Abstract
Abstract: In the automotive industry dimensional quality control is an important part of the production process, often carried out using coordinate measuring machines (CMMs). However, CMMs used in conjunction with touch probes have a relatively low measurement speed. There is also a close link between the cost of measurement and the number of discrete points captured, leading to a trade-off between the number of points that can be measured and the measurement time. Laser scanners offer a faster alternative to touch probe measurement, but have certain limitations. A number of studies have considered the accuracy of laser scanning using small artefacts; however, little work has been done on the verification of on-CMM laser scanning systems for large volume, industry-relevant measurement applications. In this research, a nominal representation of a vehicle body was used and 104 standard features were measured. The results show that the laser scanning sensor and CMM used in this study would, for the majority of measurements, provide a level of accuracy and repeatability better than which is typically required by automotive manufacturers for body shell quality inspection applications.
Highlights
In recent years, there have been significant cycle time reductions for production technologies, especially joining technologies, to improve right-first-time (RFT) capability with a minimum waste of resources and reduced product defects in pursuit of zero-defect manufacturing (ZDM)
The results showed that the Laser Radar (LR) accuracy and repeatability are well within the specification limits of typical automotive BIW inspections
The results show a significant reduction in measurement cycle time, reduced by 83% to 6 min
Summary
There have been significant cycle time reductions for production technologies, especially joining technologies, to improve right-first-time (RFT) capability with a minimum waste of resources and reduced product defects in pursuit of zero-defect manufacturing (ZDM). By using off-line measurement (taking off the assembly line), for car manufacturers, it is more difficult to predict defects before they occur or identify trends in the production line due to limited sample size. Is this time consuming, and it cannot identify the root cause of any faults. There is a growing desire to move away from off-line sample measurement to in-line data collection, and this will only be possible with fast, accurate measurement technologies This leads to a common trend in Europe (and worldwide) regarding research into in-line. CMMs are often considered a bottleneck in the quality process due to the ever-increasing product complexity, leading to an increase in the number of measurement points and the measurement time and in some cases only providing partial information on the measured area rather than the full product data
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