X-Gage3D and CarPaintVision sensors

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A new sensor with maximum measurement precision now enables highly efficient quality control in automotive production thanks to an ideal ratio of distance and measurement volume. That is why a leading premium automotive manufacturer has now chosen the multi-stereo 3D scanner and begun using it for 3D inline measurement at a German plant. The system is characterized by enhanced accuracy and the minimum measurement distance. This extremely close proximity is crucial for accessing hard-to-reach features, such as in the wheel house or transmission tunnel, and for flexible use inline, at-line and off-line.

Even under the most difficult conditions, the all-in-one sensor detects all object shapes in next to no time thanks to four high-resolution cameras and a high-performance LED projector. The innovative multi-stereo technology creates a particularly complete, ultra-fine point cloud with stereometric images from six different pairs of cameras. The various perspectives keep even reflective areas in focus, as they can be optimally captured from another angle. More so in mixed material inspections – a challenge for previous solutions – the system provides reliable data.

The premium German automotive manufacturer uses the new sensor version with higher accuracy and reduced measurement distance (190 mm) at four robot measurement stations on the line. Symmetrical measurement volume makes robot positioning especially simple, as the sensor has no preferred orientation. The optimized embedded software measures all the usual measurement features, such as holes, bolts, edges, etc. All feature measurements are analyzed directly at the sensor, reducing the costs for additional PCs to analyze. An absolutely calibrated robot ensures high absolute accuracy for the coordinates and enables high comparability with CMM measurements. Moreover, connection to the manufacturer’s database system allows the sensor to be set up automatically on the basis of existing data as well as making a comparison of the results.

Optimum quality control with point cloud technology

If a CAD data set for a component is already available, dimension deviations can be determined quickly by means of a CAD comparison. X-GAGE3D uses this process to examine all object features simultaneously, considerably speeding up quality control. For object digitization, the sensor creates the CAD data itself and makes it available for further processing in all conventional formats. X-GAGE3D is especially precise at this task thanks to its ultra-fine point cloud technology: The minimal spacing between the data points delivers a high information density and depicts the object surface precisely. This makes it ideally suited for applications in the quality lab and for integration in an automated line. As a flexible solution, X-GAGE3D is available in multiple formats covering all difficult and complex surfaces and geometries.

Object digitization as quality control

X-GAGE3D also displays high operational capability: It is suitable for every inspection from the shop floor to the laboratory, while the robust design also makes the sensor ideally suited for robot-guided applications. Another version of the system can be used for object digitization, resulting in precise digital images that depict the components fully and in detail and provide the images in all common formats for further processing. This allows even freely shaped areas to be inspected precisely and provides ideal results for additive manufacturing with a 3D printer or for reverse engineering. If a CAD data set for a component is already available, dimension deviations can be determined quickly by means of a CAD comparison. The system uses this process to examine all object features simultaneously, considerably speeding up quality control.

Designed for simple operation and Industry 4.0

An intuitive user interface with tile design allows for safe operation of the sensor even without prior experience – trouble-free operation is guaranteed. Equipped with Wi-Fi and the OPC/UA protocol, the sensor is also optimally positioned for connected production and Industry 4.0. X-GAGE3D also complements ISRA’s equipment range for absolute measurement tasks. These reference systems determine the absolute sensor position in the space in relation to a higher-level coordinate system, thus producing the most objective results possible.

Paint inspection

Today’s complete systems – such as CarPaintVision (CPV) from ISRA VISION – link robotics with surface inspection. Fast and simple integration of new vehicle types and automatic offline robot path generation make them flexible to use. What is more, the entire relevant surface is inspected inline – either on the fly, during continuous movement of the vehicle, or in a cyclical stop and go process.

CPV provides objective and consistent evaluation of the paint surface quality that can be individually adapted. It is more cost-effective than manual processes and supports process improvements with reliable statistical data.

For its solution, ISRA VISION uses the hybrid sensor PAINTSCAN, which combines two surface inspection methods. All topographical and non-topographical paint defects are thus detected reliably. Integrated analysis units ensure faster surface inspection times and reduce maintenance requirements. Meanwhile, data is processed at process speed, so that defect information is immediately available. The option of marking defects also makes reworking simple and saves time.

The oversampling method ensures continuous paint inspection: A high scan frequency and images that overlap in the direction of travel record every point on the bodywork multiple times. Redundant data with up to ten images ensures reliable inspection results with a detection rate of more than 95%. All relevant defects – such as inclusions, craters, pigment defects, scratches, dents, and indentations – are reliably detected and classified. The classification software is already pre-taught and the result of years of experience in the sector. Algorithms also enable self-teaching defect detection, so that line-specific defects can be recognized. Thanks to its flexible options for use, the system is ideal for multi-model lines, since CAD models are used to automatically plan a collision-free robot inspection path. Deployed in line-tracking operation, the robots need no additional linear axis for moving.

Software and connectivity are ready for the future

The inspection data collected enables continuous, long-lasting production optimization. In connection with the Enterprise PROduction Management Intelligence solution, EPROMI, the collected statistical data is analyzed according to individual information requirements and presented on standardized or individual dashboards.

Configuration is fast and intuitive thanks to easy-to-use software. The system can also be easily retrofitted to existing plants. Moreover, compatibility with all common robot brands guarantees optimum integration into a particular plant environment usually specified by the customer.

With such flexible applications, CPV is already geared towards order-controlled multi-line production today. The system thus supports the industry in its vision of production facilities in which cars produced according to customer preferences automatically access processing stations depending on their equipment line or distinct design – in an order-controlled, intelligent and efficient way.

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