Dual Sensor System Provides Exact 3D Inline Measurement For Smart Factories

A dual-sensor system for correlation-free gauging in automated production eliminates the need for coordinate measuring equipment. High-resolution cameras mounted directly into robot production measurement cells determine the exact position of the robot within a higher-level coordinate system. Therefore, measurements remain absolutely precise, even in the event of material changes in robots caused by thermal effects.

The higher-level multi-camera system determines the spatial position of the robot and the mounted measurement sensor in all six degrees of freedom. This significantly raises measuring precision and eliminates the typical drawback of industrial robots – their inability to maintain a high level of measuring and movement precision in continuous operation.

Absolute Measurement Reduces Need For Recalibration
The absolute inline measurement system makes the deployment of industrial measuring robots far simpler and more flexible, even in challenging production environments. The motion path of the robot arm can be programmed offline without having to take any special conditions into account. The absolute position of the sensor and robot is captured in less than a second, significantly reducing the number of recalibrations needed.

Since the higher-level coordinate system coordinate system immediately determines robot position deviations, the recorded results remain absolutely precise even in the event of changes making the traditional system recalibration through correlation no longer necessary.

Inline part measurements are performed using a compact version of ISRA’s X-GAGE3D multi-stereo sensor equipped with four cameras with high-performance LED lighting delivering precise 3D scans of objects allowing direct CAD comparison. By completely digitizing objects, X-GAGE3D allows all spatial characteristics to be checked with just one scan, significantly speeding up quality control. Moreover, due to the absolute measurement methodology employed, the results obtained through X-GAGE3D, retain their accuracy.

Independent of Temperatures Due to Carbon Fibre Frame
Several high-resolution cameras are used in each robot cell ensuring the exact determination of the sensor head, even if the robot arm blocks the sensor in the field of view of an individual camera. Since the system is mounted on a temperature-resistant frame made of a carbon-fiber composite material, environmental influences on the measurements are reduced to a minimum. Furthermore, users can completely forgo the inspection of components or car bodies in a coordinate measuring machine and, in particular, their time-consuming
transportation to the inspection lab.

Optical systems are a key technology for networked production and the “smart factory” of the future. Central data hubs generate detailed production data in addition to direct use for adaptive process adjustments. Absolutely precise inline measurement technology will be an  important factor in the future as optical systems control robots and sensors directly with optimum precision.

For more information: www.isravision.com

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