In a world where data or information is crucial for any successful business ventures, the way to collect data or having the means to provide ‘actionable information’ becomes high on the agenda of any top executives. Some observers say actionable information is specific, consistent and credible. If you were to look at the very nature of such information, you would notice it has some striking similarities to what metrology stands for.
It may be relatively straightforward to produce accurate data on a single part, but when metrology solutions providers are to scale up measuring performances to fit a large-scale automotive production line, a more holistic approach is needed to do the job.
Teaming Up
A quick check at what is available in the market today will reveal a good number of metrology equipment designed to carry out a specific task. Although they all have their own application range, it is not difficult to imagine the potential in bringing them together. In fact, by doing so, it is possible to form a modular, large scale metrology solution that can transform the production floor into essentially a large measuring room.
Engineers or operators can now be creative depending on the applications. For short-range applications, white light scanners, laser scanners, portable CMMs (arms) or CT scanners can be deployed. For something a little longer in range, portable CMMs (trackers) or optical trackers may be more suitable.
In a nutshell, putting these equipment together can help cover up whatever limitation one particular measuring equipment might have. This is of course a very simplistic view but it is the basis of producing a robust measuring system that grows along with expanding manufacturing operations.
With a wide selection of measuring equipment at its disposal, Hexagon Metrology has developed the 360° Smart Inline Measurement Solutions (360° SIMS), a family of measurement solutions that can be fully integrated into automotive production lines.
They enable full surface inspection and critical features measurement of up to 100 percent of the produced car bodies, parts and sub-assemblies within production cycle time. By leveraging its metrology methods, software and sensor technologies, the company has created an advanced means of process control.
Cutting Down Time
“Our vision was to extend our reach into the production environment and combine our measurement abilities with the in-line process control methodologies. This way, we can create a bridge between the quality department and our other measurement systems like the bridge and horizontal CMM and the quality efforts of production during new vehicle launch, ramp-up and steady state production,” said Tal Vagman, director of Automated Solutions strategy of Hexagon Metrology.
He added that the concepts and technologies have been developed with industry partners and customers.
This technology may not have been in use for a long time but he revealed that the system has managed to help users identify problem(s) during launch and ramp up period. This has cut down on the time taken to understand the root cause of the quality problem.
Lastly, production and line quality are more self-sufficient and can react faster. A large part of this can be attributed to a touchscreen interface, where operators with basic training can supervise the measurement process, visualise results and identify root cause for quality concerns.
The main point to take away here is probably the time saving. In fact, according to Mr Vagman, users have reported savings mostly coming from the measurement of parts/car bodies in the CMM, as well as the time and cost of logistics to move parts from production to measuring room. Finally, reporting and analysis time is saved in these new methods of measuring and analysing dimensional quality where the real assembly operations take place.
Adapting To Various Environments
Almost like a mixed bag of solutions put into one, the system can involve a number of robot arms and it is modular and adaptable. The modularity of the system sees it adapted to various environment and targeted industry applications. Installations typically include white light area measurement sensors and point cloud-based software tools. 360° SIMS is compatible with commonly used industrial robots, PLCs, automation devices and safety equipment.
Cell configurations will include in-line, near-the-line and offline options to support a variety of customer applications throughout stamping, body shop and final assembly sub-plants. The measuring cells can be positioned anywhere along production lines and production bays to support a customer’s dimensional control strategies.
According to Mr Vagman, the system was designed as such after intensive market studies. He said: “We identified the industry trend of moving from dedicated hardware platform to using common industrial robots which are already used in their hundreds across the automotive plant. By using industrial robots and other automation devices, we achieved high flexibility and being future ready to model changes.
We do integrate various different technologies including our patented fixture for repeatable alignment, white light sensor, 3D point cloud processing, automation and analysis software, etc. The installation is planned as yet another cell on the line or near the line and can achieve similar timelines as other body shop assembly cells.”
He also touched on the flexibility of the system, which allows future work with line builder and OEM interested in introducing the new technology. The system also allows the definition of control and automation strategy in advance to help simplify on-site implementation process.
Finally, he added that in some cases, it is possible to integrate the solutions into existing or renovated lines where down-time for commissioning will be limited to three to four months.
Wide Reliable Coverage
Apart from the obvious advantage, which is reduction in time, the holistic, accurate coverage is other point worth talking about. For one user, using a set of measuring sensors has effectively taken away the reliance on a CMM. The system has become a primary measurement tool in his production line. He added that the mix of reliability and speed in measurement has made it possible to carry out inspection 100 percent in-line.
Giacomo Barilà, head of the automated solutions product line of Hexagon Metrology said white sensors play a big part in making this possible.
“We use white sensors for providing both critical features inspection along with full area measurement. This is very helpful for the complex geometries of car bodies and automotive components. The industry solutions we’re targeting in the first stage usually have quality tolerance of +/- 0.5 mm which we’re able to support without an issue.
We usually correlate our results to a CMM after commissioning and then when the measurement and process control cell becomes independent. In addition to accuracy and repeatability, the system also needs to be fast and comes with high detection rate for the critical features,” he said.
Describing the 360° SIMS as a system that enables automotive manufacturers to take the “huge step towards the digital factory of tomorrow,” Mr Barilà said the system is designed to answer the growing need for insightful and actionable information to accelerate production launches and monitor quality.
If he is right then the system may have provided new insights into quality control for the automotive OEMS and tier-one suppliers. This further adds to the philosophy that harnessing the merits of several metrology equipment can produce a powerful measuring system that is scalable and reliable.
