Analysis of Microswitches with Computed Tomography and ZEISS INSPECT X-Ray

ODW-ELEKTRIK is an innovative development partner and supplier of high-quality cabling, solenoids and mechatronic systems. Bernd Föller, who heads the measuring laboratory for ODW-ELEKTRIK, reports from practice.

to first-tier suppliers in the automotive industry, for example. These switches are an enormous challenge from a metrological point of view: The plastic is heavily fissured with countless small elements inside. A full nondestructive inspection of these parts is possible with computed tomography only.

We use a ZEISS METROTOM 800 130 kV computed tomography system to X-ray these switches. With only one X-ray image, we get all the data we need for a component analysis. The evaluation is increasingly carried out in the ZEISS INSPECT X-Ray software.

From my point of view, compared to other CT software packages ZEISS INSPECT X-Ray is the leader in the measurement of freeform surfaces. Since introducing the software at ODW-ELEKTRIK, we have been able to precisely analyze the surface profile, for example of very small radii, during GD&T inspection and perform a tolerance comparison (nominal-actual comparison). Elements that were previously unmeasurable can now be analyzed and measured in a simpler way.

Another major advantage is the 3D shrinkage cavity evaluation in accordance with reference sheet P203 that is integrated into the software. I am sure that this advanced way of displaying quality will become more and more important in the future. This means that we are already equipped for the requirements of tomorrow.
I also want to emphasize the valuable and uncomplicated exchange with the CT software experts from ZEISS. Our contact persons manage to find solutions to our metrological questions in an impressively short time, even though our components are highly complex and not common.

Because we had such good experiences with ZEISS INSPECT X-Ray here in Germany, we will start using the software at our plants in Hungary and Ukraine this year. After all, the right software makes all the difference in component testing and measurement.”