The Easy Check System in Automotive Safety
Wear indicators in brake discs are a key element in vehicle safety, allowing rapid verification of disc condition through laser markings made at differentiated depths. This technology, called Easy Check, allows the wear level of the disc to be determined visually.
The Challenges of the Automotive Sector
The automotive industry imposes specific requirements for laser marking systems:
- High productivity with optimized cycle times for high cadence lines
- Full integration with factory robotic and MES systems
- Micrometric accuracy in marking depth
- Multi-point disc marking with consistent quality
- Real-time quality control integrated into the production cycle
- Optimal management of fumes and processing residues
The Technological Solution: Rotopic Laser System
The technological answer to these challenges is an integrated system that combines precision mechanics, advanced optics, and real-time control. At the heart of the system is a mechanical cam rotary table with three operating stations that enables machining in masked time.
Multi-station architecture
- Loading/unloading station:
- Optimized accessibility for robotic integration
- Workpiece presence sensors with dual control
- Quick disc locking system
- Marking station:
- Automatic centering system with side vision
- Integrated illuminator to optimize optical contrast
- Laser autofocus for precise positioning of the scanning head
- Rotary axis for multi-point marking with perpendicular beam
- Control station:
- High resolution optical profilometer
- 3D scan of the marked surface
- Real-time dimensional verification
- Integrated reporting system
The Operating Cycle
The marking process has been optimized to maximize efficiency through operations in masked time. The cycle consists of precise and simultaneous steps:
- At the first station, the robot loads the disc onto the rotary table. Once positioning is complete, the table rotates, bringing the part into the marking station. Here, the vision system automatically centers the disc, ensuring accurate positioning.
- The marking phase proceeds sequentially for the three wear indicators, positioned at 120° on the surface of the disc. For each indicator, the tilted rotating axis ensures that the laser beam is always perpendicular to the surface to be marked, ensuring uniformity and accuracy of marking.
- Once the marking is complete, the table rotates again bringing the disc into the third station for quality control by profilometer. During this stage, simultaneously:
- At the first station, the unloading of the previously controlled part and the loading of a new disk takes place
- In the second station the marking of the next record begins
This cycle management in masked time, combined with the presence of three operating stations, makes it possible to optimize processing time while maintaining high quality standards.
Laser Technology and Process Control
The technological heart of the system is the high-power picosecond laser, a technological choice that represents the state of the art in precision marking. This technology allows for optimal thermal control, which is essential to avoid alterations in the material that could compromise the mechanical properties of the brake disc. The system guarantees:
- Optimal thermal control to avoid material alteration
- Sharp edges and precise markings
- Uniform bottom surface without wobbles
- Operational flexibility with wide range of frequencies
System accuracy is further ensured by advanced process control that monitors all processing parameters in real time, allowing immediate adjustments to maintain consistent quality standards.
Vision and Quality Control System
Marking accuracy is ensured by a sophisticated vision and quality control system, which operates in real time during the production cycle. The side vision system, equipped with dedicated illuminator, ensures perfect centering of the disc before marking. The real innovation lies in the integrated 3D profilometer, a very high-precision measuring instrument that allows the depth of the markings to be verified with micrometric accuracy.
The system integrates:
- Side vision system for automatic centering
- Dedicated illuminator with adjustable intensity
- Image processing algorithms for edge detection
- 3D profilometer for depth measurement with micrometer accuracy
- Analysis software for real-time tolerance checking
Suction and Security System
The management of machining fumes and dust is a critical aspect in laser marking processes. The system implements an advanced extraction solution that ensures both process quality and safe working environment, with configuration options for ATEX-certified environments.
The suction system consists of a high-power pump sized specifically for the application. The main innovation lies in the design of the suction ducts: made entirely of metal in the marking area, they have been optimized to eliminate bends and accumulation points that could compromise the efficiency of the system.
Intelligent suction control includes:
- Real-time monitoring of suction efficiency
- Automatic filter saturation warning system
- Predictive maintenance management
- Safety locks integrated into the machine cycle
Integration Robotics and Industry 4.0
The system is designed as an integrated component of modern automated production lines. The robotic interface, developed in accordance with the latest industry standards, enables full automation of the loading/unloading process, while the control architecture ensures continuous data exchange with factory systems.
Integration takes place on several levels:
- Physical automation:
- Standardized robotic interface
- Calibrated reference systems for positioning accuracy
- Automatic management of loading/unloading sequences
- Real-time control of workpiece position
- Data integration:
- Two-way communication with factory MES
- Automatic management of production recipes
- Full process traceability
- Real-time quality reporting
- Intuitive operator interface with multiple levels of access
- Remote diagnostics and predictive maintenance
The system supports the main industrial communication protocols, providing maximum integration flexibility and allowing it to adapt to different production line configurations.