8/10/2019 FIAT Inprotec - Induction Bonding Monitoring

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APPLICATION STORY

The flexibility of car exteriors is regulatedin stringent safety requirements, toensure optimal safety for both drivers and

pedestrians. Currently the automotiveindustry preferred method to reach theserequirements is a combination of a lightmetal surface and sophisticated bondingwith chemical components to givestiffness to the bonnet on the edges, whilemaintaining the elasticity at the centreof the bonnet. This helps to keep the carstructure rigid, while the cars exteriorcomponents remain flexible in order toavoid injuries to pedestrians in case of anaccident.

The process of combining these twoelements is called bonding. To bond plasticand metal the adhesive needs to be within

a temperature range of 150 to 180 degreesCelsius. Modern car manufacturers use amethod called electromagnetic induction

to reach the required temperature. Usingan electromagnet so called eddy currentsare generated in an electrically conductingobject, in this case the metal layer. Theresistance of the metal leads to thegeneration of heat.

Heating up to 180 C within secondsUsing conduction the metal layer of thecomponent is heated to the requiredtemperature within mere seconds. The heatof the metallic surface allows the structuraladhesive to reach the temperature of pre-polymerization, by going through a viscousto a solid state, bonding with the metallayer in the process.

FLIR thermal imaging cameras help toensure consistent quality of FIAT carsCars need to be light to be efficient in their fuel use, but they also have to be strong. Toachieve both of these goals modern car panels are made of a combination of a metal layeron top and a structural adhesive layer underneath. These layers are glued together usinginduction.

But this is a tricky process. The temperature has to be exactly right for the adhesion to work properly. To ensure that the adhesion goes smoothly FIAT has started to use FLIR thermalimaging cameras to provide automatic feedback during the process.

Each green square in this thermal image stands for oneof the measurement spots, 19 in this case. The user candene as many measurement spots as needed.

FLIR A615 thermalimaging camera

8/10/2019 FIAT Inprotec - Induction Bonding Monitoring

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APPLICATION STORY

For more information about thermal imagingcameras or about this application,please contact:

FLIR Commercial Systems B.V.Charles Petitweg 214847 NW Breda - NetherlandsPhone : +31 (0) 765 79 41 94Fax : +31 (0) 765 79 41 99e-mail : flir@flir.comwww.flir.com

The time it takes to complete this processdiffers depending on the type of adhesiveused and on the amount of bonded jointsrequired. Usually, it takes approximately 40to 45 seconds, from start to finish.

But like with all other processes somethingcan go wrong. If for some reason thetemperature at one or more adhesionpoints is not within the temperature rangeat which the adhesive functions properly,either too high or too low, this leads toweakness in the resulting component.

Quality controls with A-Series cameraensure proper adhesionFIAT was looking for a method to ensurethat the adhesion had worked, while theproduction process is in full operation. TheItaly based company Inprotec delivered justthat: a quality test using the FLIR A615thermal imaging camera.

Inprotec was founded in 1992 in Milanas a distributor of high-tech equipmentfor industrial safety applications. Soonthe professionals of Inprotec realized thepotential of thermal imaging technology,so the company became an official FLIR

products distributor. Nowadays the InprotecGroup has regional offices not only in Milan,Italy but also in Rome, Sicily, and even inAlgeria.

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Automatic alarm in case of unsuccessfulbond The reliable and accurate FLIR A615 thermalimaging camera detects temperaturedifferences as small as 0.05 degreesCelsius and produces thermal images ata resolution of 640 480 pixels. If theinduction heating process fails to reach theright temperature an automatic alarm willgo off, to warn the operating personnel.Since the bond is unsuccessful if thetemperature requirements arent met, thecomponent has to be discarded if that isthe case.

Roberto Ricca, Director of Sales at Inprotecs Thermal Imaging Department is very happywith the quality of the FLIR A615 thermalimaging camera. It provides exactly thedetailed thermal data needed for this typeof application.

SoftwareUsing the FLIR Software DevelopmentKit, Inprotec developed the interface forthe thermal acquisition of the inductionprocess using the FLIR A615. The thermaldata are stored on a server for qualitytraceability of the production of car bonnet.

The technicians at Inprotec insertedthe thermal imaging camera in a hardprotective exterior and installed a fan thatprevents fumes from dirtying the thermalimaging cameras optics. The distance to themeasured component is 4 meters, to allowautomated robot arm handling duringloading and unloading of components. Auser friendly touch screen user interfaceallows quick and easy operation by theplants personnel.

GigE Ethernet connectionThe thermal imaging cameras fullyradiometric video footage is transferredto the computer using a GigE Ethernetconnection, continues Ricca. GigE Vision isa new camera interface standard developedusing the Gigabit Ethernet communicationprotocol. GigE is the first standard to allowfor fast image transfer using low coststandard cables even over long distances.With GigE Vision, hardware and softwarefrom different vendors can interoperateseamlessly.

Marco Simioli, technical manager atKGR, the manufacturer of the induction

equipment, is very pleased with the FLIRA615 thermal imaging camera. "With theFLIR A615 system we are able to reach theoptimum performance of the productionline. The thermal data allows us to evaluateand optimize the heating process. Thealarm allows the operators to eliminatethe components that do not fit therequirements and to take corrective actionsto ensure a perfect production line."

System can be adapted for future use

The computer compares the temperaturereadings of 16 or more locations withpreviously determined parameters. If thedetected temperature values are too highor too low an alarm will go off. Accordingto Ricca the user can quite easily add extrameasurement spots. This is an importantfeature. Because this system is flexible it canbe adapted for use with future car modelsas well.

Every new car model includes an increasingnumber of bonded joints, explains Ricca.This makes a reliable and cost efficientquality check an even more important factorin maintaining high quality and productionrates. The automatic quality check using theFLIR A615 thermal imaging camera makesthat possible.

This thermal image shows induction heating at work.The metal parts heat up from room temperature to180 C in matter of seconds.

The technicians at Inprotec inserted the thermalimaging camera in a hard protective exterior. Thedistance to the measured component is 4 meters, toallow automated robot arm handling during loadingand unloading of components.