Autoneum are a manufacturer of automotive lining materials and carpets to some of the biggest car brands in the world including Jaguar Landrover, Audi and Volvo. They produce raw blanks for everything from car mats to floor liners, sound baffles and heat barriers. Car manufacturers then take these blanks and form specific parts for their models and makes of vehicle. Autoneum were looking for a Q.C solution to help them quickly and easily test a large carpet sample for consistency and thickness and weave. They wanted an adjustable illuminated table with integrated camera rig to achieve this.
The strict quality control standards insisted upon by their clients mean their manufacturing process is both high-tech and high precision. This ensures consistency across any and all batches of the same liner or carpet. The quality control task identified involved squares of carpet up to 2m x 2m being measured for thinness or where the pile of the carpet was below a minimum thickness.
By presenting a bright light behind a test sample of carpet, clusters of pin-hole light become visible in any areas where the weave is not close enough or the pile not thick enough. This can be manually inspected by a technician by getting up close to the surface and moving across in a logical grid pattern. Alternatively a faster solution is to photograph the sample from a set distance and use software to help identify inconsistencies.
The carpet manufacturing process involves several stages, from spinning and weaving the fibres to final inspection and shipping. One crucial step in this process is quality control, and this is where light tables come into play. Carpet manufacturers use light tables to inspect carpets for thin areas or holes, which can weaken the structure of the carpet and affect its durability. By shining light through the carpet, manufacturers can identify these issues and take corrective action before the carpet is sent to the customer.
The use of light tables in carpet manufacturing has become increasingly popular in recent years, and for good reason. Not only do they provide a simple and effective way to check for issues, but they also help to improve the overall quality of the carpet. With the help of a camera, the light from the table shines through the carpet, revealing any areas that may need attention. This allows manufacturers to identify potential issues early on and take corrective action, reducing the risk of defective products being sent to customers.
One of the key benefits of using light tables in carpet manufacturing is that they help to ensure consistent quality across all products. By providing a clear and accurate visual representation of the carpet, manufacturers can quickly identify any deviations from the expected quality standard. This helps to ensure that each carpet produced is of the highest quality, and reduces the risk of customers receiving a product that does not meet their expectations.
Another benefit of using light tables in the carpet manufacturing process is that they help to improve the efficiency of the production line. By detecting issues early on, manufacturers can take corrective action without having to waste time and resources reworking the carpet. This helps to reduce costs and increase the overall productivity of the manufacturing process.
In addition to the benefits outlined above, light tables also have a number of other advantages in the carpet manufacturing process. For example, they are easy to use and require minimal training, which makes them accessible to a wide range of users. They are also cost-effective and require very little maintenance, making them a valuable investment for carpet manufacturers.
Overall, the use of light tables in the carpet manufacturing process provides a number of benefits for manufacturers, including improved quality control, increased efficiency, and cost savings. Whether you are a small carpet manufacturer or a large-scale producer, incorporating light tables into your production process is a wise investment that will pay off in the long run.