KAIZEN

FOR AUTOMOTIVE INDUSTRY PROFESSIONALS

IMPROVEMENT CASES FOR EACH PRODUCTION PROCESS
 AUTOMOTIVE INDUSTRY
MAJOR KAIZEN CASE STUDIES

PRESS  Pages 04 - 05 WELDING  Pages 06 - 07

PAINTING  Pages 08 - 09 BODY/AXLE ASSEMBLY  Pages 10 - 11

FORGING  Pages 12 - 13 CASTING  Pages 14 - 15

2
 Press
PROCESSING  Pages 16-17 ENGINE ASSEMBLY  Pages 18-19

Welding
Painting
Body/axle
Forging
TRANSMISSION PERFORMANCE PRODUCTS
ASSEMBLY  ASSEMBLY 

Casting
Pages 20-21 Pages 22-23

Processing
Engine
Transmission

ELECTRONICS/
ECU ASSEMBLY
Performance

Pages 24-25
products
ECU
Introduction
Product

3
 PRESS

Pressing

Material cutting

Press environment
Environment is harsh with the presence of vibration, oil,
burrs, and chippings. There are variations in materials
and processing methods due to strength improvement,
weight reduction, and use of thinner plates.

KAIZEN achievements
Measuring the change over time in pressed high tensile
strength steel parts
Detecting double feeding of blanks
Detecting the thinning of hoop material winding
Measuring the parallelism and checking the behaviour of
die stroke
Differentiation of product types or cracks/wrinkles
Detecting feed bar stop position
Detecting brake shoe wear
Checking the seating or front/back of pressed parts

4
KAIZEN CASE STUDIES
MEASURING THE CHANGE OVER TIME IN PRESSED
HIGH TENSILE STRENGTH STEEL PARTS
GT2 Series
ADVANTAGES FEATURES
Quantifying the displacement after pressing makes The IP67G-compliant sensor ensures highly accurate
the process condition setting easier according to measurement even in environments with oil splashes.
the change in materials and processing methods. Moreover, KEYENCEs original principle prevents

Press
tracking errors and unknown origin position.

Welding
DETECTING DOUBLE FEEDING OF BLANKS
IA/IL Series
ADVANTAGES FEATURES

Painting
Detection immediately before pressing prevents die The High pass filter and Calculation functions can
breakage. remove the vibration of the target, ensuring stable
detection.

Body/axle
DETECTING THE THINNING OF HOOP MATERIAL WINDING

Forging
IA/IL Series
ADVANTAGES FEATURES
The amount of thinning can be managed with The SCAN function allows stable detection even when

Casting
numerical values, which allows controlling the the target has a metal surface or is inclined.
amount of remaining material. The reflective Measurement is possible from a distance of up to
sensor head enables easy set up of targets. 3.5m.

Processing
MEASURING THE PARALLELISM AND CHECKING THE BEHAVIOUR
OF DIE STROKE

Engine
IA/IL Series
ADVANTAGES FEATURES
Transmission

The parallelism of the die can be monitored
constantly. The data analysis of the behaviour
during pressing can be managed.
Data can be acquired using a PC or other device,
allowing for analyses and reports to be created.
Performance
products

CHECKING THE SHAPE OF AND CRACKS/WRINKLES IN PRESSED PARTS

IV Series
ECU

ADVANTAGES FEATURES
It is easy to differentiate NG targets having cracks The HS-HDR function and polarised filter ensure
or wrinkles which appear at random positions or stable detection even of a glossy metal surface.
Introduction

OK NG
Different to check the position of holes after pressing.
Product

marking

5
 WELDING

Floor welding

Side welding

Side mounting

Inspection

Final welding

Additional welding

Welding environment
Various methods are used such as spot
welding, arc welding, and laser welding.
The environment is extremely harsh with
presence of noises, spatters, and flux. There
are variations in materials and processing
methods due to strength improvement and
weight reduction.

KAIZEN achievements
Differentiation between the front and back/
presence and absence of weld nuts
Detecting the position of weld bead
Detecting low sealant
Z-axis control for a vision system
Measuring the waveform of welding current/
voltage
Checking the position of a welding torch

6
KAIZEN CASE STUDIES
DIFFERENTIATION BETWEEN THE FRONT AND BACK/PRESENCE
AND ABSENCE OF WELD NUTS
GT2 Series
ADVANTAGES FEATURES
The sensor can differentiate between the front and The sensor offers long service life of over 200 million
back of nuts. It also checks the presence of the tip cycles. Furthermore, the Scale Shot System II
based on not only counting but also the amount of prevents tracking errors and unknown origin

Press
wear. position.

