Height sensing used to verify gear assembly versions during production


An Indian manufacturer of pre-assembled, forged and machined components for the automotive industry uses height sensing to ensure that the correct gear model is assembled with other parts during production.

Customer Values

  • Cost saving due to reduced component rejection
  • Reliable confirmation of gear model

Specific Product Advantages

  • Rugged laser sensor with metal housing
  • Sensing range up to 250 mm
  • Built-in changeover outputs
  • Easy adjustment due to visible beam
  • Adjustable focus of beam

    Customer Application

    The customer has two models of gears, both of which are designed to fit into the same location in the assembly, depending on which version is being produced. During the production process for each specific assembly, confirmation is required that the correct gear model has been mounted. This is achieved by verifying the assembly as a whole. Since the height of the assembled component differs depending on which gear model has been mounted, immediate identification of assembly height is the chosen sensing solution. Space is limited, so a compact sensor with a long sensing range is required. 

    Customer Solution

    The LTS-1180L-103 compact sensor from the 1180 series of photoelectric laser sensors is ideal for this application. Its compact size, easy adjustment and rugged metal housing make it suitable for this tough industrial environment.

    The mounted assembly has a curved section at the top. The sensor task is to detect the highest point of this curved section and verify the height of the finished component. The small beam spot of this laser sensor is therefore essential. By targeting the beam of sensor on this curved part, when the correct gear is in place the beam will be deflected and the sensor will not trigger the output. However, if the wrong part is mounted, i.e. with more height, it will obstruct the sensor beam and trigger the sensor output. By using a sensor with integral changeover outputs, the same sensor can be used to verify both models. Only one selection switch is required.