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Detection of Holes

Detecting holes can be a major challenge. Perforated surfaces and objects with holes cause many sensors problems that can lead to damage or material jams. Here, you will find sensor solutions for reliable hole detection.

What Are the Advantages of wenglor Products?

Diverse Usage Options

Broad portfolio for diverse applications

Precise Hole Detection

Detection of different hole sizes and deviations in hole diameter

Avoidance of Quality Problems

Early identification of deviations and errors

Optimization of Material Use

Reduction of material waste in production

Challenges in Hole Detection

Hole Detection

In the production of paper, films and even sheet metal strips, the quality of the endless materials must be continuously checked. Failure to detect holes or cracks in time can lead to serious consequences, such as impaired product quality, damage to the machine, but also safety risks.

Solution

Retro-reflex sensors for transparent objects
Ultrasonic distance sensors
2D/3D profile sensors

Quality Control of Objects in Holes

The quality control of objects in holes ensures that, for example, a thread is present inside a sleeve to ensure the quality standard in further process steps.

Solution

Reflex sensors with background suppression
Triangulation laser distance sensors

Detection of Objects with Holes

The detection of perforated objects, such as perforated sheets, grid boxes or printed circuit boards, poses a particular challenge for sensors. Sensors with an inadequately sized detection area could perceive the non-continuous surface of the object as interruptions or errors and thus generate erroneous signals.

Solution

Retro-reflex sensors with light band
Ultrasonic distance sensors

Measurement of Holes

When industrially manufacturing components or other objects, such as body parts, holes must be drilled. Before the parts can be joined together, it must be ensured that the holes have the exact dimensions so that the screws fit perfectly into the holes.

Solution

Vision systems
Smart cameras

Look Through a Hole

A major challenge in industrial production environments is the limited space for installing sensors. In conveyor lines, for example, the sensors look at the conveyor belt through holes in the side walls to detect passing objects.

Solution

universal retro-reflex sensors
Fiber-optic sensors
Energetic reflex sensors

Presence Check for Screws and Nuts

Challenge:
After the robot-controlled screwing process of body parts, it must be ensured that all screws and nuts are correctly installed in order to ensure the quality of the assembled body parts and to immediately detect faulty screws.

Solution:

Measuring the Indentation Diameter

Challenge:
To ensure the quality of the punching process in the automotive industry, it is necessary to precisely measure the diameter of the resulting indentations. Incorrect or inaccurate measurement can lead to quality issues and increased waste.

Solution:

Hole Inspection of Battery Covers

Challenge:
When manufacturing battery covers, one challenge is precisely monitoring the punched holes. Fiber-optic sensors enable reliable and fast identification, ensuring quality for further processing.

Solution:

Presence Check of PCBs

Challenge:
In the electronics industry, PCBs must be checked for presence at multiple stations to ensure safe transport and correct further processing. In particular, the different surface structure and insertion density of the PCBs require the use of sensors that work reliably despite these differences.

Solution:

Empty PCB Monitoring

Challenge:
When manufacturing PCBs, it is crucial that the blanks have exact holes. These must therefore be checked carefully before further processing, as even slight deviations can impair the function of the entire circuit. Sufficient illumination of the boards must also be ensured.

Solution:

Detection of Perforated Objects

Challenge:
In logistics, perforated boxes or cartons pose a particular challenge. To reliably detect objects with a non-continuous surface on the conveyor belt, a sensor with an enlarged detection area must be used. Sensors with a point light spot can misinterpret the hole as an interruption or error.

Solution:

Hole Detection for Precise Compartment Positioning

Challenge:
When it comes to precise compartment positioning in high-bay warehouses, the exact positioning of the shuttle in front of the compartment is crucial for error-free storage and retrieval of goods. This requires sensors that detect holes of different sizes at single and double depth and are insensitive to external light and temperature fluctuations.

Solution:

Presence Check of Storage Containers

Challenge:
In modern storage systems, the continuous checking of the load handling attachment assignment and the matching of the target and actual assignment is a challenge. The sensors installed on the shuttle must be able to reliably detect perforated boxes and containers at short distances.

Solution:

Detection of Containers with Drain Holes

Challenge:
In logistics, special containers made of metal or plastic are used, which have a drain hole to allow any condensate created in the containers can drain off. The challenge is to reliably detect the containers to enable a frictionless flow of material.

