During the automobile manufacturing process, quality monitoring of key process characteristics of automobile parts and bodies is an important guarantee for the quality and safety of the entire vehicle.
In response to the quality inspection needs of parts production, body assembly and other links in the automotive industry, Mekamande has launched a new AI+3D vision online measurement solution to achieve efficient, accurate and real-time production quality monitoring, and help the automotive industry intelligent and flexible production .
Application Difficulties
01Customer pain points
Traditional CMM measurement systems have expensive equipment, high maintenance costs, and strict environmental requirements; their measurement efficiency is low and data feedback lags behind.
The automotive industry has high quality standards and involves complex processes; measurement accuracy and speed need to meet the production needs of automated production lines, and provide real-time feedback on quality trends.
02 Live Challenge
Typical workpieces from the automotive industry:
The workpieces to be tested in the automotive industry (such as subframes, side panels, doors, etc.) are large in size, and a 3D camera is required to be compact and highly flexible, and to be matched with a robotic arm for feature collection.
The workpiece to be tested often has characteristics such as surface reflection, complex structure, and special shape. High requirements for 3D camera imaging capabilities.
Some typical features:
There are many types of features of the workpiece to be tested, such as round holes, waist holes, threaded holes, studs, etc. Some features have complex conditions such as reflection, chamfering, and precision structure. A 3D camera is required to image various features with high quality, and the online measurement system can calculate and output information such as feature size, shape and position tolerances.
The heat generated by the robot working for a long time and the changes in ambient temperature lead to changes in the kinematic parameters of the robot and affect the measurement accuracy. The robot needs to be compensated for temperature drift.
It is necessary to analyze and organize the measurement data in real time, and feedback quality problems to the front-end process to avoid waste caused by defective products flowing to the back-end process.
Modern automobile factories mostly adopt the co-line production model of multiple models, and the online measurement system needs to be compatible with multiple models.
Solution
Measuring station:
01System configuration
Mech-Eye UHP-140 micron-level precision industrial 3D camera, Mech-Vision machine vision software, and self-developed measurement software.
02Application scenarios
All aspects of automobile manufacturing, including auto parts production, sub-assembly tailor welding, body-in-white assembly welding, etc.; new energy battery box surface material incoming materials, CNC processing, welding, etc.
03Measurement object
High-precision measurement of key feature geometric dimensions (such as length, width, circle diameter, etc.) and geometric tolerances (such as position, flatness, coaxiality, etc.).
04Workflow
The workpiece to be measured is transported to the measurement station, and the workpiece is fixed by the workpiece fixture.
When the measurement process starts, the robot calls the corresponding measurement program according to the workpiece model, triggering the vision system to measure each feature point of the workpiece.
The measurement results of each feature point are saved in real time during the measurement process.
After the measurement is completed, the overall measurement results are output and a report is generated.
Solution advantages
01 Micron-level precision industrial 3D camera to better cope with high-precision measurement scenarios
Mech-Eye UHP-140 has micron-level accuracy and self-developed fusion imaging algorithm and anti-reflective three-dimensional reconstruction algorithm. It can effectively deal with the interference to optical measurement caused by workpieces with complex structures, diverse materials, visual blind spots, special-shaped reflections and other complex conditions. Generate high-quality point cloud data for various typical features.
Mech-Eye UHP-140 is compact and suitable for installation at the end of a robotic arm. It can flexibly move with the robot to feature points at different locations to collect feature size/position information of various large workpieces in the automotive industry.
02 Rapidly deploy measurement projects and control production quality in real time
Mech-Vision has built-in advanced measurement algorithms, which can quickly complete key feature geometric dimensions and geometric tolerance measurement applications without writing code. Easily adapt to a variety of models and support customers to quickly complete model change production.
Self-developed measurement software outputs measurement data in real time and can provide functions such as overview view, data trend chart, data display, and data summary. Achieve real-time control and analysis of production data and provide closed-loop quality management solutions for automotive industry production.
03Efficient and accurate online measurement system, professional service team
The overall measurement accuracy of the Mecamander online measurement system can reach ±0.2mm, and the average time consumption of a single measuring point can reach up to 2 seconds at the fastest. The key indicators of the measurement solution (accuracy, speed) have reached the industry-leading level.
The self-developed temperature compensation model uses a robot to measure the reference ceramic ball in real time and establishes an error model to correct the system offset to ensure that the measurement results are true and reliable.
Mecamander can provide customers with online measurement system deployment services, and has a strong sales, delivery, and after-sales team to provide global customers with 7*24-hour rapid response and support to ensure smooth project implementation and stable operation.
Applications
3D vision guided subframe size measurement | A large automobile OEM:
01Project site:
02Project background:
The customer needs to measure the key parameters of various assembly features of the subframe of a large workpiece, including position, flatness, coaxiality and other geometric tolerances. Real-time control of production quality to ensure body molding quality.
03Project advantages:
Micron-level precision industrial 3D camera Mech-Eye UHP-140, with ultra-high precision, can generate high-quality point cloud data for subframe assembly features with strong reflective surfaces.
Advanced point cloud processing technology and measurement algorithms can quickly and accurately complete high-precision measurements of ordinary round holes, threaded holes, studs, waist holes and other features.
Multi-cameras and multi-robots work together to flexibly respond to characteristic hole positions at different locations and quickly complete the measurement task of large workpieces.
Summarize measurement data in real time and provide data trend analysis to facilitate customers to control production quality and improve production processes in real time.
Mecamander's online measurement system has passed terminal verification for large-scale projects at many auto parts factories and automotive OEMs. In addition to online measurement, Mecamander has profound technical accumulation in appearance defect detection, weld defect detection, glue path detection, high-precision measurement and other applications, which can help automobile, 3C, lithium battery, new energy, PCB and other industries realize Quality monitoring greatly improves operation accuracy, production efficiency and quality.