Welding
DETECTING THE POSITION OF WELD BEAD
IA/IL, IV Series
ADVANTAGES FEATURES

The height or colour of the welded section can be
detected regardless of any change in materials.
Painting
The filter function ensures stable detection of height
differences (IL). The auto-focus function allows
detection of targets with different diameters from the
same installation distance (IV).

Body/axle
DETECTING LOW SEALANT

Forging
IV Series
ADVANTAGES FEATURES
The sensor can detect mastic, HEM and other The colour and shape differentiation ensures stable

Casting
sealant to ensure the quality of water resistance/ detection. The vision system with an ultra-compact
vibration insulation. head can be mounted where desired.

Processing
Z-AXIS CONTROL OF IMAGE INSPECTION FOR SMOOTH CHANGEOVER

Engine
IA/IL Series
ADVANTAGES FEATURES
Measuring the Z-axis during image inspection The SCAN function suppresses the influence of
Transmission

allows automatic switching of focal points surface conditions or colours. The laser emission
according to product types. timing can be controlled in order to not affect the
image inspection.
Performance
products

CHECKING THE POSITION OF A WELDING TORCH

IG Series
ECU

ADVANTAGES FEATURES
Monitoring the position deviation of the torch tip The built-in CCD is free from measurement errors
prevents failures such as welding line deviation. due to dirt. The position monitor allows easy optical-
Introduction

axis alignment and shows light attenuation at a

Product

glance.

7
 PAINTING

Drying

Preprocessing Under floor

rustproofing

Sealer

Middle painting

Inspection

Drying

Painting environment

Each of the electrodeposition, painting, and

drying processes requires strict control of
chemical solutions and temperature/humidity in
wet, explosion-proof, and clean environments.
Vigorous Processes are occurring for
environmental protection.

KAIZEN achievements

Preventing foreign particles from adhering

before painting
Measuring chain elongation constantly
Visualising static electricity
Eliminating static electricity quickly from
wrapping sheets
Recording the pH of a chemical solution bath
Checking the presence/absence of car body
markings

8
KAIZEN CASE STUDIES
PREVENTING FOREIGN PARTICLES FROM ADHERING BEFORE PAINTING
SJ Series
ADVANTAGES FEATURES
Static elimination can greatly reduce the adhesion The I.C.C. system allows static electricity elimination
of foreign particles. according to the electric charge. The self-diagnosis
function significantly reduces the man-hours for
maintenance.

Press
Welding
MEASURING CHAIN ELONGATION CONSTANTLY

Painting
IG Series
ADVANTAGES FEATURES
The sensor prevents car body from falling due to The inner diameter/clearance measurement mode

Body/axle
worn chains. Daily inspection can be replaced with is used to measure the chain all the time. The CCD is
constant monitoring based on quantitative control. resistant from measurement errors due to dirt.

Forging
Casting
DIFFERENTIATION OF CAR MODELS DURING ELECTRODEPOSITION PAINTING
IV Series

ADVANTAGES
The vision sensor enables the differentiation of car
models before painting or confirmation whether the
slide door is open or closed.
Processing
FEATURES
The detecting distance of 2 m eliminates the worry
for collision. The 32-bank, 16-point detection
supports flexible manufacturing.

Engine
Transmission
Performance
products
ECU
Introduction
Product

9
 BODY/AXLE ASSEMBLY

Trim

Engine

Fluid injection
and inspection

Final

Chassis

Car body assembly environment

Car body: T he process in a mixed flow production
line where the coordination between human
workers and robots is required.
Axle: T he process for handling many important parts
where assembly accuracy and process control are
required.

KAIZEN achievements
Measuring transfer chain elongation constantly
Differentiation of doors and side outer panels by
product types
Measuring the car height for the final inspection
Checking the carrier lock position
Controlling the liquid surface in the LCC injector

Differentiation of rotor types

Measuring the height of bush for press fitting
Detecting the position of uniformity marks
Feedback control for axle distortion correction

10
KAIZEN CASE STUDIES
MEASURING CHAIN ELONGATION CONSTANTLY
IG Series
ADVANTAGES FEATURES
The sensor prevents car body from falling due to The inner diameter/clearance measurement mode is
worn chains. Daily inspection can be replaced with used to measure the chain all the time. The CCD is
constant monitoring based on quantitative control. free from measurement errors due to dirt.

