[Major companies / Automotive / Electronic materials line] Inline full thickness inspection system
Proposal for maximizing production capacity by incorporating an "inline full thickness inspection system" into existing automatic machines for large-scale automotive/electronic materials mass production lines.
For large-scale production lines with a total budget of over 30 million yen. We propose inline thickness measurement to eliminate bottlenecks in the inspection process.
◆ Solving the issue of "production capacity not improving due to inspection processes" In mass production sites for automotive battery casings, thermal interface materials (TIM) for AI servers, and 300mm semiconductor wafers, while the acceleration of processes is progressing, challenges such as "the final thickness inspection being reliant on human intervention and causing bottlenecks" and "inability to handle inline measurement errors and noise, leading to abandonment of automation" persist. Our company has experienced technical sales personnel who have directly developed specifications and implemented automatic inspection systems using high-precision displacement meters in some of the leading advanced mass production multi-lines in Japan. We will integrate our reliable transport technology to ensure seamless incorporation into existing lines. 【What we can solve for large mass production lines】 1. Maximizing production capacity (throughput): Eliminating bottlenecks in processes with a non-stop automatic inspection system that does not halt transport. 2. Advanced optimization of inline thickness measurement: Eliminating errors caused by line-specific micro-vibrations and workpiece tilting. Through our unique holding mechanisms and noise processing, we establish stable full monitoring that is practically usable in real-world settings. 3. Data linkage to upper systems: Real-time transfer and aggregation of acquired data, ensuring traceability.
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basic information
◆Basic Specifications of the Corresponding System and Engineering Flow 1. Structural Design Tailored to the Site Environment Careful structural design that considers the impact of delicate sensing due to fine floor vibrations in the factory and seasonal temperature changes in the manufacturing environment. We propose an optimal frame structure that fits within the limited installation space and transport layout of existing lines without strain. 2. Sensor Position Adjustment and Calibration Support Design of an easy-to-use position adjustment mechanism for finely tuning the installation angle and parallelism of the displacement gauge head. We also provide consultation on user-friendly jig designs that align with practical calibration procedures during work changes and regular maintenance. 3. Practical Flow from Specification Development to Delivery (Acceptance) A dedicated representative will visit the headquarters and development sites in the Kanto region directly to clarify the upstream specification development and acceptance criteria (thresholds for judgment and methods for handling measurement errors) in advance. After conducting preliminary actual machine tests (simulations) at the Oita factory, we will ensure reliable integration into the actual line. *We will visit the headquarters and development sites directly in the Kanto region (Tokyo, Kanagawa, Chiba, Saitama, Ibaraki, Tochigi, Gunma).
Price information
◆Target for Construction: Parallel Multiple Line and Inline Full Automatic Inspection System 【Price Estimate: 30 million yen to several hundred million yen per project】 We propose optimal inline thickness measurement that includes transportation, measurement, judgment, and data collection for mass production processes of automotive battery materials, high heat countermeasure sheets, semiconductor and electronic materials, etc. We will provide individual estimates based on equipment specifications, number of lines, inspection takt, etc. *Please feel free to consult us even for tabletop inspection jigs or small-scale partial automation, with a budget of several million yen, especially if you are considering future mass production or multiple line deployment, or if you have workpieces that are difficult to measure with conventional methods.
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Applications/Examples of results
◆Achievements in System Integration on Large-Scale Production Lines 1. Fuel Cells and Next-Generation Energy Sector An inline total thickness management system for electrolyte membranes at a major fuel cell development factory. A data processing specification was established that is practical for actual manufacturing sites, addressing laser scattering caused by the "surface roughness" specific to coating materials and substrates. 2. Battery and Lithium-Ion Battery Sector A coating thickness management system on a coating line for aluminum materials. Appropriate data processing and sensor placement were implemented to address variations and noise in measurement data caused by the overlap of substrate surface roughness and coating material roughness, contributing to the establishment of mass production systems for major manufacturers. 3. Thermal Interface Materials (TIM) An automatic thickness measurement system that monitors thickness variations in thermal conductive sheets used for thermal management. It addresses data variations due to surface roughness (irregularities) of the sheets and insufficient light reception (noise) specific to black materials by implementing appropriate sampling specifications. 4. 300mm Semiconductor Wafer Process An inline automatic thickness and warpage measurement system within the processing process. It responds to variations in measurement data caused by surface roughness and material characteristics of wafers during processing by constructing a data management and automatic inspection system synchronized with high-precision displacement meters.
Company information
Denken Co., Ltd. is a company that provides all-in-one solutions for the manufacturing, sales, and service of equipment and system development. Currently, we leverage our technological expertise cultivated in diverse fields such as FA equipment, semiconductors, energy, bicycle parking, health and medical devices, and precision sheet metal machining to contribute to solving social and customer challenges. We are also actively engaged in addressing environmental concerns and social issues, contributing to the realization of a sustainable society, while continuously creating new value based on the technology and trust we have built over many years of history.
