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Detection of Holes

Detecting holes can be a major challenge. Perforated surfaces and objects with holes cause many sensors problems that can lead to damage or material jams. Here, you will find sensor solutions for reliable hole detection.

What Are the Advantages of wenglor Products?

Diverse Usage Options

Broad portfolio for diverse applications

Precise Hole Detection

Detection of different hole sizes and deviations in hole diameter

Avoidance of Quality Problems

Early identification of deviations and errors

Optimization of Material Use

Reduction of material waste in production

Challenges in Hole Detection

Hole Detection

In the production of paper, films and even sheet metal strips, the quality of the endless materials must be continuously checked. Failure to detect holes or cracks in time can lead to serious consequences, such as impaired product quality, damage to the machine, but also safety risks.

Solution
  • Retro-reflex sensors for transparent objects
  • Ultrasonic distance sensors
  • 2D/3D profile sensors

Quality Control of Objects in Holes

The quality control of objects in holes ensures that, for example, a thread is present inside a sleeve to ensure the quality standard in further process steps.

Solution
  • Reflex sensors with background suppression
  • Triangulation laser distance sensors

Detection of Objects with Holes

The detection of perforated objects, such as perforated sheets, grid boxes or printed circuit boards, poses a particular challenge for sensors. Sensors with an inadequately sized detection area could perceive the non-continuous surface of the object as interruptions or errors and thus generate erroneous signals.

Solution
  • Retro-reflex sensors with light band
  • Ultrasonic distance sensors

Measurement of Holes

When industrially manufacturing components or other objects, such as body parts, holes must be drilled. Before the parts can be joined together, it must be ensured that the holes have the exact dimensions so that the screws fit perfectly into the holes.

Solution
  • Vision systems
  • Smart cameras

Look Through a Hole

A major challenge in industrial production environments is the limited space for installing sensors. In conveyor lines, for example, the sensors look at the conveyor belt through holes in the side walls to detect passing objects.

Solution
  • universal retro-reflex sensors
  • Fiber-optic sensors
  • Energetic reflex sensors

Application Areas of Hole Detection

Presence Check for Screws and Nuts

Challenge: 
After the robot-controlled screwing process of body parts, it must be ensured that all screws and nuts are correctly installed in order to ensure the quality of the assembled body parts and to immediately detect faulty screws.

Solution:

Measuring the Indentation Diameter

Challenge:
To ensure the quality of the punching process in the automotive industry, it is necessary to precisely measure the diameter of the resulting indentations. Incorrect or inaccurate measurement can lead to quality issues and increased waste.

Solution:

Hole Inspection of Battery Covers

Challenge: 
When manufacturing battery covers, one challenge is precisely monitoring the punched holes. Fiber-optic sensors enable reliable and fast identification, ensuring quality for further processing.

Solution: 

Presence Check of PCBs

Challenge:
In the electronics industry, PCBs must be checked for presence at multiple stations to ensure safe transport and correct further processing. In particular, the different surface structure and insertion density of the PCBs require the use of sensors that work reliably despite these differences.

Solution:





Empty PCB Monitoring

Challenge:
When manufacturing PCBs, it is crucial that the blanks have exact holes. These must therefore be checked carefully before further processing, as even slight deviations can impair the function of the entire circuit. Sufficient illumination of the boards must also be ensured.

Solution:





Detection of Perforated Objects

Challenge:
In logistics, perforated boxes or cartons pose a particular challenge. To reliably detect objects with a non-continuous surface on the conveyor belt, a sensor with an enlarged detection area must be used. Sensors with a point light spot can misinterpret the hole as an interruption or error.

Solution:

Hole Detection for Precise Compartment Positioning

Challenge:
When it comes to precise compartment positioning in high-bay warehouses, the exact positioning of the shuttle in front of the compartment is crucial for error-free storage and retrieval of goods. This requires sensors that detect holes of different sizes at single and double depth and are insensitive to external light and temperature fluctuations.

Solution:

Presence Check of Storage Containers

Challenge:
In modern storage systems, the continuous checking of the load handling attachment assignment and the matching of the target and actual assignment is a challenge. The sensors installed on the shuttle must be able to reliably detect perforated boxes and containers at short distances.

Solution:

Detection of Containers with Drain Holes

Challenge:
In logistics, special containers made of metal or plastic are used, which have a drain hole to allow any condensate created in the containers can drain off. The challenge is to reliably detect the containers to enable a frictionless flow of material.