Solution:

Distance Measurement for Forklift

Challenge:
In large warehouses and distribution centers, the challenge is to ensure that forklifts pick up pallets with all kinds of goods correctly. For this purpose, the sensor used must reliably measure the distance of the autonomously moving forklift truck to the pallet foot, even in the event of uneven surfaces, holes or cracks.

Solution:

Film Tear Monitoring in Packaging Plants

Challenge:
A continuous supply of film material must be ensured in packaging plants. If (semi-)transparent films tear during the packaging process, faulty packaging is created. The sensors used must reliably detect damage regardless of color, surface and transparency.

Solution:

Determination of the Bore Center

Challenge:
Automatic bolting of bakelite and MDF boards is a particular challenge, as both boards and the screw must be positioned precisely. To allow for a tight fitting, a sensor should be used that can accurately determine the drill center.

Solution:

Fill-Level Measurement of Disinfectant Bottles

Challenge:
In automated filling systems in the hygiene product industry, the correct fill level is checked after filling disinfectants. This requires sensors that can measure the fill level contactlessly and precisely through the narrow bottle opening, regardless of color, transparency, reflection and degree of gloss.

Solution:

Hole Control for Paper Webs

Challenge:
In the printing industry, it is necessary to continuously check the paper web to ensure a continuous flow of material. This requires sensors that check the entire width of the paper web for cracks or holes at high speeds.

Solution:

Open-End Wrench Ejection Control

Challenge:
When checking the ejection of open-end wrenches on sliding devices, it is particularly important to detect material jams in good time. To reliably detect the flat shiny objects, a sensor must be positioned just above the conveyor belt.

Solution:

Hole Inspection of Flanges

Challenge:
Hole inspection of metal flanges in CNC machining portals is an important quality control measure. Due to the harsh ambient conditions prevailing there, the sensors used must be robust and resistant in order to reliably detect the drilled holes in the shiny components.

Solution:

Quality inspection of components

Challenge:
When manufacturing components in special machine construction, holes must be drilled in one work step. Before the components can be further processed, they must be checked for the presence of the holes to be drilled. This requires a sensor that reliably detects the holes in the reflective surfaces.

Solution:

Detection of Holes in Rotor Components

Challenge:
In mechanical engineering, it is necessary to check rotor components for the presence of holes for a smooth processing process. This requires the use of sensors that accurately detect holes both from a long distance and on glossy surfaces.

Solution:

Hole Check for Steel Belts

Challenge:
In the steel industry, continuous monitoring of sheet steel is crucial to ensure high product quality during processing. Detecting holes on the glossy and reflective surface at very high speeds is a major challenge for many sensors.

Solution:

Drill Hole Monitoring on Aircraft Wings

Challenge:
In the automated production of wing surfaces in aircraft construction, holes must be drilled on the wings. A machine vision camera is used to precisely drill these holes, ensuring reliable and accurate measurements. Additional lighting ensures sufficient illumination.

Solution:

Overview of Solutions

Triangulation Laser Distance Sensors

The contactless laser triangulation sensors work according to the angle measurement principle, which enables reliable and highly precise measurement in the close range up to 1,000 mm. The triangulation sensors deliver stable measured values regardless of color, shape, rough and textured surfaces.

Time-of-Flight Laser Distance Sensors

Time-of-flight laser distance sensors (ToF) work according to the principle of transit time measurement, which means that they cover large working ranges up to 10,000 mm, so that objects can be reliably detected even at great distances. The ToF sensors are extremely robust against interfering ambient light, which ensures reliable operation.

Fiber-Optic Sensors

Fiber-optic sensors use plastic or glass fiber-optic cables, which can also be used in hard-to-reach places due to their high flexibility. Plastic or glass fiber-optic cables are connected to fiber-optic sensors for use in applications with limited space or high temperatures.

Reflex Sensors with Background Suppression

Reflex sensors with background suppression detect and measure objects contactlessly and detect them in front of any defined background. They work with red light, infrared light, blue light or laser light. Thanks to the principle of angle measurement, the color, shape and object surface have no influence on the switching behavior of the sensors.

Retro-Reflex Sensors with Light Band

Retro-reflex sensors with light band detect objects with variable edges, shapes and sizes. Thanks to the continuous, homogeneous laser light band, the sensor monitors a much larger area than a light barrier with a dot-shaped light spot. The light band can also detect small or translucent parts.

