Reimagining Spring Quality Control with Optical 3D Scanning Technology
Inspecting springs has long been considered a challenging task in metrology. Their complex geometries, tightly wound coils, and small tolerances make traditional measurement approaches time-consuming and prone to error. Recognizing this, Ajile has developed a comprehensive, fully automated solution that brings precision and efficiency to spring inspection.
At the core of Ajile’s system is the ability to capture complete 360° views of springs from any random starting orientation. The solution leverages two DepthScan 3D imagers paired with a rotational turntable, ensuring that every surface of the spring is scanned multiple times from different angles. Each scan generates an individual point cloud, which is referenced to the turntable’s absolute angular position using Ajile’s absolute magnetic encoder. Proprietary alignment algorithms then stitch these point clouds into a single, fully meshed 3D model, enabling high-accuracy measurement of key GD&T features, even for complex or tightly coiled spring geometries.
The system achieves 30 μm accuracy in full 360° point cloud generation and surface meshing. The turntable features a 0.006° angular resolution via a capacitance absolute rotary encoder and can handle loads up to 2 kg, making it suitable for a wide range of spring sizes.
Ajile’s inspection software fully automates the capture process. It manages the scanning sequence, point cloud stitching, model filtering, CAD alignment, and comparison to GD&T specifications. For the final reporting and analysis, Ajile integrates seamlessly with Polyworks, enabling manufacturers to not only verify compliance with specifications but also track production trends over time.
The benefits of automated spring inspection extend far beyond measurement accuracy. By delivering rapid feedback on production issues, manufacturers can identify machinery problems early, reduce scrap, maintain consistent quality, and ultimately improve customer satisfaction. The system’s integration with Polyworks further supports long-term statistical process tracking, helping manufacturers optimize and monitor production in real time.
Ajile offers complete inspection solutions, including turntables, robotic part handling, and software for capture, filtering, stitching, surfacing, and analysis. Its flexible approach also supports integration with third-party software such as Polyworks, providing manufacturers with a fully automated, end-to-end inspection workflow.
With the combination of advanced 3D imaging, high-precision turntables, and intelligent software, Ajile is redefining spring inspection – transforming what was once a challenging and labor-intensive process into a reliable, automated, and highly accurate solution.
For more information: www.ajile.ca
