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Glass Flatness Checker

DBI Control have recently worked on a project for Qioptiq – a worldwide recognised supplier of components for space-based applications such as cover glass, optical solar reflector and ultra-thin glass, and are a long lime client of DBI Control.

They came to us on this occasion to see if we would be able to help them supply a Siemens PLC system capable of measuring the flatness of glass to 1 thousand of an inch for their Solar Cell Cover glasses; designed and manufactured to provide radiation protection.

Checking flatness is extremely important for the functional use of many glass products. This involves characterising flatness for the most diverse areas of use.These surface profilers can continuously record height data at selected points in real time for immediate feedback regarding the production process.

DBI Control supplied the materials required to create the glass flatness checker …

Siemens S712000PLC and HMI Touch Hardware
Keyence Profinet Interface
Phoenix Contact Industrial Ethernet 5 Port Switch
IAI Linear Servo Drive System
Heavy Duty Item Aluminium Profile Work Station

Additionally, our team of engineers provided the software development, and worked on a …

Measurement System
PLC Software
Communications
Data Capturing

Finally, DBI Control laboured to manufacture the system and the prototype. During the development, the optical reader had been used to check the flatness of the cover glass.

The cover glass had to be measured on both sides; since different measurements can be obtained depending on which sign of curvature is uppermost. A single measurement would take approximately 5 seconds.

The maximum total measurement available (the glass thickness plus the box) was approximately 200 thou (5mm). Given the tolerance of the linear drive, which is +- 20 microns, we were able to accurately measure the glass to give a flatness requirement of 10 thou /254 microns.

Depending on the quality of the glass, we were easily able to reduce these tolerances and give pass or fail rates down to 5 thou / 127 microns.

This proves that DBI Control can take on a challenge and provide the best results to support our suppliers’ needs, as we excelled Qioptiq’s basic requirements to provide an even more precise machine.