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KO C O S - T H E T E C H N O L O G Y G R O U P | W H E R E P R E C I S I O N M E E T S Q UA L I T Y

KOCOS OPTICAL MEASUREMENT GMBH

Catalytic Converter MeasurementOMCAT.

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n Catalytic converter measurement with OMCAT ................................................................................   3

n OMCAT 550 | 600 – Quality and process control in production  ...............................................   4

n OMCAT XA6 – The solution for laboratory applications  ...............................................................   5

n OMCAT L50 | L60 – Integration in the production line  ................................................................   6

n OMCAT – Measuring catalytic converters quickly and precisely  ...............................................   7    No alignment of measurement objects .............................................................................................    7    No manual settings for the measurement sensor  .........................................................................   7    Three measurement levels in seven seconds  ..................................................................................   7    Precise measurement with uneven surfaces  ...................................................................................   8    High-accuracy, maintenance-free stages ...........................................................................................   8    Temperature compensation for measurement accuracy  .............................................................   8    Poka-yoke for guaranteed process stability  .....................................................................................   9    SPC concept for process reliability  .....................................................................................................   9    Simple, reliable calibration  ...................................................................................................................   9    Acquisition of codes for tracking  ........................................................................................................   10    Base codes  ..................................................................................................................................................   10    Sleeve codes  ...............................................................................................................................................   10    Box codes  ....................................................................................................................................................   10    Process control on the basis of GBD  .................................................................................................   11    Local evaluation of gap and GBD .......................................................................................................   11    Flexible for pre- and post-canning  ......................................................................................................   11    Measuring multiple catalyst bricks in a stack .................................................................................   11

n Software ..............................................................................................................................................................   12    OMCAT-Vision: Operation via touch screen  ....................................................................................   12    OMCAT-Automate: The solution for automated manufacturing  .............................................   12    OMCAT-Expert: Detailed analyses and evaluations  .....................................................................   13    Admin module for OMCAT-Expert .......................................................................................................   13    Simple and intuitive operation  ............................................................................................................   14    Reliable and comprehensive storage of results  .............................................................................   14    In-process data interface  .......................................................................................................................   14

n Technical data  .................................................................................................................................................   15

C O N T E N T S

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Catalytic converter measurement with OMCATThe  exact  position  of  the  ceramic  substrate  within  the  catalytic converter  sleeve  is  of  decisive  importance  for  the  durability  of exhaust  catalytic  converters.  Premature  damage may  result  if  the substrate is fixed too loosely or too tightly.

OMCAT  catalytic  converter measuring  systems provide a  fast  and efficient means of carrying out complex geometrical measurements on  exhaust  catalytic  converters  and  of  determining  the  gap  bulk density (GBD).

OMCAT  measuring  systems  feature  innovative  measurement functions  combined  with  reliable  technology.  High  measurement speed  and  accuracy  and  high  availability  due  to  their  rugged construction are the major strengths of these systems which come to  the  fore  in  the  harsh  conditions  which  prevail  in  production environments.

All OMCAT systems are  tried and  tested standard solutions. Their components  and  modules  have  undergone  a  lengthy  test  phase and rigorous quality inspections. However, in the unlikely event that a  problem  should  arise,  first-class  service  is  available  worldwide and  the  standardised  construction  of  these  measuring  systems guarantees long-term, global availability of spare parts.

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OMCAT 550 | 600 Quality and process control in production

OMCAT 550 and OMCAT 600 measuring systems are designed to withstand  the  harsh  conditions  in  manufacturing  environments. Their  robust  construction  guarantees  longevity,  while  the  use  of maintenance-free components ensures high availability.

Smooth and robust sheet steel panelling without nooks and crannies makes  for  easy  cleaning. Because of  the  fan-free  electronics,  dust is not sucked into the system housing. Maintenance access points with several access levels for connections, electronics and the rotary stage allow easy access for maintenance and servicing.

The  measurement  functions  are  controlled  using  ergonomically designed robust push buttons. These large, metal push buttons are specially arranged for intuitive operation. They are guaranteed for 10 million switching cycles and meet all the requirements of harsh manufacturing environments and 24/7 production.

The  measuring  system  is  controlled  with  the OMCAT-Vision  software  which  is  optimised  for operation  using  the  function  buttons  and  10“ touch  screen  and  allows  all  major  functions, from basic configuration through to the creation of recipes, to be run on the device itself.

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OMCAT XA6 The solution for laboratory applications

OMCAT XA6 features analytical, statistical and graphical tools which make it suitable for use in development, process optimisation, quality assurance and the technological preparation of the manufacturing process.