Press
DIFFERENTIATION OF DOORS AND SIDE OUTER PANELS BY PRODUCT TYPES

Welding
IA/IL Series
ADVANTAGES FEATURES
The shape differences between product types can The SCAN function suppresses the influence of
be identified based on the distance, which is surface conditions or colours. This ensures stable

Painting
effective for preventing assembly of wrong parts. distance detection.

Body/axle
INSPECTION OF CAR HEIGHT
IA/IL Series
ADVANTAGES FEATURES
The height or vibration of a car can be measured Data can be acquired using a PC or other device,

Forging
easily on multiple points. allowing for analyses and reports to be created.

Casting
DIFFERENTIATION OF ROTOR TYPES
IA/IL Series

Processing
ADVANTAGES FEATURES
During the assembly in a mixed flow production The SCAN function enables measurement of even a
line, the diameter or thickness is measured for the glossy metal surface from some angle.
differentiation of product types.

MEASURING THE HEIGHT OF BUSH FOR PRESS FITTING Engine

GT2 Series
Transmission

ADVANTAGES FEATURES
The assembly of important parts can be controlled The sensor offers long service life of over 200 million
based on digital values. cycles. The IP67G-compliant sensor can be used
Performance

reliably even in harsh environments with rubber

products

powder.

DETECTING UNIFORMITY MARKS

ECU

IV Series
ADVANTAGES FEATURES
The positions can be checked easily without the The 32-bank, 16-point detection supports flexible
Introduction
Product

need of severe positioning such as a light point manufacturing.

mark or a valve position. The auto-focus function supports switching of focal
points.

11
 FORGING

Inspection

Shot blasting

Heat treatment
Steel products

Cutting

Heating

Forging

Forging environment

Since various methods are used such as hot forging, cold

forging, and sintering, this process requires experience and
expertise for controlling pressure and temperature and taking
measures against heat or impact. The equipment is generally
highly expensive.

KAIZEN achievements

Controlling the sign for the wear in a clutch/brake unit

Distortion measurement and feedback control after forging
Controlling billet temperature and a preheating heater
Controlling the signs in equipment/IOT for environment
and condition management
Managing forging conditions (pressure, load)
Protecting heaters through continuous temperature control
Detecting the seating/looseness of targets

12
KAIZEN CASE STUDIES
CONTROLLING THE SIGN FOR THE WEAR IN A CLUTCH/BRAKE UNIT
GT2 Series
ADVANTAGES FEATURES
The sign for wear can be controlled through the The sensor offers long service life of over 200 million
check of the amount of wear in the clutch/brake unit cycles.
of a forging press. The Scale Shot System II prevents tracking errors
and unknown origin position even when impact is

Press
applied.

Welding
DISTORTION MEASUREMENT AND FEEDBACK CONTROL
GT2 Series
ADVANTAGES FEATURES

You can manage process conditions by controlling
the amount of distortion with digital values. The
inline measurement enables 100% inspection.
Painting
A wide choice of communication units supports the
communication with variety of PLC models.
Furthermore, the sensor offers long service life of
over 200 million cycles.

Body/axle
CONTROLLING BILLET TEMPERATURE AND A PREHEATING HEATER

Forging
FT Series
ADVANTAGES FEATURES
The surface temperature can be checked and used The laser pointer is useful for the repositioning during

Casting
for reducing the tact time in the preheating process changeover. The high-speed response of the
through temperature control. thermopile saves time.

Processing
DETECTING THE LOOSE SEATING OF A TRIMMING PRESS

Engine
IG Series
ADVANTAGES FEATURES
Detecting a loosely set target prevents die breakage. The built-in CCD is free from measurement errors
Transmission

due to dirt. The position monitor allows easy optical-

axis alignment and shows light attenuation at a
glance.
Performance
products
ECU
Introduction
Product

13
 CASTING

Melting/holding furnace

Casting/die-casting

Processing

Shot blasting/Burr removal

Casting environment

Various methods are used such as sand mould casting,

die casting, low pressure casting, and gravity casting.
Controlling temperature, pressure, and other factors is
extremely important to prevent blowholes, cavities, and burn
marks.

KAIZEN achievements

Checking die closure

Detecting the level of molten metal
Measuring the clearance/misalignment between die halves
of a core making machine
Measuring the stretch of a tie bar
Measuring height during finish processing
Measuring the inclination of a sand mould
Controlling the temperature of a holding furnace
Measuring the swell of an insert die

14
KAIZEN CASE STUDIES
CHECKING DIE-CASTING DIE CLOSURE
GT2 + DL Series
ADVANTAGES
Controlling the clearance between the die surfaces
is also effective for preventing burrs or providing
feedback control of the irregular swell of an insert
die caused by temperature distribution.
FEATURES
The Scale Shot System II prevents tracking errors
and unknown origin position even when impact is
applied. The calculation function provides automatic
calculation of parallelism.

