Use of projector based augmented reality to improve manual spot-welding precision and accuracy for automotive manufacturing

Ashish Doshi,Con Bouras,Ross T Smith,Bruce H Thomas

doi:10.1007/s00170-016-9164-5

Ashish Doshi, Con Bouras + Show 2 more

Open Access

https://doi.org/10.1007/s00170-016-9164-5

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Abstract

This paper presents the use of a projector-based spatial augmented reality system in an industrial quality assurance setting to highlight spot-weld locations on vehicle panels for manual welding operators. The aim of this work is to improve the precision and accuracy of manual spot-weld placements with the aid of visual cues as a proactive step by the automotive manufacturer to enhance product quality. The prototype system was deployed at General Motors (GM) Holden plant in Elizabeth, Australia on the production line building Holden Cruze vehicles. Production trials were conducted and techniques developed to analyse and validate the precision and accuracy of spot-welds both with and without the visual cues. A reduction of 52 % of the standard deviation of manual spot-weld placement was observed when using augmented reality visual cues. The average standard deviation with-AR assistance (19 panels and 114 spot-welds) was calculated at 1.94 mm compared to without-AR (45 panels and 270 spot-welds) at 4.08 mm. All welds were within the required specification and panels evaluated in this study were used as the final product made available to consumers. The visual cues enabled operators to spot-weld at a higher degree of precision and accuracy.

Highlights

General Motors (GM) Holden have a long history of producing safe and reliable road vehicles.1 As per their charter, they are actively seeking to improve existing manufacturing practices and vehicle designs using new technology to meet the challenges of future automotive requirements
The performance figures reported are for 45 panels welded without using augmented reality (AR) and 19 panels welded with AR assistance
The results are further validated statistically by confirming that there were small to medium improvements for W1 and W6 whilst large improvements were made for W2, W3, W4 and W5

Summary

Introduction

General Motors (GM) Holden have a long history of producing safe and reliable road vehicles. As per their charter, they are actively seeking to improve existing manufacturing practices and vehicle designs using new technology to meet the challenges of future automotive requirements. General Motors (GM) Holden have a long history of producing safe and reliable road vehicles.1 As per their charter, they are actively seeking to improve existing manufacturing practices and vehicle designs using new technology to meet the challenges of future automotive requirements. They are actively seeking to improve existing manufacturing practices and vehicle designs using new technology to meet the challenges of future automotive requirements This is an evolving process that the automotive industry as a whole are involved in since the Model T assembly line was revolutionised in 1913 to gain a production advantage in the automotive market. Due to the expense of robotic dexterity, not all of the assembly processes have been automated This meant spot-welding and adhesive applications of small assembly panels are performed manually. Visual inspection checks are undertaken to ascertain whether spot-welds are in the appropriate location

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