High-Speed Structured Light Scanning Elevates Automotive HVAC Component Inspection
Denso Manufacturing Czech s.r.o. needed a more efficient and accurate way for inspecting air conditioning units (HVAC) and their components – heat exchangers, fans, and plastic parts – as its previous system reached the end of its serviceability. By adopting the Hexagon SmartScan VR800 structured light scanner, Denso now performs fast, high-accuracy, non-contact inspection of multiple parts simultaneously. This upgrade led to time savings, improved defect detection, and greater flexibility, enhancing product quality and helping Denso meet the strict standards of their global automotive clients.
Denso Manufacturing Czech s.r.o., a subsidiary of the Japanese DENSO Group, has been a cornerstone of the automotive industry since its establishment in 2001. Located in the industrial zone of Liberec, Czech Republic, the plant employs 2,000 skilled professionals committed to producing high-quality components for automotive thermal systems. As one of two key manufacturing bases in the Czech Republic, alongside Denso Czech s.r.o. in Zruč nad Sázavou, the Liberec facility specialises in climate control systems that ensure ideal temperature conditions for both passengers and vehicles.
Each year, the plant delivers approximately 2.5 million air-conditioning units to leading European and Japanese car manufacturers, such as Volkswagen Group (including Škoda Auto), BMW, Toyota, Suzuki, Ford, and Volvo. The company’s dedication to quality is reflected in its stringent control processes and use of cutting-edge production technologies to consistently meet the high standards of the global automotive industry.
Driving Innovation With Trusted Partner
Denso Manufacturing Czech s.r.o. has maintained a close partnership with Hexagon for nearly two decades, incorporating several Hexagon solutions into its quality control toolkit, including GLOBAL series coordinate measuring machines, PC-DMIS metrology software, and the Absolute Arm 7-Axis portable measuring arm.
In 2024, Denso upgraded its inspection capabilities to overcome the limitations of its ageing third-party structured light scanner. The old system’s slow scanning and data processing, especially with larger part volumes, couldn’t keep up with the fast-paced demands of product development and production. Acknowledging the limitations of traditional methods, Denso sought more advanced solutions and ultimately turned to the latest generation optical scanning technology. The newly launched SmartScan VR800 stood out for its high precision, speed, and efficiency – qualities that align with the ever-increasing demands of modern manufacturing.
Hexagon supported the transition with practical training on real parts, enabling Denso’s team to begin using the system almost immediately in their regular operations. With four trained operators, the factory now benefits from both flexibility and in-house expertise. Pavel Knirsch, Quality Manager at Denso, notes, “It was important to ensure that we could adapt to the new system as quickly as possible and start using it effectively in our daily practice.”
Enhancing Quality Inspection of Plastic Parts with Optical Scanning
The introduction of the SmartScan VR800 at Denso significantly improved the inspection of plastic components used in their air-conditioning systems. These parts, often highly intricate and irregular in shape, are ideally suited to the VR800’s optical scanning capabilities, which enable detailed surface digitisation without manual probing, unlike traditional tactile methods. The scanner’s motorised zoom lens allows users to adjust resolution and measurement volume entirely via software, eliminating the need for manual lens changes.
The scanner is particularly effective when measuring plastic materials, which are susceptible to deformation. As Knirsch explains, “Plastic materials are sensitive to deformation, and this is precisely where the scanner truly excels. Thanks to rapid scanning and the ability to generate colour maps, it efficiently reveals deviations and shape changes that could affect a part’s functionality.” This capability is crucial for identifying common defects such as sink marks from the injection moulding process, allowing for precise analysis and informed corrective action.
The scanner is typically used every other day, depending on production needs. The workflow is structured to maximise efficiency: one day is dedicated to scanning parts, such as components of flap movement kinematics, while the following day focuses on detailed evaluation of the data. Separating scanning from analysis enables the team to work efficiently and respond quickly to production requirements.
While complete HVAC units undergo verification using inspection machines on the production line, the SmartScan VR800 is employed for inspecting individual components. “An HVAC system is made up of a huge number of parts, each fulfilling a specific function while needing to fit precisely into the overall design,” says Knirsch. “This is especially critical during the early stages of new projects, where individual parts are fine-tuned to ensure seamless system integration.”
The scanner’s ability to rapidly measure multiple parts simultaneously supports evaluation of their mutual compatibility, allowing Denso to identify and implement the necessary adjustments to ensure the final assembly meets customer specifications. The resulting data is shared with design engineers and suppliers, facilitating collaboration on design modifications or tolerance optimisations.
Significant Time Savings and Improved Efficiency
The SmartScan VR800 has significantly enhanced Denso’s inspection processes through its advanced features, delivering time savings and operational efficiency. Antonín Kvasnička, Component Quality Team Leader, comments: “One of the first visible benefits of the new system is a significant time saving.” He explains that the VR800 “…offers faster scanning and data processing compared to the previous system, which is particularly noticeable when we inspect larger volumes of parts.” This improvement allows Denso to work with a large amount of data more quickly and respond more flexibly to the needs of development or production.
The SmartScan VR800’s Smart Zoom and Resolution functions allow high-resolution scanning of critical areas without requiring full-part scans. This streamlines the inspection process through software-based control of resolution and measurement volume. In addition, the Smart Snap function uses four digital cameras to capture scan and orientation data simultaneously, with LED flash support enabling target positioning outside the 3D scan area. This reduces the number of required targets and expands the measurement volume, accelerating the entire scanning workflow.
Software-driven adjustments provide Denso with the flexibility to adapt quickly to varying inspection needs without the need to change lenses or optics. The ability to integrate data of differing resolutions into a single project further enhances efficiency. As a result, Denso can manage high part volumes, maintain production schedules, and uphold the stringent quality demands of its automotive clients.
Partnering for Progress
Denso is actively sharing knowledge with other companies of the group to standardise measurement methodologies. The use of 3D scanning is becoming a shared approach that aligns expectations, requirements, and technical capabilities across the group. Looking ahead, Denso is enthusiastic about the future. With plans to introduce new products, particularly for electric vehicles and next-generation air conditioning systems, the SmartScan VR800 will be a vital asset. The company is also committed to sustainability, aiming to achieve carbon neutrality by 2030.
By embracing innovative technology and strengthening strategic partnerships, Denso continues to set the benchmark for quality and innovation in the automotive industry. Its collaboration with Hexagon exemplifies how mutual trust and shared goals can lead to remarkable progress, ensuring Denso remains at the forefront of automotive component manufacturing.
For more information: www.hexagon.com