Press
Welding
DETECTING THE LEVEL OF MOLTEN METAL
IA/IL Series
ADVANTAGES FEATURES

Non-contact detection is possible. The sensor
allows not only checking the upper and lower limits
but also displaying the height of molten metal
surface all the time.
Painting
The SCAN function suppresses the influence of
surface conditions to enable stable detection. The
sensor can be installed at a distance, preventing the
influence of heat.

Body/axle
MEASURING THE CLEARANCE/MISALIGNMENT BETWEEN DIE HALVES

Forging
OF A CORE MAKING MACHINE
EX Series
ADVANTAGES FEATURES

Casting
Retrieving data continually during manufacturing The small, heat-resistant sensor head has high
enables real-time process control. environmental resistance, allowing flexible layout
and facility behaviour analysis.

Processing
MEASURING THE STRETCH OF A TIE BAR

Engine
EX Series
ADVANTAGES FEATURES
Measuring the distortion of a tie bar during die The stretch can be measured easily through the
Transmission

closure allows quality control of moulded products use of a magnet jig. The linearity correction circuit
and preventing die breakage. provides 0.4 m resolution to achieve high accuracy
measurement.
Performance
products

MEASURING HEIGHT DURING FINISH PROCESSING

GT2 Series
ECU

ADVANTAGES FEATURES
Measuring every assembly reference plane ensures The pencil type enables measurement in a tight
shipment of highly reliable products. space. The Scale Shot System II prevents tracking
Introduction

errors and unknown origin position.

Product

15
 PROCESSING

Rough processing

Quenching

Inspection

Cleaning

Super finishing

Finish processing

Processing environment
Harsh environment that requires environmental
resistance against swarf, thermal expansion, and
so on, as well as accuracy through cutting oil
management, seating confirmation, and tool
management.

KAIZEN achievements

Flatness measurement, 100% inspection of

processed parts
Measuring outer diameter/thickness after
processing
Measuring the run-out of the main shaft of a
processing machine
Adjusting the chuck position of a processing
machine
Controlling improper chucking
Controlling table stroke
C
 hecking the rotation and contact of a grind stone
Checking for the chipping of tools

16
KAIZEN CASE STUDIES
FLATNESS MEASUREMENT, 100% INSPECTION OF PROCESSED PARTS
GT2 Series
ADVANTAGES FEATURES
One-hundred percent inspection is possible even The IP67G-compliant sensor ensures highly accurate
in harsh environments. The feedback control of measurement even in environments with oil splashes.
measurement data improves quality. Moreover, KEYENCEs original principle prevents
tracking errors and unknown origin position.

Press
Welding
MEASURING OUTER DIAMETER/THICKNESS AFTER PROCESSING

Painting
GT2 Series
ADVANTAGES FEATURES
You can manage process conditions by controlling The various calculation functions allows for easy

Body/axle
the thickness or outer diameter of processed outer diameter/thickness measurement. Since no PLC
targets with digital values. The inline measurement calculation unit is necessary, the cost can be saved.
enables 100% inspection.

Forging
Casting
MEASURING THE RUN-OUT OF THE MAIN SHAFT OF A PROCESSING MACHINE
EX Series

Processing
ADVANTAGES FEATURES
The eccentricity caused by trapped swarf can be The sampling of 40000 samples/second can follow
detected. high-speed rotation. The environment-proof sensor
head works reliably even in oily environments.

Engine
Transmission

ADJUSTING THE CHUCK POSITION OF A PROCESSING MACHINE

Performance
products

IA/IL Series
ADVANTAGES FEATURES
The sensor greatly reduces the man-hours for The SCAN function suppresses the influence of
changeover adjustment. The detection prevents surface conditions and enables stable detection even
ECU

damage to the equipment due to improper when the sensor is installed at an angle.
installation.
Introduction
Product

17
 ENGINE ASSEMBLY

Head Sub

Cam Housing Sub

Block Sub

Piston Sub

Test Bench

Main Assy

Engine assembly KAIZEN achievements

Block Sub Assy

Screening of bearing thickness before insertion
Detecting FIPG application to cases

