Fully automated, robot-based painting of diesel truck engines using ATENSOR LS1 technology*
Up to now, the great variety of diesel engines for trucks and other commercial vehicles has prevented automated painting by robots, due to the very high manual programming effort required. The automationCONTROL DPS 8005.T system uses optical sensors to measure the engines in a scanning cabin, and then generates custom robot programmes that can be adapted to all types with their different attachments. The programmes are loaded into the robot's memory and then executed automatically.
Benefits:
Robot-assisted processing is possible for a variety of objects
Versions are detected automatically and correctly handled
Continuous processing quality for a wide range of products
Automated cleaning by robots prior to the coating process is possible
Material parameters:
Diesel engines for commercial vehicles of all kinds
The engines are moved through the scanning cabin on hangers
*ATENSOR LS1 technology = robotic process automation for products with a high number of versions, which makes manual robot programming impossible. With the ATENSOR-LS1 (LS1 = lot size 1), robot programmes are dynamically generated on the basis of measurements. The programmes are then loaded and run in the robot memory.
By scanning in a scanning cabin, the location and geometry of the objects to be processed can be recorded digitally. Based on this data, the system generates individual collision-free and singularity-free robot programmes for each object. These programmes are then run by the processing robot. The process is carried out automatically, without any manual intervention.
Fully automatic surface inspection of painted automobile attachments
A perfectly painted surface is every car's staple feature. Thus the quality requirements for painted parts attached to the car body are the same as with the body itself. Objective inspection is possible with the reflectCONTROL PSS 8005.D robot-assisted inspection system for large and complex attachments such as bumpers. The defects are measured laterally and in depth and classified on the basis of catalogs and optionally marked during robot-based inspection with the automationCONTROL 8005 PSS 8005.M system using ATENSOR-LS1 technology*. This way, follow-up work and process improvements can be performed precisely as required and easily.
Benefits:
Objective 100% inspection of all vehicles manufactured
Employees can concentrate on remedying critical defects and not on identifying them
Detection of defects immediately after the painting booth, when they can still be easily reworked
Cutting costs by reducing defects
Reducing the number of rework lines
Material parameters:
Defect sizes of from 10 µm, lateral
Local 3D-reconstruction allows the automation of follow-up work
Detection rate that is practically independent of color
Not dependent on the robot type
*ATENSOR LS1 technology = robotic process automation for products with a high number of versions, which makes manual robot programming impossible. With the ATENSOR-LS1 (LS1 = lot size 1), robot programmes are dynamically generated on the basis of measurements. The programmes are then loaded and run in the robot memory.
The reflectCONTROL PSS 8005.D system uses robot-controlled sensors that inspect shiny surfaces on the principle of the phase-shifting deflectometry. The robot tracks are defined offline by simulation with the aid of CAD data of the objects being inspected. Optionally, automatic defect marking can be performed with the automationCONTROL PSS 8005.M system.
Special features:
Inspection time <1 s per robot position
Detection rate >95% for all relevant defect types
Reproducible inspection, regardless of the personal constitution of human auditors
Fully automatic surface inspection of painted car bodies
A perfectly painted surface is every car's staple feature, and thus represents a very emotional measure of quality for the customer. To optimize this surface, two to four robot-assisted systems (depending on the cycle time) of the reflectCONTROL PSS 8005.D type allow objective in-line inspection of each car body. The defects are measured laterally and in depth, and classified on the basis of catalogs and optionally marked by the automationControl 8005 PSS 8005.MQ system using ATENSOR-LS1 technology*. This way, follow-up work and process improvements can be performed precisely as required and easily.
Benefits:
Objective 100% inspection of all the vehicles manufactured
Employees can concentrate on remedying critical defects and not on identifying them
Detection of defects immediately after the painting booth, when they can still be easily reworked
Cutting costs by reducing defects
Reducing the number of rework lines
Material parameters:
Defect sizes of from 10 µm, lateral
Local 3D-reconstruction allows the automation of follow-up work
Detection rate that is practically independent of color
Not dependent on the robot type
*ATENSOR LS1 technology = robotic process automation for products with a high number of versions, which makes manual robot programming impossible. With the ATENSOR-LS1 (LS1 = lot size 1), robot programmes are dynamically generated on the basis of measurements. The programmes are then loaded and run in the robot memory.
PSS 8005.D
The reflectCONTROL PSS 8005.D system uses robot-controlled sensors that inspect shiny surfaces on the principle of the phase-shifting deflectometry. The robot tracks are defined offline by simulation with the aid of CAD data of the objects being inspected. Optionally, automatic defect marking can be performed with the automationCONTROL PSS 8005.M system.
Special features:
Inspection time <1 s per robot position
Detection rate >95% for all relevant defect types
Reproducible inspection, regardless of the personal constitution of human auditors
Quality of surfaces is an important criteria for customers. Deviations impair the overall impression and must be recognized early, or ideally, avoided. The surfaceCONTROL and reflectCONTROL inspection systems from Micro-Epsilon are intended for mat and shiny surfaces respectively. Depending on their area of use, different models are available from inline to robotic.
The compact deflectometry sensor is guided over the measurement object by a robot. The sensor enables the inspection of objects whose geometry requires several measuring positions. The defects found are evaluated and displayed in the 3D model.
Details
Fast and high resolution measurement on large surfaces up to 210 x 86mm
Ideal for high-gloss parts with complex geometries, e.g. car attachments
Comprehensive software
Customer-specific modifications on request
Scope of supply
Complete system incl. robot, sensor & evaluation unit, housing
Software package for the adjustment and evaluation of measurements
Objective 100% inspection of all the vehicles manufactured
