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Automotive

Case Studies

Learn how automotive companies are using accurate structured blue light 3D scanners, comprehensive inspection software, photogrammetry technology, and/or automation to improve manufacturing processes with rapid precision measurements

This presentation explains how TRITOP photogrammetry and ATOS were used for CFD analysis to help reach world record speeds of 200+ mph.

In 2006, BMW delivered a presentation at the GOM International Users Conference enlightening the audience on their vision into automated robotic metrology for inspection of sheet metal parts.

The press shop at BMW‘s Dingolfing plant relies on optical metrology systems including automation and standardization for inspection of shee t metal components. Here, 3D coordinate measuring technology from GOM sets completely new standards, offering high time-saving potential since sensor, automation and inspection software all come from a single-source provider. The automation processes in particular, have been subjected to continuous development in close collaboration with BMW.

In 2007, BMW presented on their automated ATOS scanning robotic solution for the automotive design application.

This presentation by BMW describes their die panel inspection process as well as a comparison to CMM versus ATOS structured light 3D scanning.  Every panel measured in GOM generated a colour map and also a CMM Series point report including Form, Trim and pierce.  The review of problems found highlighted that 97% of problems ware form related.  After Discussion with the Press shop they confirmed the that generally only the form process would vary due to material spec and press pressure changes and that change in form could be linked the trim and pierce changes due to the change in form location on the die.

Mobile optical 3D coordinate measuring technology is used for quality assurance on the production line in the BMW Regensburg plant. For the assembly of roof modules for convertibles, optical measuring equipment is used in process planning for the machine capability study (MCS) even before the start of serial production. On the assembly line the photogrammetric system then enables flexible inspection to be carried out during manufacture. Thus trends and deviations in production can be detected at an early stage. As result of using optical metrology rework time is reduced and production costs are cut down significantly. Also Quality Management can be specifically improved by means of process capability studies.

Boeing REsolutions presentation discussing process for reverse engineering and designing a classic Corvette body onto a newer model using ATOS for 3D scanning to create the digital model.  

The ATOS 3D digitizer, for full-field measurements of surfaces, is utilized world-wide in the injection-molding and plastic-processing industry for form and dimension inspection of injection-molded parts. Due to the 3D full-field color deviation plot, the evaluation of parts is considerably faster and much more efficient compared to conventional measuring methods. In particular, warpage and shrinkage of injection-molded parts are fast and clearly displayed speeding up mold try-out and production control. Thus, the ATOS technology allows companies to keep pace with shorter product cycles and faster lead times.

With a CMM comparison to ATOS, Brembo explains the benefits of using the ATOS 3D scanner in their engineering processes for quality control inspection, first article inspection, 3d machining, production, prototype tests, assembly checks, incoming inspection and failure tests.  

This presentation describes Honeywell's implementation of ATOS for inspection of turbine engine components as well as a CMM comparison.  

Already before the first article inspection (FAI) of the casting, 3-D shape and dimensional analyses provide reliable information for quality control and targeted process optimization. Foundries and forging shops the world over use the ATOS 3-D digitizer from GOM mbH, Braunschweig/Germany, for surface measurements in shape and dimensional control of patterns, sand cores and castings. GOM also offers inspection software, training and support – all from a single source. Longstanding users above all appreciate GOM´s integrated solutions of non-contact and tactile measuring within one system.

This presentation by Chrysler describes their die manufacturing process and how ATOS is utilized from product development to production for 3D scanning and inspection

It was in France in the mid-1960s that the great American supercar came to life. A low-slung, muscular racing car built to win on the legendary Le Mans race circuit, the Ford GT40 project was spearheaded by Chairman and CEO Henry Ford II. His goal was to change performance car history - and he did. The Ford GT40 car beat the world's best in endurance racing, placing first, second and third at the 24 Hours of Le Mans in 1966 and winning the next three consecutive years.

In automotive production, the individual parts are held in fixtures during mounting and are combined such that precise components and assemblies result.  When using large body sheet metals that are not stable themselves, it is particularly important that the fixture forces the sheet metal into the correct shape. Thus, solid welding and rebated joints can be produced and the shape of the assemblies complies with the specifications. In production, Ford uses 60 welding fixtures in the production chain for the right and also for the left side panel. These so-called jigs can be adjusted for holding and clamping the side panel of the 3 and 5 door Ford Fiesta and the Ford Fusion.

Ford Stamping engineering has identified 14 key areas where white light scanning is an enabler to improve timing and quality –process improvements.  Systematically going through list and addressing each area in order of importance and what makes business sense –various rates of success. By far the most effective and most successful application to-date is to reduce die rework. Panel inspection using automated cells also expected to be highly successful.