Head Sub Assy

Checking the height of stem oil seals
Checking the height/assembly of retainer cotters
Screening of valve lifter shims

Piston Sub Assy

Measuring piston heating temperature
Measuring the press-fit of pistons
Checking the presence of snap rings

Main Assy
Detecting the peeling of oil seals
Measuring the height of tightened screws

18
KAIZEN CASE STUDIES
MEASURING THE PRESS-FIT LEVEL OF STEM OIL SEALS
GT2 Series
ADVANTAGES FEATURES
The assembly accuracy of important parts can be The Scale Shot System II prevents tracking errors
managed with a contact-type sensor reliably and and unknown origin position. The pencil type can be
accurately on the order of microns at low cost. mounted in a tight space.

Press
MEASURING BEARING HEIGHT

Welding
GT2 Series
ADVANTAGES FEATURES
The height measurement is performed when a The pencil type with a flange can be mounted
bearing is put into the bearing cap. This enables anywhere. The sensor offers long service life of over

Painting
control to reduce friction and abrasion. 200 million cycles for reliable operation.

SCREENING OF VALVE LIFTER SHIMS

Body/axle
GT2 Series
ADVANTAGES FEATURES
High-accuracy measurement can be achieved on The pencil type can be mounted even in a tight space.

Forging
the order of microns according to the height of the Furthermore, the sensor offers long service life of
valve. over 200 million cycles.

Casting
CHECKING THE PRESENCE OF SNAP RINGS
IV Series

Processing
ADVANTAGES FEATURES
Various metal parts can be differentiated based on The shape detection tool ensures reliable
shapes or colours, even with a metal background. differentiation between similar colours. The ambient
light correction function is also provided as
standard.

ADJUSTING THE CHUCK POSITION OF A PROCESSING MACHINE Engine

IA/IL Series
Transmission

ADVANTAGES FEATURES
The sensor greatly reduces the man-hours for The SCAN function suppresses the influence of
changeover adjustment. The detection prevents surface conditions and enables stable detection even
Performance

damage to the equipment due to improper when the sensor is installed at an angle.
products

installation.

DETECTING THE PRESENCE OF ADHESIVE

ECU

IV Series
ADVANTAGES FEATURES
The camera checks the presence and amount of The ultra-small vision sensor can be mounted easily.
Introduction
Product

adhesive to prevent coolant leak reliably. Saving OK/NG images is useful for cause analysis.

19
 TRANSMISSION ASSEMBLY

Carrier/Clutch Sub

Case/housing Sub

Valve Body Sub

Inspection

Main Assy

Transmission assembly KAIZEN achievements

Clearance measurement and screening of shims

Measuring the side clearance of oil pumps
Measuring clutch packs for assembly
Checking for different bolts
Checking for missing parts of a valve body
Detecting check balls and keys simultaneously
Detecting the presence of adhesive
Differentiation of bearing types, Measuring press-fit height
Measuring carrier assembly
Measuring the thickness of friction material
Differentiation of the front/back of friction material
Checking the assembly position of planetary gears
Static electricity elimination during valve body assembly
Identifying O-rings

20
KAIZEN CASE STUDIES
CLEARANCE MEASUREMENT AND SCREENING OF SHIMS
GT2 Series
ADVANTAGES FEATURES
Measuring the clearance in the case during the The pencil type enables measurement in a tight
press-fit of a bearing improves assembly accuracy. space. The Scale Shot System II prevents tracking
errors and unknown origin position.

Press
MEASURING THE SIDE CLEARANCE OF OIL PUMPS

Welding
GT2 Series
ADVANTAGES FEATURES
The clearance and flatness of the gear compartment The amplifier expansion function allows easy
can be managed accurately and easily on the order calculation of measured values. The data of multiple

Painting
of microns. amplifiers can be exchanged easily with a PLC.

MEASURING CLUTCH PACKS FOR ASSEMBLY

Body/axle
GT2 Series
ADVANTAGES FEATURES
The sensor ensures the accuracy of measurement The pencil type can be mounted even in a tight space.

Forging
during plate cutting or of clearance measurement Furthermore, the sensor offers long service life of
during pack assembly. over 200 million cycles.

Casting
CHECKING FOR DIFFERENT BOLTS
IG Series

ADVANTAGES
The thrubeam sensor with wide measuring area
allows detection of different bolts based on
numerical data of length or diameter instead of
presence or absence.
Processing
FEATURES
The built-in CCD hardly causes measurement errors
due to dirt. The position monitor allows easy optical-
axis alignment and shows light attenuation at a
glance.

