New Applications of In-Process Monitoring for Assembly Operations

A new approach to in-process monitoring has been described in earlier papers, based on non-contact sensors mounted right in the assembly weld tools. These sensors provide instant data to detect process variations, right at the station where operations occur. The current paper describes several new applications of the technology, particularly related to broad distribution of in-process sensors throughout assembly lines, including applications covering an entire body shop.

A major new application is described where the same in process sensor technologies are applied to monitor moving tooling components, such as dumps, slides and rotary tables. Monitoring positioning repeatability of these details quickly identifies problems due to wear or breakage.