objective and what you want to achieve. From this, we derive the specific task, develop the solution approach and implement it step by step. Our common goal is to achieve the best possible result for your requirements.
Welding system developed by Dimensionics:
Part of a production line for fully automated welding & bolting including parts handling and quality monitoring.
Practical examples
The areas of application and industries for our systems are just as versatile as the machines themselves. To give you an idea of the range of the products we have developed, we would like to introduce you to some of the projects we have produced over the years.
Fully automated welding
The automation of processes is an integral part of the current development of manufacturing processes. For a large supplier to the automotive industry, the task was to develop a section of a production line that bolts components fully automatically and carries out welding processes at defined points. Together with our partners in the field of automation, a system was developed that makes it possible to handle the complex components and successfully implement the individual steps in the processes. The complexity of the task was primarily in the control and regulation of sub-processes and their successful interaction. The integrated measuring technology monitors the process and makes it more transparent and comprehensible for the customer. The documentation of the processes and the preparation of the measured values and results takes place within the system and can be easily transferred to higher-level ERP systems.
High-precision positioning of a nozzle
For the coating of foils, it is essential that the working nozzle is fed with high precision. The basic task of the system we developed was to position a manually inserted and tensioned nozzle with an accuracy of one micrometre. Not only should the translational infeed be secured, but also a possible rotation should be compensated for. Another task was to make the system ATEX-compliant. A complex tactile solution was requested and successfully executed. The algorithm we have developed enables all parameters and influencing factors to be recorded and processed and guarantees high precision even under difficult conditions.
Wiring aid as manual workstation
Our goal is to create optimal working conditions for our customers and their employees. The task in this case was to optimise the process of manually wiring circuit boards. The individual plates are made by hand, with wires the thickness of a hair and soldering points barely visible to the naked eye. In order to simplify this difficult task, a workstation was developed at which the worker is given optimal working conditions through a microscope. So that the worker does not have to control the individual points manually, a cross table was installed that uses an algorithm developed by us to control the position to be wired and to position the plate precisely to the micrometre. The worker can move to the next machining point by simply tapping a pedal. The system saves the progress and enables direct re-entry into the production process even during shift changes.
Fully automated measuring of beer kegs
The demand for ever more precise manufacturing and the associated documentation of results can also be found in one of Germany's most popular industries: beer brewing. In this case, the task was to randomly measure barrels that had been rolled and formed from sheet metal for external characteristics. The system relied on the optimised interaction of optical and tactile measuring technology.
After successful insertion, the barrel is moved to the alignment position by means of a gantry and a vacuum suction cup. Due to existing mirror shadows and a weld seam and the fact that a tactile measurement is taken on the surface, it is important that the barrel is aligned precisely. Probing at these measuring points would result in an incorrect assessment of the barrel with regard to various characteristic values. These features are detected by an image processing algorithm developed by us and enables the detection of the interference fields on a wide variety of colour spectra. From raw barrel measurement to a wide variety of colour and contrast levels, mirror shadows can be captured and the barrel aligned accordingly. This is followed by a complete tactile measurement, in which the system also implements complex measurement processes thanks to its sophisticated control concept. While the barrel is still being diverted back onto the conveyor belt, all the data is already processed for quality management and can be forwarded to a higher-level ERP system.
Example project flow
A reliable process is very important for your project. All steps must be interlocked. That's why Dimensionics delivers the complete solution, from concept to finished machine. This is how we guarantee the best quality and reliability of your special system.