The  system  is  equipped  with  a  22“  swivel  monitor,  mouse  and keyboard. The parameters and measurement results are graphically displayed  in detail on  the  large monitor, allowing comprehensive, detailed analyses.

The OMCAT-Expert software, included in the scope of delivery, and the module  for  local  evaluation of GBD and gap  can be used  to display  measurement  results  in  detail  and  to  carry out  all  the  measurement  tasks  required  in  a laboratory,  e.g.  the  inspection  of  details during the development of new products.

In order to guarantee optimum protection from  dirt  and  unauthorized  access,  the system  is  integrated  in  a  cabinet with a lockable shutter. The cabinet is fitted with castors  and  also  provides  enough  space for  optional  peripherals,  such  as  a  label printer and weighing scales, as well as for SPC and calibration pieces. The screen can be swivelled into the cabinet so that it too can be stored behind the closed shutter.

OMCAT L50 | L60 Integration in the production line

The OMCAT L50 and L60 systems offer a cost-effective alternative when catalytic converter measurement  is  to be  integrated directly within  the production  line. While  no  compromises  are made with regard  to  quality  or  measurement  accuracy,  there  is  no  need  for panels, push buttons and connections on the system itself when the placement of measurement objects and the start of the measurement process are to be automated.

Only  the measuring  instrument  itself  is  located  in  the production line, while a decentralised unit is used for controlling and evaluating measurements. This unit can be accommodated in existing standard 

cabinets  in  a  19“  drawer,  for  example.  Control  for carrying out measurements is automated by means of a direct communication interface with the production line. 

Automation  of  the  measurement  process  increases process security and creates synergies for the operation of the entire production line.When a new production plant is planned, the measuring system  can  be  integrated  by  the  manufacturer  of  the plant, but installation in existing plants is also possible at any stage.

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OMCAT Measuring catalytic converters quickly and preciselyOMCAT  can measure any  component with a  convex  cross-section. The  measurement  object  is  rotated  on  a  rotary  stage  while  the measurement  sensor  is  moved  to  defined  measurement  levels by means  of  a  linear  stage.  The measured  data  is  automatically compared with nominal contours which are saved in measurement recipes.

No alignment of measurement objectsThe measured  contour  is  automatically  aligned with  the  nominal contour,  eliminating  time-consuming  alignment  of  measurement objects  before  measurement.  The  measurement  object  is  simply placed on the precision rotary stage and the measurement process is started directly.

No manual settings for the measurement sensorDifferent measurement levels and diameters can be measured across the entire detection range without the need for manual settings to be made to the sensor or for the subsequent re-calibration that this would involve.

Three measurement levels in seven secondsFast  stages  for  positioning  measurement  object  and  sensor,  a powerful internal evaluation and control processor and an additional real-time processor allow fast, fluent processing because processes run in parallel.A  measurement  with  three  measurement  levels  and  a  speed  of rotation of 360°/s takes less than 7 seconds from the start of the measurement until the results have been saved.

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Precise measurement with uneven surfacesThe high sampling rate of the triangulation sensor (50 kHz) makes it  possible  to  adjust  the  power  of  the  laser  dynamically  and  to measure on a wide range of surfaces, including dark ceramics and shiny  metals.  Even  measurement  objects  with  surface  variations caused  by welded  joints,  for  example,  can  be measured  precisely without outliers.

High-accuracy, maintenance-free stagesFast, high-accuracy positioning and the direct response characteristic of  the  stepper  motors  are  key  features  of  the  stages.  The  rotary stage with direct coupling guarantees precise positioning even with heavy measurement objects. Thanks to the integrated rotor position detection sensor, additional position encoders, which would require adjustment and maintenance, are superfluous. In combination with the lifetime lubrication, this makes the stages maintenance-free.

Temperature compensation for measurement accuracySeveral  internal sensors and multi-level, decentralized temperature compensation  guarantee  that  precise  measurement  results  are delivered consistently, even when the ambient temperature varies.

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Poka-yoke for guaranteed process stabilityVarious  poka-yoke  measures  are  available  for  the  immediate detection and prevention of errors during operation of the measuring systems. Attempts to manipulate measurements and operator errors are reliably identified by the software and a correction message is displayed. In order to continue the measurement process, only the erroneous step must be corrected and not the entire measurement.

