Wagon Automotive Implements Inline Metrology Cell for Complex Chassis Components
German automotive system supplier Wagon Automotive has deployed an automated inline measurement solution to address the growing complexity of chassis components and the increasing demand for efficient, high-precision inspection directly on the production line.
The company, a long-established supplier to the automotive sector, sought to modernize its inspection processes to meet strict tolerance requirements while improving production throughput. Traditional manual measurement methods and legacy coordinate measuring machines (CMMs) were no longer able to deliver the flexibility or efficiency required for modern chassis manufacturing.
Inline Measurement Challenges
Wagon Automotive’s production environment involves highly complex parts with varied geometries that must be inspected with tight tolerances. Ensuring consistent measurement accuracy while maintaining production speed presented a significant challenge.
Manual inspection processes and older CMM systems created bottlenecks and required extensive calibration and maintenance. In addition, the company needed a measurement approach capable of operating directly within the production environment while minimizing downtime and reducing operator complexity.
Automated Measurement Cell
To address these challenges, automation specialist Eleven Dynamics implemented a fully integrated inline metrology solution. The system combines a KUKA industrial robot, a Leica Absolute Scanner AS1 paired with the AT960 laser tracker, a motorized turntable, and Eleven Dynamics’ EDAS (Eleven Dynamics Automation Software) platform.
The robotic cell enables automated scanning of complex chassis components directly within the production workflow, capturing measurement data with absolute values rather than relying on relative positioning methods.
The inclusion of a turntable allows parts to be rotated during scanning, optimizing robot travel paths and enabling complete part coverage without repositioning. This configuration significantly reduces cycle times while maintaining measurement accuracy.
Operators highlighted the usability of the EDAS software, particularly its intuitive programming environment and seamless integration with CAD models. The software simplifies robot path planning and eliminates the need for operators to manually manage complex coordinate systems, making it easier to program measurement routines for new parts. “EDAS made inline measurement faster, easier, and more reliable.”
Improved Efficiency and Scalability
Since deploying the system, Wagon Automotive has reported improvements in both inspection efficiency and operational flexibility. The automated cell can handle a wide range of part geometries, including components that were previously difficult to measure using manual systems.
By integrating scanning, robotics, and advanced automation software, the company has reduced calibration and maintenance requirements compared with older measurement equipment.
The modular design of the solution also allows for scalable deployment across additional production lines. Based on the success of the installation, Wagon Automotive is already planning to expand the use of robot-based inspection cells and replace aging measuring arms with similar automated systems powered by EDAS.
The project highlights the growing role of automated metrology in automotive manufacturing, where inline inspection systems are increasingly required to deliver accurate measurement data without slowing production.
As vehicle platforms become more complex and tolerance requirements continue to tighten, solutions that combine robotics, high-speed scanning, and intelligent automation software are becoming a key component of modern quality control strategies.
Conclusion: a partnership that drives innovation
As one of Eleven Dynamics’ early-stage customers, Wagon Automotive played a key role in improving the EDAS software and automation processes. The successful deployment of the flexible, inline measurement solution marks a step forward in automated metrology and sets the foundation for future expansion within Wagon’s production lines.
“Wagon Automotive’s collaboration with Eleven Dynamics shows what’s possible when early adopters and innovative developers shape the future of metrology together.”
For more information: www.11dynamics.com