CHECKING FOR MISSING PARTS OF A VALVE BODY Engine

Transmission

IA/IL Series
ADVANTAGES
The assembly of valves and check balls allows not
only checking presence and absence but also their
FEATURES
The SCAN function suppresses the influence of
surface conditions or colours and enables height
Performance

height values, which improves assembly accuracy. measurement as well as presence/absence detection
products

even when the sensor is installed at an angle.

DETECTING THE PRESENCE OF ADHESIVE

ECU

IV Series
ADVANTAGES FEATURES
The camera checks the presence and amount of The ultra-small vision sensor can be mounted easily.
Introduction
Product

adhesive to prevent coolant leak reliably. Saving OK/NG images is useful for cause analysis.

21
 PERFORMANCE PRODUCTS ASSEMBLY

Winding wire
Assembly

Joining/adhering

Adjustment/inspection

Sealing/moulding

Performance products assembly KAIZEN achievements

Checking the height before screw tightening

Checking the presence of multiple parts during assembly
Z-axis control of image inspection
Measuring the height for assembly/press fitting
High-speed static electricity elimination of a parts feeder
Measuring the height of moving/rotating objects
Detecting low adhesive
Measuring the temperature during welding of resin cases
Measuring the height after welding
Checking the marking on aluminium case housing
Colour differentiation of collars
Checking the number of spring windings
Measuring the looseness of seating
Measuring load pressure

22
KAIZEN CASE STUDIES
CHECKING THE HEIGHT BEFORE SCREW TIGHTENING
GT2 Series
ADVANTAGES FEATURES
Checking the height before screw tightening The pencil type can be mounted in a tight space.
prevents problems such as trapped objects. The sensor can be used for long service life of over
200 million cycles.

Press
CHECKING THE PRESENCE OF MULTIPLE ASSEMBLED CLIPS
IV Series

Welding
ADVANTAGES FEATURES
A single sensor can detect multiple points, which The 32-bank, 16-point detection supports flexible
OK NG Missing clips eliminates the need for changeover adjustment. manufacturing. The auto-focus function supports

Painting
switching of focal points.

Z-AXIS CONTROL OF IMAGE INSPECTION FOR SMOOTH CHANGEOVER

Body/axle
IA/IL Series
ADVANTAGES FEATURES
Measuring the Z-axis during image inspection The SCAN function suppresses the influence of

Forging
allows automatic switching of focal points surface conditions or colours. The laser emission
according to product types. timing can be controlled in order not to affect the
image.

Casting
MEASURING THE HEIGHT FOR ASSEMBLY/PRESS FITTING
IG Series

ADVANTAGES
Checking the accuracy before parts assembly
improves the accuracy of selective assembly.
Processing
FEATURES
The multi-wavelength laser + I-BRAIN achieve
stable and accurate detection. The position monitor
allows easy optical-axis alignment and shows light
attenuation at a glance.

Engine
HIGH-SPEED STATIC ELECTRICITY ELIMINATION OF A PARTS FEEDER
SJ Series
Transmission

ADVANTAGES FEATURES
The static eliminator improves the operating rate The I.C.C. function provides optimum ion control for
which would decrease due to clogged parts. the charge, and allows high-speed static electricity
elimination and low maintenance.
Performance
products

MEASURING THE HEIGHT OF MOVING/ROTATING OBJECTS

IA/IL Series
ECU

ADVANTAGES FEATURES
Measuring the height of targets while they are The High pass filter function allows height
moving or rotating reduces the cycle time and measurement without being affected by target
Introduction
Product

saves the process of inspection. movement. The influence of equipment vibration can
also be eliminated.

23
 ELECTRONICS/ECU ASSEMBLY

Soldering

Assembly

Implementation

Coating

Case assembly

Inspection

KAIZEN achievements

Visualising static electricity during PCB transfer

Eliminating static electricity from both front and
back sides during tunnel transfer
Checking the application of coating material
Adjusting the alignment of PCBs
Measuring the parallelism of ECU frames
Measuring the height during welding of resin
covers
Differentiation of connector types
Counting connector pins, Detecting broken pins
Measuring height after gel application
Checking the presence of marking
Checking for different ECU labels

24
KAIZEN CASE STUDIES
CONTROLLING THE HEIGHT DURING PCB/COVER ASSEMBLY
GT2 Series
ADVANTAGES FEATURES
Checking the height before screw tightening The pencil type can be mounted in a tight space.
prevents problems such as trapped objects. The sensor can be used for long service life of over
200 million cycles.

