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Metrology Goes Inline With Automated Production Systems

Due to the fast transformation in the manufacturing world – the electrification of the automotive industry and the reali­zation of smart factories – more and more automotive body shops are asking for fully integrated metrology systems in their lines. The digital transformation of inline metrology reduces the workload on measuring rooms while significantly increasing the number of measured parts.

When using inline systems, the shop floor staff can imme­diately respond to quality problems where they arise and control the production process proactively. The high-precision and absolute ZEISS inline solutions do not require any correlation and deliver reliable and conclusive measurement data for ­series production control.

Process Monitoring and Feature Based Inline Metrology

The ZEISS AICell trace inline measuring system is helpful during production ramp-up and ensures process control directly in the production line. The highly accurate and fast ZEISS AIMax cloud 3D sensor captures very complex features on assemblies and bodies, e.g. bolts edges, holes, rivets or even the position of a welding nut behind sheet metal, in real time. The tracking technology used in the ZEISS AICell trace monitors the sensor position on the robotic arm with high precision, thus eliminating the need for complex correlation measurements in the measuring room. With this method, users will be able to obtain reliable, traceable measuring and inspection data from the first part produced during ramp-up onwards. Depending on the cycle time and the number of robots, the system captures up to 100 features per cycle. Rolling measurement and pause programs for analysis measurements also come with the features.

ZEISS AICell trace combines process monitoring and feature based inline metrology in one single cell.

Full-Field Digitization of Body-in-White

After the features have been measured, robot-controlled ATOS sensors digitize the entire body-in-white from different perspectives with high precision and high detail resolution. Users can then extract process- and quality-related inspection characteristics for statistical evaluations by using the resulting absolute, correlation-free and traceable data. The sensors produce full-field 3D coordinates with every scan. As a result, you will see a complete digi­tization of the body-in-white, known as a geometric digital twin. Using the full-field measurement data, the 3D metrology software automatically derives the inspection feature plan and identifies deviations between the ­digital twin and the CAD data. The analysis clearly illustrates whether the chassis marriage is flush and without gaps. In the digital assembly, users can analyze the interaction of the outer skin with the hang-on parts before the actual assembly occurs.

ATOS sensors digitize parts or even complete car bodies in the production line.

Surface Inspection Measurement

ZEISS ABIS is the tailored solution for surface inspections in the press and body shop. The system inspects sheet metal panels quickly, easily and objectively throughout the complete process chain. A robot moves the optical 3D sensor over the parts to be inspected. The ABIS software recognizes surface defects and evaluates them according to the specification’s corporate standards. ZEISS ABIS easily inspects moving parts and is therefore ideally suited for inline use.

The recently launched ABIS III sensor combines high-speed inspection with a reliable detection of all relevant surface defects such as dents, bulges, sink marks, ripples, neckings, cracks and now also scratches and pressure marks. The system inspects both moving and stationary parts reproducibly and highly precise during live production and within the cycle time.

The patented Multi-Color-Light technology allows for detecting even the smallest defects. After only a few seconds, a digital inspection report will be issued. This way, functions such as a Q-stop and digital quality details such as defect visualizations for scheduled rework are always available. They provide the basis for closed loop circuits and the precondition for implementing the Smart Process Control. Designed and developed in Germany to fulfill the highest quality standards, ZEISS ABIS III is the ideal solution for both modern press shops and future-oriented body shops.

ZEISS ABIS uses multi-color-light technology to detect smallest defects

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