A hole lot better

German researchers have developed a method to enable car manufacturers to detect immediately if errors have been made on the production line.

A team from the

in Braunschweig has designed a tiny, low-cost sensor that will monitor the accuracy of machines used to punch holes into the sheet metal of car bodies. Those holes are used to mount other components of the car. If any holes are missing or misplaced, the entire component of the vehicle has to be either scrapped or reworked.

To punch a hole, the metal has to be positioned exactly over the hole of a die. The new sensor, which is integrated into the punch itself, will register if the piece slips before it is punched. That would result in the tool striking only the edge of the metal. The sensor will also be able to detect if the machine fails to make a punch, or if it is using tools that are too blunt. This would enable machine operators to exchange blunt tools before they break or the material is damaged.