Gap and Flush Inspection

KEYENCE offers a line of laser displacement sensors for automotive manufacturers to help verify that vehicle body panels are joined correctly and meet strict dimensional specifications. Our gap and flush inspection systems deliver unrivaled inspection performance and profile measurements.

Use our technology to ensure doors, hoods, trunk lids, door panels, and other automotive components align correctly and have uniform gaps.

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What is Gap and Flush Inspection?

Flush refers to the alignment of two adjacent components or panels, while gap refers to the distance or space between the components. Inspecting for these two important parameters is done through either manual or automated inspection systems.

For manual methods, measuring devices such as feeler gauges are utilized for gap measurement of two automotive parts. On the other hand, equipment like calipers typically finds measurement use for surface flushness.

Significant changes to automotive designs over the years mean new materials and complex geometries, presenting accuracy challenges to manual-based inspection methods. For accurate fit and finish results, automated systems are desired.

Advanced, automated systems like laser profilers feature sensors, cameras, and 3D profiling technology that allow them to create detailed three-dimensional data of auto parts under inspection. A 3D Laser Snapshot Sensor can perform accurate gap and flush measurements on different materials and intricate curves. Measurements are delivered as pass/fail to show human operators whether or not assembled parts meet the proper standards.

In addition to accuracy, rapid inspection is another advantage automated systems have over manual inspection techniques. Inspecting a large number of components quickly makes for efficiency and reduces labor costs that would otherwise be required to inspect the same number of parts.

Why Accurate Gap and Flush Inspection Matters

From solid to translucent, sheet metal to carbon fiber, and reflective to dull, materials used in automotive manufacturing are not the same. For this reason, accurate inspections of all kinds of materials are important. Here are some of the main reasons why gap and flush inspection matters:

Appearance

With fit and flush components, assembled vehicles have a smooth and consistent appearance. Inconsistent flushness or gaps can negatively affect consumer perception of a brand, leading to a negative brand image and reduced market share.

Structural Integrity

The structural integrity of automotive products is also at risk if the right gap and flush aren't in place. For instance, water entering a vehicle through its door or hood can damage electric and interior components.

Compliance

Industry standards are another reason for precision-based flush and gap measurement during inspection efforts. Various regulatory bodies have standards regarding specific tolerances in gaps and flushness. Failure to meet these requirements may expose a product developer to fines and legal problems.

Overall, accurate gap and flush measurement helps ensure final auto products are defect-free and function according to established quality standards.

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Key Benefits of Using KEYENCE Measurement Sensors for Gap and Flush Inspection

Our measurement sensors bring significant advantages to automotive manufacturing facilities. We designed these sensor products for accurate and efficient gap and flush measurement in automotive applications.

Versatility

KEYENCE 2D/3D laser sensors can accurately perform measurements on all materials and from different angles. With a wide variety of heads, robust light source, and 3200 data points per profile, these inspection and measurement devices can reliably handle reflective surfaces such as glass, polycarbonate, chrome, sheet metal, carbon fiber, and painted metal.

Ease of Use

Setup and programming are also easy. We built these solutions with users of all experience levels in mind. Easy operation is a great way to speed up inspections and avoid downtime associated with complicated configurations and setups. In addition, our sensor products can be mounted on robots or installed in other inline inspection environments.

Inline Measurements

With the capability to make inline measurements, utilize our laser-based gap and flush inspection systems to help line operators and managers detect inconsistencies in flushness and gaps of automotive parts before issues reach final assembly.