Press
CHECKING FOR DIFFERENT COMPONENTS DURING PCB ASSEMBLY
IV Series

Welding
ADVANTAGES FEATURES
The area detection allows a single sensor to detect The 32-bank, 16-point detection supports flexible
multiple points. This eliminates the need for sensor manufacturing.

Painting
adjustment during changeover. The auto-focus function supports switching of focal
points.

DETECTING BROKEN OR BENT CONNECTOR PINS

Body/axle
IG Series
ADVANTAGES FEATURES
The thrubeam model can reliably detect broken or Various application modes make gap or width

Forging
chipped pins regardless of their shapes or colours. measurement easy. The multi-wavelength laser
ensures stable, high-accuracy detection.

Casting
HEIGHT/WARPAGE INSPECTION OF PCBS
IA/IL Series

ADVANTAGES
The height of targets, which cannot be measured
with image processing, can be detected without
being affected by product surface conditions.
Processing
FEATURES
The SCAN function suppresses the influence of
surface conditions and enables stable detection even
when the sensor is installed at an angle.

Engine
STATIC ELECTRICITY ELIMINATION OF A PRINTER
SJ Series
Transmission

ADVANTAGES FEATURES
Eliminating the static electricity of PCBs and The I.C.C. function provides optimum ion control for
visualising electrostatic charge improve printing the charge, and allows high-speed static electricity
quality. elimination and low maintenance.
Performance
products

DETECTING THE TEMPERATURE OF A SOLDERING DEVICE

FT Series
ECU

ADVANTAGES FEATURES
Direct control of the temperature is possible based The high-speed response of the thermopile enables
on checking the actual device, instead of indirect reading of instantaneous change in temperature. The
Introduction
Product

control based on process conditions. laser pointer indicates the point to be measured at a
glance.

25
 KEYENCE TECHNOLOGY
ISSUE/PROBLEM
VISION SENSOR IV Series
First-in-class
automatic focus mechanism
This is a newly developed compact
mechanism providing high accuracy.
The optimum design combining the
autofocus drive and lens case results in
an ultra-compact body that is 40% of a
conventional size.
HIGH-ACCURACY DIGITAL CONTACT SENSOR GT2 Series
Scale Shot System II
This revolutionary system is standard
in newly developed devices. The light
source is HL-LED that produces
high-intensity, consistent light passing
through the absolute value glass
scale; and the receiver is an ultra
high-resolution CMOS offering high
sensitivity and resolution.
8 mm
Absolute value
glass scale
HL-LED
CMOS MULTI-FUNCTION ANALOGUE LASER SENSOR IL Series
Sharp line beam
KEYENCEs original optical system has
achieved detection with unprecedented
high stability by focusing the beam
diameter to the limit (25 m).
Received-light wave pattern on the CMOS
IL-S
Conventional
Light intensity
NEAR CMOS
26
PRINCIPLE/FUNCTION SOLUTION
HP-Quad lens HS-HDR function
A special lens containing four layers When the reflected light fluctuates, the
of glass is used. This achieves low light-receiving sensitivity is expanded
aberration (blurring) and high light- to stabilise the detection. The high-
gathering power to capture a bright and speed processing that completes
clear image with low distortion. adjustment with a single image capture
ensures reliable detection of moving
targets.
HS-HDR
function: OFF
1 2 3 4
COMPARISON OF DISTORTION
Single lens
HP-Quad lens HS-HDR
function: ON
IP67G/NEMA Type 13 Durable over 200 million cycles
The sensor head, including the The high-strength linear ball bearing
connector and cable section, complies used in the spindle achieves
with two standards: IP67G and NEMA durability over 200 million cycles. This
Type 13. The sensor head can be significantly reduces maintenance cost
mounted almost anywhere, even in and man-hours for replacement.
environments with splashing water or
oil.
High-resolution I P67G
CMOS
No ingress of oil drop/splash from
any directions
No ingress of water even when
the enclosure is immersed in
water under defined conditions of
pressure and time
Linear ball
No ingress of dust bearing used
First-in-industry SCAN function for providing
ultra high-resolution algorithm a wide dynamic range
The sensor performs optimum This function adjusts the laser power,
waveform processing automatically shutter time, and light receiving gain
by recognising the difference in the (amplification factor) to ensure stable
received-light wave pattern on the detection of every kind of target.
CMOS caused by the change in the Moreover, a newly-developed digital
surface condition of the target. circuit has achieved a 1.5 million times
dynamic range (2.5times wider than
Received-light wave pattern on the CMOS conventional models).
CMOS Metal Ceramic Resin
Dark target Bright target
[Increased power] [Reduced power]
The focused spot diameter
makes the received-light
wave pattern on the CMOS
sharper. This enables precise Photos of actual spots
identification of the peak of Reflectance
the waveform.
Shutter time / power / gain
FAR
MULTI-PURPOSE CCD LASER MICROMETER IG Series
Multi-wavelength laser + I-BRAIN Position monitor Edge detection of