SPC concept for process reliabilityFor the purposes of statistical process control, the system requests a  specific  component  to  be  measured  at  defined  intervals  and the  results  of  the  measurement  are  compared  with  a  reference measurement of the very same component. If the measured values lie within the permissible range, the current measurement process can be continued immediately. If the values lie outside the permissible tolerance, calibration is requested automatically.Measurement and evaluation take only a few seconds.The SPC tests and results are recorded in the database. They are safe from any kind of manipulation and can be viewed and exported at any time. 

Simple, reliable calibration Calibration as may be required after an SPC measurement, for example, can be carried out quickly and easily. The use of just one calibration piece guarantees clear-cut results and drastically reduces the probability of calibration errors. If there are deviations, the adjustment is carried out automatically with no need for manual intervention or settings.

SPC

Acquisition of codes for trackingMeasurement objects can be  identified and  tracked by  reading  in a wide range of different codes. To guarantee maximum flexibility within  the production process,  the  functions of  the code scanners can  be  freely  assigned  using  the  measurement  recipe,  making  it possible, for example, to process codes on catalyst bricks, lot codes, etc. OMCAT therefore complies fully with the requirements stipulated in the 008-06-17 OEM standard.

Base codesThe scanner integrated in the turntable can be used to read code labels  on  the  base  of measurement  objects  and  to  process  them for  tracking purposes.  If  there  are  no  labels  on  the measurement objects,  labels  can  be  printed  on  an  optional  printer  and  affixed before or after the measurement.

Sleeve codesIf  code  labels  are  affixed  to  the  surface  of  the  sleeve  of  the measurement  objects,  another  optional  scanner  can  be  used  to read in the codes during rotation within the measurement process. The  scan  for  checking  the orientation of  the measurement object and  thereby  ensuring  the  correct  positioning  and  allocation  of measurement levels can be used as a Poka-yoke measure.

Box codesIf components are delivered without proper product codes, box codes such as batch and part numbers can be scanned instead. The part number, which may be included in the product code, can be used as a poka-yoke measure in order to check or automatically select the recipe.

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Process control on the basis of GBDIn combination with digital scales, the optional software extension offers  the  prerequisites  for  the  evaluation  of  mat  weight  for  the purpose of process control on the basis of GBD or for determining the mean GBD for quality control.The mat weights are automatically requested and transmitted to the software. Mats with a weight of up to 3 kg can be weighed with a resolution of 0.1 g. The  software  extension  contains  poka-yoke  measures  for  the verification of mat switch and placement of the right mat.

Local evaluation of gap and GBDThis optional  function makes  it possible  to determine  the position of the catalyst brick in the finished catalytic converter. Using the 2D scan system integrated in the turntable, the eccentricity of the brick in the metal sleeve is measured with the aid of a DMC affixed to its base. By determining the position of the brick, it is possible for the software to perform an automatic evaluation of the gap and GBD for individual angular sections. The number, angular position and size of the sections can be defined in the measurement recipe. In addition, it is also possible to define separate tolerances for individual areas. Adherence to these tolerances is checked by means of the software.

Flexible for pre- and post-canningOMCAT enables pre- and post-canning measurements to be carried out with the same measuring system or with separate systems. The database allocates the data automatically in both cases.

Measuring multiple catalyst bricks in a stackIf several bricks are installed in a converter, they can be measured in  a  stack  in  order  to  increase  throughput.  The measurement  for the sleeve can also be carried out in one step without rotating the converter. Up  to  four  bricks  can  be measured with  one  recipe  so there is no need to keep changing the recipe.It  is easy to prevent measurements being mixed up by mistake by using a recipe in combination with optional code scanners to check the part number.

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SoftwareDepending on the system model and the field of application, a num-ber of different software versions are available for OMCAT measu-ring systems.

OMCAT-Vision: Operation via touch screenOMCAT-Vision is optimised for operating and controlling the measu-ring systems via  touch screen and  is  specially designed  for use  in serial production. It is installed as the standard operating software in OMCAT 550 and OMCAT 600 measuring systems. The ergonomically designed user interface is clearly structured and easy  to  understand,  enabling  operators  and  setters  alike  to work intuitively.  The  touch  screen  is  used  for  the  configuration  of  the measuring system and for the creation of recipes for measurements. In  addition  to  automatic  tolerance  detection,  a  graph  comparing the nominal and the actual contour is displayed for the purposes of immediate assessment.