Solution:

Distance Measurement for Forklift

Challenge:
In large warehouses and distribution centers, the challenge is to ensure that forklifts pick up pallets with all kinds of goods correctly. For this purpose, the sensor used must reliably measure the distance of the autonomously moving forklift truck to the pallet foot, even in the event of uneven surfaces, holes or cracks.

Solution:

Film Tear Monitoring in Packaging Plants

Challenge:
A continuous supply of film material must be ensured in packaging plants. If (semi-)transparent films tear during the packaging process, faulty packaging is created. The sensors used must reliably detect damage regardless of color, surface and transparency.

Solution:



Determination of the Bore Center

Challenge:
Automatic bolting of bakelite and MDF boards is a particular challenge, as both boards and the screw must be positioned precisely. To allow for a tight fitting, a sensor should be used that can accurately determine the drill center.

Solution:

Fill-Level Measurement of Disinfectant Bottles

Challenge:
In automated filling systems in the hygiene product industry, the correct fill level is checked after filling disinfectants. This requires sensors that can measure the fill level contactlessly and precisely through the narrow bottle opening, regardless of color, transparency, reflection and degree of gloss.

Solution:

Hole Control for Paper Webs

Challenge:
In the printing industry, it is necessary to continuously check the paper web to ensure a continuous flow of material. This requires sensors that check the entire width of the paper web for cracks or holes at high speeds.

Solution:

Open-End Wrench Ejection Control

Challenge:
When checking the ejection of open-end wrenches on sliding devices, it is particularly important to detect material jams in good time. To reliably detect the flat shiny objects, a sensor must be positioned just above the conveyor belt.

Solution:

Hole Inspection of Flanges

Challenge:
Hole inspection of metal flanges in CNC machining portals is an important quality control measure. Due to the harsh ambient conditions prevailing there, the sensors used must be robust and resistant in order to reliably detect the drilled holes in the shiny components.

Solution:

Quality inspection of components

Challenge:
When manufacturing components in special machine construction, holes must be drilled in one work step. Before the components can be further processed, they must be checked for the presence of the holes to be drilled. This requires a sensor that reliably detects the holes in the reflective surfaces.

Solution:





Detection of Holes in Rotor Components

Challenge:
In mechanical engineering, it is necessary to check rotor components for the presence of holes for a smooth processing process. This requires the use of sensors that accurately detect holes both from a long distance and on glossy surfaces.

Solution:

Hole Check for Steel Belts

Challenge:
In the steel industry, continuous monitoring of sheet steel is crucial to ensure high product quality during processing. Detecting holes on the glossy and reflective surface at very high speeds is a major challenge for many sensors.

Solution:

Drill Hole Monitoring on Aircraft Wings

Challenge:
In the automated production of wing surfaces in aircraft construction, holes must be drilled on the wings. A machine vision camera is used to precisely drill these holes, ensuring reliable and accurate measurements. Additional lighting ensures sufficient illumination.

Solution:



Overview of Solutions

Hole Detection with Sensors

Hole Detection with Machine Vision

Downloads of Product Flyers for Hole Detection

P3 Series Product Flyer
P3 Series Product Flyer (2 MB)

This document provides an overview of the P3 series laser distance sensors.

der wintec. Brochure
der wintec. Brochure (1 MB)

This document contains the brochure on long-range laser distance sensors with wintec (wenglor interference-free technology).

Retro-Reflex Sensors with Light Band Product Flyer
Retro-Reflex Sensors with Light Band Product Flyer (3 MB)

This document contains the product flyer for the retro-reflex sensors with light band.

PNG//smart Product Flyer
PNG//smart Product Flyer (1 MB)

This document contains the PNG//smart sensors product flyer. Photoelectronic Next Generation stands for a new age of smart photoelectronic sensors.

Ultrasonic Sensors Product Flyer
Ultrasonic Sensors Product Flyer (995 KB)

This document contains the product flyer for the ultrasonic sensors.

B60 Smart Camera Product Flyer
B60 Smart Camera Product Flyer (968 KB)

This document contains the product flyer for the B60 smart camera.

weQube B50 Product Flyer
weQube B50 Product Flyer (6 MB)

This document contains the product flyer for the weQube B50.

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