With normal lasers, the transmission
spot produces a speckle pattern as
shown below. This is a laser-specific
phenomenon of interference caused by
the laser having a single wavelength.
The IG Series has solved this problem
The position monitor on the IG Series
allows users to visually check how a
target is detected. The user can prevent
mounting or setting errors by observing
the red lights that indicate the received
light position and the green lights that
Press
transparent targets
The edges of transparent objects such
as glass have low transparency which
decreases the amount of light received.
The IG Series detects edges exploiting

Welding
this nature and automatically changes
by using a multi-waveform laser. indicate the measurement position. measurement sensitivity appropriately
to detect a transparent target.

SPOT IMAGE
RED:
Edge detection algorithm + Glass edge mode
Single wavelength laser (conventional laser sensors)
Indicates the received

Painting
light position
The measurement

Received light level

A speckle pattern appears. sensitivity is
automatically changed
Multi-wavelength laser (IG) GREEN: 
Indicates the
measurement

Body/axle
position.
Multiple waveforms overlay each other to average the intensity. The edge is enhanced

DIGITAL INFRARED TEMPERATURE SENSOR FT Series

Forging
Fastest response in its class: High stability Ultra-compact case
15 ms
To maximise the sensors stability, A cylindrical housing with the
KEYENCE has significantly increased which is the most important element thermopile and other detecting element
the responsiveness of the thermopile of a sensor, we developed new inside is suspended inside of the
that detects temperatures in the technologies: an IPC circuit and centre sensor head. This gives a thermal air
FT Series by: (1) Thinning a far-

Casting
floating structure. These are the heart buffer between the sensor and the
infrared resonance film to the of FLASH Thermo to support the basic ambient air allowing the sensor size to
minimum thickness; (2) Positioning functionality of the sensor. be minimised.
thermocouples in a geometrically
efficient way and detecting the
absorbed heat quickly and accurately.

Processing
Far-infrared Conventional sensor
resonance film
Thermocouple FT Series

Thermopile
chip of approx.
0.6 mm 0.6 mm

Engine
The FT Series displays stable temperatures under varying
conditions. FT Series

HIGH-SPEED, HIGH-ACCURACY DIGITAL INDUCTIVE DISPLACEMENT SENSOR EX-V Series

Transmission

High-speed sampling Highest accuracy in its class Preprogrammed modes for

The high-speed digital processing The FLL (Flat Level Linearisation)
easy configuration
circuit allows for accurate detection of circuit applies the optimal linearisation Optimal settings for common
real peak (bottom) values that cannot correction for the characteristics of applications are preprogrammed.
Performance
products

be detected at conventional sampling
speeds.
High-speed sampling: 40000 samples/second
each individual sensor head. You can
achieve the measurement with best-in-
class accuracy with simple setting.
High-resolution: 0.02% of F.S.; Linearity: 0.3% of F.S.
Simply selecting the appropriate mode
completes the setting. There is no need
for time-consuming initial setting or
adjustment.

KEYENCEs conventional model Resolution: 0.04% of F.S.

Linearity: 1% of F.S. Select the mode
Ideal line
ECU

KEYENCEs conventional model: 2000/s

For automatic setting

Introduction

EX-V Resolution: 0.02% of F.S.

Linearity: 0.3% of F.S. Bottom-dead-centre mode
Product

Ideal line

Eccentricity/vibration mode

EX-V: 40000/s
Thickness/gap mode

27
 www.keyence.com

SAFETY INFORMATION
Please visit: www.keyence.com Please read the instruction manual carefully in
order to safely operate any KEYENCE product.

KEYENCE CORPORATION
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The information in this publication is based on KEYENCEs internal research/evaluation at the time of release and is subject to change without notice. WW11-1066
Company and product names mentioned in this catalogue are trademarks or registered trademarks of their respective companies.
Copyright (c) 2016 KEYENCE CORPORATION. All rights reserved. AppliAutoKAIZEN-WW-AG-GB 1076-1 600I97