Control 2025: Measurement technology from Kistler for quality assurance across the manufacturing value chain

Whether connectors, screws or safety-relevant parts in industrial production: manufacturing companies need to thoroughly analyze their processes from the first to the last step for meeting highest quality standards and ensure continuous process optimization. An end-of-line inspection of individual components provides additional assurance that no faulty part leaves the production line. The modular KVC 821 Vision Inspection System is the proven solution for this purpose. For the first time, it will be on show at the Kistler booth with a pocket plate, which allows comprehensive inspection of safety-relevant parts in a shorter cycle time.

KVC 821: system for optical quality assurance in a new configuration

Visitors to Control can observe the KVC 821 testing and sorting system as it transports suspended screws to the camera stations for inspection. The cameras capture both the thread and the entire screw head. The Multicapture Device from Kistler inspects the drive and the side edges. Equipped with eight cameras, the Multicapture Device generates high-resolution images of the entire lateral surface without having to mechanically move the screws. Thanks to the additional 2.5D and 3D measurements and the precise evaluation by the KiVision software, every single screw can be checked for scratches, dents and dimensional accuracy – even at cycle times of up to 800 parts per minute. Kistler additionally uses artificial intelligence to detect previously unknown or rarely occurring anomalies.

The measured values can be imported directly into the software which performs the statistical evaluation and visualizes it simultaneously on an external terminal. Thanks to the modular design of the testing system, it can also be adapted to other test objects and testing requirements in quality assurance – for example for connector components – in collaboration with Kistler's experts.

Reliable bolting in production: caliTEST-B and cerTEST

With caliTEST-B and cerTEST, Kistler presents two solutions from the field of fastening technology. They are designed for use in screw assembly and the calibration of the required tools. The caliTEST-B calibration device is suitable for torque wrenches or torque tools with an effective length of up to 1320 mm. Thanks to individually applicable sensors, these can be calibrated in a range between 0.2 and 1,000 N·m in accordance with DIN EN ISO 6789. Visitors can test this process at the show using a bend wrench and other tools.

With up to four integrated screwdriving simulators and a measuring range between 0.2 and 500 N·m – or up to 6000 N·m when using external simulators – the cerTEST test system is designed for mobile use in production. Users can test their torque tools such as cordless, rotary and impulse screwdrivers in accordance with VDI/VDE 2645 Sheet 2, VDI/VDE 2647 or DIN EN ISO 5393 directly on the assembly line. With both solutions, the user-friendly CEUS software guides users step by step through the measurement, saves various measurement settings and histories, and automatically creates test reports.

Data management and statistical evaluation in the plastics sector: AkvisIO IME

The AkvisIO IME (Injection Molding Edition) process data analysis software demonstrates how comprehensive data analysis and statistical evaluation can be achieved in injection molding processes. AkvisIO can be easily connected to Kistler's process monitoring and control solutions such as ComoNeo and ComoScout. This allows users to correlate their process and machine data for quality assurance and create process reports based on established methods of classical statistics with just one click. Thanks to communication standards such as the Ethernet-based Euromap 77, the machine itself becomes the data source – and AkvisIO the single source of truth for reliable production data. At the booth, Kistler uses its contact element, a demonstration kit, to show how data from ComoNeo can be recorded in high resolution and transferred to AkvisIO for archiving and display.

Measurement data management: new versions of jBEAM and MaDaM at Control 2025

Kistler's portfolio is rounded off by the jBEAM software for measurement data analysis and MaDaM software for measurement data management. With the latest version of jBEAM, Kistler presents a solution that supports users in setting up and monitoring rapidly changing processes. It can be used to merge measurement data from different process steps and brings to light sources of error. Users benefit from uncomplicated operation via drag and drop. Kistler is demonstrating a wide range of application and customization options at the trade show. Visitors can bring their own measurement data and have it evaluated directly at the booth by Kistler experts – and thus discover optimization potential on site at Control 2025.