B60 Smart Camera

The high-performance B60 smart camera carries out a wide range of industrial image processing tasks. The highly modular hardware platforms in combination with powerful machine vision software offer the computing power of a vision system in the housing of a smart camera.

Ultrasonic Distance Sensors

Distance sensors are suitable for the detection, differentiation and measurement of objects using ultrasound. Different operating modes, such as synchronous, multiplex or through-beam mode, can be set via the display or centrally via IO-Link, and different output variants and formats enable a wide range of possible applications.

B50 Vision Sensors

Vision sensors from the B50 series include numerous image processing functions for the automation industry. From simple presence checks to color and shape recognition, the counting and sorting of objects, these sensors are used for quality assurance – even in real time via Industrial Ethernet.

Vision Systems

Vision systems solve complex image processing applications. They consist of up to 16 machine vision cameras with C mount lenses, external illumination and a machine vision controller. The right software offers numerous evaluation options and a wide range of interfaces make connectivity easier.

Hole Detection with Sensors

	Products	Benefits	Product links
	Triangulation laser distance sensors	Material-independent hole detection Accurate measurements Easy mounting
	Time-of-flight laser distance sensors	Reliable measurement on reflective and transparent surfaces Large working range Extremely robust
	Fiber-optic sensors	Can be used in hard-to-reach places Quick response time Contactless measurement
	Retro-reflex sensors	Contactless measurement High reliability Detection of transparent objects
	Reflex Sensors with background suppression	Emitter and receiver in the same housing Color-, shape- and surface-independent hole detection Detection of objects in front of any type of background
	Ultrasonic distance sensors	Surface- and color-independent hole detection Resistant to contamination


Products Triangulation laser distance sensors	Benefits Material-independent hole detection Accurate measurements Easy mounting	Product links

Products Time-of-flight laser distance sensors	Benefits Reliable measurement on reflective and transparent surfaces Large working range Extremely robust	Product links

Products Fiber-optic sensors	Benefits Can be used in hard-to-reach places Quick response time Contactless measurement	Product links

Products Retro-reflex sensors	Benefits Contactless measurement High reliability Detection of transparent objects	Product links

Products Reflex Sensors with background suppression	Benefits Emitter and receiver in the same housing Color-, shape- and surface-independent hole detection Detection of objects in front of any type of background	Product links

Products Ultrasonic distance sensors	Benefits Surface- and color-independent hole detection Resistant to contamination	Product links

Hole Detection with Machine Vision

	Products	Benefits	Product links
	Machine vision systems	Complete solution Up to 16 machine vision cameras on one machine vision controller Powerful: For demanding applications
	B60 smart cameras	Solving complex image processing tasks with the HALCON Script module Up to 5 MP resolution with C mount or auto-focus High modularity
	B50 vision sensors	Compact format C mount or auto-focus All-rounder for standard image processing tasks
	Illumination technology	Wide illumination portfolio with different designs, sizes and types of light Realization of simple and complex applications


Machine vision systems	Complete solution Up to 16 machine vision cameras on one machine vision controller Powerful: For demanding applications

B60 smart cameras	Solving complex image processing tasks with the HALCON Script module Up to 5 MP resolution with C mount or auto-focus High modularity

B50 vision sensors	Compact format C mount or auto-focus All-rounder for standard image processing tasks

Illumination technology	Wide illumination portfolio with different designs, sizes and types of light Realization of simple and complex applications

Downloads of Product Flyers for Hole Detection

P1XD Product Flyer (902 KB)

This document provides an overview of the P1XD series fiber-optic amplifiers.

P3 Series Product Flyer (2 MB)

This document provides an overview of the P3 series laser distance sensors.

der wintec. Brochure (1 MB)

This document contains the brochure on long-range laser distance sensors with wintec (wenglor interference-free technology).

Retro-Reflex Sensors with Light Band Product Flyer (3 MB)

This document contains the product flyer for the retro-reflex sensors with light band.

PNG//smart Product Flyer (1 MB)

This document contains the PNG//smart sensors product flyer. Photoelectronic Next Generation stands for a new age of smart photoelectronic sensors.

Ultrasonic Sensors Product Flyer (995 KB)

This document contains the product flyer for the ultrasonic sensors.

B60 Smart Camera Product Flyer (968 KB)

This document contains the product flyer for the B60 smart camera.

weQube B50 Product Flyer (6 MB)

This document contains the product flyer for the weQube B50.

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