Defektdetektering på olackerade karosser (BIW)
Mätsystemet surfaceCONTROL 2500 används för detektering av defekter hos diffust reflekterande ytor. Tillsammans med robotar används surfaceCONTROL 2500 för helt automatisk defektdetektering hos olackerade karosser. Systemet utnyttjar principen för ströljusprojektion. Med en självlärande metod detekteras bucklor, fördjupningar och dylikt samtidigt som tillåtna avvikelser ignoreras.
surfaceCONTROL-systemen består av sensor, robot, dator och ett program- och gränssnittspaket. Beroende på beställning finns olika systemversioner tillgängliga, som konfigureras specifikt per kund. Antalet sensorer och robotar som behövs kan anpassas flexibelt till den begärda omsättningstakten.
Detaljer
- Komplett integrering med Micro-Epsilon: Sensorer, robotar, bedömning och integrering från samma leverantör
- Kompatibel med vanliga industrirobotar
- Objektive 100-procentig inspektion av alla producerade fordon
- Integrerat inline i produktionslinjen
- Flexibla konfigurationer med flera robotar och/eller celler
- Hög positionsnoggrannhet hos defekter
- Hög detekteringsfrekvens
100% inspection with high detection rates
surfaceCONTROL Automotive impresses with a high defect detection rate for the inspection of automotive body shells. The inspection system achieves outstanding area coverage of ≥ 97%, enabling inspection right up to the edges. Design edges and strongly curved areas, such as door handle recesses, are also reliably detected and evaluated during defect detection. Defects on sanded or pre-treated surfaces of the body-in-white can also be detected with surfaceCONTROL Automotive.
Integrated 6D position compensation
The surfaceCONTROL measuring systems are equipped with an integrated 6D offset compensation that automatically corrects positional or orientation deviations of the car body. This enables fast, precise and with highly repeatable measurements, even when slight misalignments are present.
Thanks to the fully automatic calculation of the object position in space, the system adjusts the measuring positions accordingly and also corrects the opening angles of doors and fuel filler flaps.
CAD-based simulation for efficient Setup
The robot-based inspection solution uses state-of-the-art simulation methods based on the CAD model of the body-in-white. Even in the planning phase, the virtual sensor model enables precise analysis of fields of view, measurement distances and potential shadowing. This makes it possible to define optimal assembly positions and motion sequences without having to use physical prototypes.
The simulation offers a high level of planning reliability: critical surface areas are identified at an early stage, inspection strategies can be tested realistically and integration into existing production lines is significantly simplified. The system can also be quickly adapted to new models and variants. The result is efficient and reproducible inspection processes with minimal setup effort and high measurement quality.
Software tools for data analysis
Individual defect classification with tolerances
By generating real 3D data, detailed 3D features such as diameter, area and height are assigned to each defect. Tolerances are configured according to customer specifications and can be adapted quickly – ideal for deployment across multiple plants and model series.
All data is stored in an XML file and made available to the user, enabling seamless integration of the results into existing quality assurance systems.
Optimized car body flow & targeted reworking
The precise detection of various surface form defects enables optimized reworking processes. The extremely high coverage also allows bodyshells to pass directly, eliminating the need for manual inspection.
As a result, surfaceCONTROL measuring systems contribute to a significant increase in efficiency in automotive production.
En kontaktperson för hela projekteringen
Som generalentreprenör sköter Micro-Epsilon hela projekteringen. Detta omfattar förutom mätteknik robotkonstruktion, planering, integration i befintliga styrsystem och implementering av data- och mjukvarugränssnitt. Du får också paket för regelbunden service och underhåll av anläggningar.