OMCAT-Automate:The solution for automated manufacturingOMCAT-Automate,  used  in  OMCAT  L50/L60 measuring systems, has been developed in or-der  to  integrate  the  full  range of  features of the OMCAT measuring systems in an automa-ted manufacturing process.OMCAT-Automate  makes  it  possible  to  use external automation  systems,  such as PLCs, to control the measurement process. The con-figuration of the measuring instrument and creation of recipes are also performed using commands in the control protocol.

OMCAT-Expert: Detailed analyses and evaluationsThe Expert software features comprehensive analytical, statistical and graphical tools and is recommended for use in development, process optimisation, quality assurance and the technological preparation of the manufacturing process. The software is included in the standard scope of delivery of the OMCAT XA6 laboratory system. It can also be installed on a PC in order to evaluate measurement data on screen during serial production or create recipes within the work preparation process  without  tying  up  the  measuring  system,  for  example.  The  applications  listed  below  are  given  as  examples  of  the comprehensive possibilities afforded by the software:

nFlexible measurements thanks to execution of individual measurement steps and examination of individual contours

n   Automated multiple measurements and recording of changesn   Superimposition of contours from various measurementsn   Reverse measurementsn   Determination of local measurement values or curvature in 

specific areasnStatistical functions such as trend analysis and histograms n  Use of measurement data from external sensors, such as 

temperature and humidity n  Horizontal and vertical measurements for the fast 

determination of contour and height

Admin module for OMCAT-ExpertThe  Admin  module  allows  complete  central  management  of  all OMCAT measuring systems using a network. This makes it ideal for operators with several measuring systems which may even be located at different sites. These systems can be configured for scheduled measurement tasks, serviced and monitored in various ways via remote access. This also includes the upload of  updates  and  recipes.  Monitoring  plant  and  production parameters provides effective support for the preparation of production reports and statistics. 

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Simple and intuitive operationThe intuitive and easy-to-understand user interface guarantees easy operation and minimizes the time it takes to become familiar with the measuring system.Guided  data  entry  in  the  recipe  generator  and  data  plausibility testing ensure reliable configuration and automatic fault detection. Nominal contours can be created directly or read in via DXF files.The measurement procedure is fault-tolerant: individual measurement steps can be corrected at any time without the entire measurement process having to be carried out all over again.The  results  are  tailored  to  suit  the  specific  application  and  are displayed clearly on the monitor.

Reliable and comprehensive storage of resultsThe data is securely stored in a database which is insusceptible to manipulation. A highly efficient database system allows the storage of at least 2 million data sets in the measuring system with consistent access  times.  The  data  sets  contain  the  complete  measurement results, including the plant and recipe parameters, enabling repeat measurements and further analyses to be carried out. Remote access for analysis and statistics is protected by a password and certificates.

In-process data interfaceAll the measurement, adjustment and SPC data can be exported to ASCII files  in CSV  format  regularly and automatically and can be saved on a network drive. This makes is possible to import files into databases and spreadsheet programmes for the purposes of quality management  and  mandatory  documentation  where  they  can  be subjected to customer-specific further processing.

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15

Technical data

Name OMCAT L50 OMCAT L60 OMCAT 550 OMCAT 600 OMCAT XA6

Operation

Protocol for communi-cation with PLC, etc.

Protocol for communi-cation with PLC, etc.

10“ TFT monitor with touch screen and function buttons

10“ TFTmonitor with touch screen and function buttons 

22“ TFT  monitor with mouse and keyboard, swivel- mounted

Diameter measuring range (mm) 45–205 50–450 45–205 50–450 50–450

Repeat accuracy, diameter 0.01 mm

Standard deviation, diameter < 0.003 mm

Repeat accuracy, gap 0.015 mm

Standard deviation, gap < 0.003 mm

Repeat accuracy, GBD 0.002 g/cm³

Standard deviation, GBD < 0.0005 g/cm³

Repeat accuracy, weights 0.2 g

Standard deviation, weights < 0.05 g

Dimensions (mm)W:  410H: 1008D:  645

W:  410H: 1008D:   956

W:  430H: 1100D:  929

W:  430H: 1100D:  1254

W: 1400H: 1980D:  1330

VersionIntegration device

Integration device

Table-top device

Table-top device

Cabinet system on castors, lockable

Software OMCAT L50 OMCAT L60 OMCAT 550 OMCAT 600 OMCAT XA6

OMCAT-Automate 

OMCAT-Vision

OMCAT-Expert

Local evaluation of gap and GBD

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2015

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Opt

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KoCoS Optical Measurement GmbHDöbereinerstr. 2299427 Weimar, GermanyPhone +49 3643 906 38-0info@kocos.comwww.kocos.com

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