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
reflectCONTROL Compact has been specifically developed for the inspection of shiny surfaces. The system projects a striped pattern onto the measurement object. Defects on the surface cause deviations from the striped pattern which are recorded by cameras and evaluated by software.
The fully integrated system is available in two versions that each provides different measuring fields. The 2D version is used for pure defect recognition on reflecting surfaces. In addition, the 3D version allows for the measurement of reflecting surfaces at submicrometer accuracies. This device is also used in individual operations (e.g. laboratories) as well as directly in production lines.
Details
Fast and high resolution measurement on large surfaces up to 265 x 110mm
Versions for defect recognition or 3D reconstruction
Proven technology for offline inspection and integration into processing lines
Interfaces: USB, VGA, Ethernet, Digital I/O
Application examples
Inspection of touchscreens for smartphones and tablets
Defect detection on car attachments and interior components
Measurement of telescope mirrors and lenses
RCC130 is used for defect recognition and measurement of defects.
RCC100 and RCC110 are used for pure defect recognition.
Identification of the most minute defects and deviations
Consistent and reproducible identification rate
High-precision measurements, flatness deviation in the submicron range
Large measuring field of 170x160 mm
Deflectometry sensor for 3D measurements of shiny surfaces
The reflectCONTROL RC130 is intended for shape measurements of shiny objects. This sensor displays a striped pattern which is mirrored by the surface of the measuring object into the sensor cameras. The sensor provides a 3D image of the surface which allows for the topology of the components (e.g. flatness, deflection, curvature) to be determined. The RCS130 model is specially optimized for measurement and inspection tasks, e.g., in production lines. Moreover, the sensor has a GigE Vision interface that offers GenICam compliant data.
Surface inspection of shiny components
The reflectCONTROL RCS110-245 with integrated controller is designed for stationary measurements or integration into machines. This compact sensor detects anomalies on shiny surfaces which are processed and displayed as reflectivity and curvature image by software. GigE Vision enables the transfer of surface images to a wide range of image processing software packages for further analyzes.
3DInspect software for 3D measurement tasks and inspection
The 3DInspect software is a powerful tool for sensor parameter set up and industrial measurement tasks. This software transmits the measurement data from the sensor via Ethernet and provides the data in three-dimensional form. This 3D data is further processed, evaluated and assessed with 3DInspect measuring programs on the PC and, if necessary, logged and transmitted via Ethernet to a control unit. If required, these 3D data can be saved with the software. Furthermore, the set up and configuration of the sensor is possible via the software.
Software integration via Micro-Epsilon’s 3D-SDK
reflectCONTROL is equipped with an easy-to-integrate SDK (Software Development Kit). The SDK is based on the GigE Vision and GenICam industry standards including the following function blocks:
Network configuration and sensor connection
Comprehensive sensor control
Control of image transfer
Management of user-defined parameter sets
C++ example programs and documentation
Accessing the sensor via GigE Vision is also possible without SDK if you have a GenICam client.
Objective 100% inspection of all the vehicles manufactured
