Laser sensor detects black bumpers in the assembly cell

The LASE group, whose name stands for "Laboratory Aiding Systems Europe" makes products including machines for manufacturing automotive interior components such as dashboard panels, door panels, sunroofs, seat systems and center consoles. The company also develops solutions for assembling fenders, spoilers and fuel tanks. Another key area includes powertrain assembly systems. "Around 65 percent of our revenue comes from interior components and fender systems," explains CEO Gert Peetersem. "Our solutions are used by many OEMs."  

Peetersem founded the LASE Group in 2001 because, as he recalls, he saw a need for a solution-oriented machine builder capable of automating the assembly of automotive interior components. "Car manufacturers would have specific designs in mind for their products, but weren't able to implement satisfactory automation concepts to produce them," he continues. "Because our machines meet global standards, we've grown into a company that operates worldwide. Today, our systems can be found all over the world, from Australia to Europe and from North Africa to Russia."  

LASE originally started by producing assembly cells for interior components, but gradually expanded its portfolio to include solutions such as fuel tank systems and fender assembly systems. With increasing experience and expertise, the company has earned an excellent reputation in the automotive sector. "We've been involved in the design process for several OEMs, enabling our solutions to streamline the their production processes right from the start."  

Maximum vertical integration  

As a provider of turnkey solutions for the automotive industry, it is necessary to be able to implement the customer's requirements quickly and reliably. And these requirements are constantly evolving. Digitalization, for example, has now become an important factor. Customers want to be informed about the status of their process, want a clear user interface, and data collection is also always higher on their wish list. Customers often want to manufacture several variants of a component without losing production time, i.e. preferably with the same machine.  

The LASE Group has a specific approach to meet these requirements. Peetersem said about this: "We do everything with our own people, from day one. I do not want to be dependent on subcontractors or be confronted with suppliers who are unable to meet deadlines. This approach enables us to achieve a fast throughput time for the production of our machines. It is also easy for our customers: they have a specific contact person at LASE who bears full responsibility for the project. This clear structure makes sense, because it also allows us to keep our prices competitive worldwide."  

Component suppliers must lead the way 

Peetersem therefore places high demands on its component suppliers, as they too must adapt to its working methods. "Turck Multiprox is a good example of this intensive and cooperative partnership: we specify the type of detection we need, determine the design and measuring distances, and then work out a solution in consultation with Turck Multiprox. They are often involved in the test phase as well." LASE uses a wide range of components from the Turck Multiprox range: optical sensors, lasers, inductive proximity switches, I/O modules, tower lights, two-hand controls, etc. For machines exported worldwide, TURCK's Ethernet multiprotocol I/O modules are also ideal, as they can communicate via Profinet, Ethernet/IP, or Modbus TCP in the same module. This allows customers worldwide to work with the systems used locally, for which they can also obtain local service and spare parts—an important advantage. 

Integrated solution 

During a visit to the production hall, the finishing touches were being made to a bumper assembly cell. The great care taken in developing these machines is remarkable. For Peetersem, it is very important that the cells are part of the overall production line. “Isolated solutions require too many logistical movements with the product, which would increase the risk of damage. That is one of the success factors of our approach.” The average lead time for developing a bumper assembly cell is 24 weeks. All those involved always keep the big picture in mind: the mechanics and electrical engineering, the software, the manufacture of the parts, and the assembly. LASE employees also carry out processes such as laser cutting, plasma cutting, and panel construction themselves. 

The Q4X laser distance sensor makes the difference  

The painted fenders are used in the first fender assembly cell to punch ultrasonic holes for parking sensors. In addition, the brackets for the side reflectors are also attached in this cell using ultrasonic welding. These side reflectors are not required for European cars, but are mandatory for the American market. The machine can process all variants without any problems and without long changeover times. This process only begins after the painting process, so that absolutely no processing traces should remain on the fenders. Sensors play an important role here.  

In another assembly cell, LASE is using the Q4X laser distance sensor from TURCK’s optoelectronics partner  Banner Engineering. This sensor in a robust stainless steel housing plays a decisive role in the efficient approach of the machine manufacturer. On the one hand, the Q4X, with its IP67/69K rating, is resistant to mechanical stresses such as impacts, overloading, or extreme vibrations. On the other hand, the assembly cell must not only detect the presence of a fender, but must also be able to distinguish between a matte black and a glossy black fender. This is a particular challenge because black absorbs most of the light. But the Q4X doesn't just have a high excess gain , but also "dual mode" detection. As a result, the sensor not only measures the distance, but also analyzes changes in light intensity. This makes the Q4X different from sensors from other manufacturers. However, the sensor is not only highly reliable with black objects, but also with transparent objects, in bright ambient light, or at sharp detection angles. It detects distance differences in a range of 25 to 300 millimeters with an accuracy of up to one millimeter.  

For Peetersem, the laser sensor is a symbol of cooperation with suppliers such as Turck Multiprox : fast, high-performance and 100 % reliable. "Thanks to these components too, we are able to achieve a throughput time of 30 seconds per fender. “Creating efficient, high-performance machines is what we're all about,” says Peetersem.

Customer | www.lase.be