As part of the expansion of its product portfolio to include megacasting, the traditional supplier Handtmann is adapting its quality control for automotive components. With the introduction of new measuring technology and testing procedures, series monitoring is being implemented that ensures the high quality of particularly large components from the die casting process in real time, detects any deviations and can provide the customer with full data transparency for each component. With this step, Handtmann is investing not only in innovative megacasting but also in the upstream and downstream processes in order to achieve the best possible customer supply and market positioning.
For the inspection chain, the responsible company, Albert Handtmann Metallgusswerk GmbH & Co. KG installed a ZEISS OMNIA GC 200-180 X-ray system from ZEISS Industrial Quality Solutions. Using ADR Automated Defect Recognition technology, the X-ray system is designed for automatic defect detection in large components made of aluminum alloys and can not only detect deviations, but also report them. In addition, the system's software contains all the important libraries for acceptance standards and therefore enables testing according to customer-specific requirements. Typical components that are tested with the OMNIA GC are car rear ends, battery frames for electric vehicles and other structural components. These components must meet high safety and performance requirements.
Handtmann has also invested in a ZEISS ScanBox 5130 optical measuring system in order to carry out rapid series monitoring and analysis measurements. The device works in parallel with the production process. Whereas previously random samples were taken from ongoing production, sometimes sawn up and checked in a separate measuring room, the robot-guided, optical 3D scanner can now be used. With this ScanBox, heavy cast components with large dimensions of up to 3.5 metres can be inspected and fully digitized within 30 minutes. The measurement results and the resulting findings are sent online to the specialist department in real time using data-driven solutions.
In production measurement technology, it is important to identify, analyze and resolve quality problems as quickly as possible. In addition, the measurement results are stored in a database for subsequent statistical analysis in line with the existing Handtmann standard and can be made available to customers. The aim is to gradually integrate different components into the quality process.
Handtmann provides its employees with comprehensive training in the operation of the devices and compliance with quality standards. The training focuses on automatic component testing, programming the machines and the optimum use of the software. In the training sessions, important processes as well as programming and evaluation steps are taught and the applications for structural components are trained.
