Online Measurement Methods

Fraunhofer Center HTL develops customized measurement methods for process and product control. Depending on customer requirements, these can be designed for inline, online, at-line or offline measurements. The usual approach is to first determine the relevant process/product characteristics that need to be recorded. Often, more sophisticated laboratory methods are required for this purpose. For example, component defects can be detected very precisely using computed tomography. Inadmissible deviations can be classified by mechanical testing or by analyzing the effects of defects. Then, tests are conducted using less expensive, industry-suited measurement methods. Procedures are identified that can check warning and intervention threshold within the available time. For failure monitoring, simple and fast non-destructive testing methods can be used, such as X-ray inspection, sound and ultrasound tests, thermal wave or terahertz wave analysis.

Definition of Requirements and Framework Conditions

In the next step, a task specification is jointly developed with the customer, in which the requirements and framework conditions are precisely defined. The result of the task specification is a list of requirements that contains all relevant data/characteristics of the measurement system to be developed. Based on this, the HTL creates a concept for the specific system. Commercially available systems or system components and sensors are used to the greatest possible extent. The concept is coordinated with the customer.

Design of Machine Components and Construction of the Measurement System

Subsequently, the thermal, mechanical and electrical design of the machine components is carried out. The necessary CAD plans and the technical specifications for the system software are created. If necessary, FE simulations are carried out to verify the design and identify critical elements. The software is developed - if not commercially available - including the user interface and the interface to the process control system at the customer's site. If necessary, AI algorithms can be used to automate the interpretation of measurement data. In addition, a hazard analysis is performed. The construction of the measurement system is carried out using commercially available standard components as well as special parts manufactured on the machining center, the 3D printers or in the workshops at the HTL. The competencies at the Center for Device Development (CeDeD) of the Fraunhofer ISC are also used for construction of the system. If necessary, an EU Declaration of Conformity and CE labelling are carried out. After internal acceptance, the measurement system is handed over to the customer and the corresponding training is carried out.

Service Offering:

  • Selection and qualification of measurement methods suitable for the production environment
  • Creation of concepts for customer-specific measurement systems
  • Construction of customer-specific measurement systems for process or product control
  • Development and manufacture of high-temperature sensors
  • Development and construction of measurement ovens for high-temperature investigations

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