The automotive supplier GEDIA is taking a new approach to quality control.  The company is replacing measuring technology based on tactile systems and gauges with full-surface optical 3D coordinate measurement. The implementation of optical metrology systems is making GEDIA more flexible. It i s cutting costs and reducing measurement times.

This presentation will cover the strategic implementation of ATOS into Gedia's manufacturing process.  

Dimensional analysis of the prototype molds was conducted with the aid of an ATOS Triple Scan optical 3-D digitizing scanner equipped for blue light scanning (blue light permits accurate measurements regardless of ambient light conditions), supplied by Capture 3D (Costa Mesa, Calif.) and developed by GOM mbH (Braunschweig, Germany). Scanner feedback guided development of the multicavity production molds, optimizing dimensional results while eliminating tuning loops.

This example shows how the photogrammetric system TRITOP is used for local as well as global deformation analysis by the automotive industry.

Quality assurance and management are growing in importance in industrial development and production. The decentralized production of components by suppliers mean that tight specifications have to be meet to ensure problem-free assembly in final production, resulting in a high-quality final product. As such, optical digitizing systems have become firmly established for inspection of individual sheets, in assembly analysis, and during forming tool try out.

Fuel tanks for cars are typically manufactured using plastic blow molding. To verify the production parameters and optimize the production, the digitizer ATOS II was used. 10 samples were taken out of two production lines with 20 minutes digitizing time for each part. The parameters which were monitored and validated were the production line, the cooling water (temperature and flow), the object temperature before digitizing and the influence of a special process step.

Lamborghini explains why they chose ATOS for 3D scanning applications such as reverse engineering and inspection of their luxury super sports car, and gives a comparison to their previous process using Faro.  

This presentation given in 2012 continues from their last presentation in 2010 to cover the further enhancements and improvements Mann+Hummel have achieved by purchasing an additional ATOS system but this time automating the 3D scanning and inspection process- 300% process improvement with automation, $212K savings in eliminating outsourcing and 75% ROI within the first 6 months of implementation.  

This presentation gives an in-depth explanation of how Mann+Hummel have reduced their tool tuning loops with ATOS structured light 3D scanning in comparison to their previous CMM process. Mann+Hummel utilizes ATOS to overall measure their parts more accurately due to the versatility of the data, resulting in significant time savings and cost improvements - conservative savings in excess of $320k per year.

North American Eagle asked Capture 3D to help create a digital model of their vehicle for CFD analysis to help in their attempt to break the World's Land Speed Record.  This presentation will cover TRITOP photogrammetry, ATOS 3D scanning, and the analysis portion.  

This presentation covers the history of ATOS 3D scanners at Opel's manufacturing facility and their progression to automated inspection for quality process improvement and higher production.  

Penske Technology Group's presentation regarding utilizing ATOS for reverse engineering and CFD analysis for improving top speed.  

A typical application for 3D digitization is the recording of the actual shape of a physically existing model during the design and product development phase. The mobile ATOS II 3D scanner and TRITOP photogrammetry systems provide for a time-saving and flexible performance of this task. The measuring results in form of high-resolution triangulated meshes can easily be manipulated and processed.

 This presentation discusses the competitive vehicle digital benchmarking process of vehicle disassembly, 3D scanning, post processing, data compilation, and deliverables.  

Simulation of forming processes has become an important tool for the current process optimization. It can be supported significantly by modern optical measuring methods based on digital image processing providing full-field information of 3D surface geometry (ATOS) and strain and thickness reduction distributions of formed sheet metal parts (ARGUS). These optical systems have become important tools in industrial tool making and sheet metal forming processes in the last years and together with the simulation of forming they have significant potential for quality improvement and optimization of development time for products and production.

A travel into the die-casting and metallization technologies of aluminium die-cast reflectors for the automotive lighting industry- fog lamps, head lamps, heat dissipators, containers for electronics and steering wheel control housings.  Tecnomeccanica manufacturings approximately 6.5 million of these parts every year.  

The Virtual Targets Center provides weapon system developers, testers, evaluators and trainers with target geometries and simulation model inputs of variable resolution in multi-spectral domains, to answer the life-cycle simulation needs in support of the soldier.

Measuring tasks that so far could only be performed using tactile 3D coordinate measuring machines, measuring arms or measuring aids, can now be carried out easily and efficiently with the TRITOP as it does not require any complex and maintenance-intensive hardware.

The focus of the presentation was the mutual project from Volkswagen and GOM in the area of optical in-line measuring technology, with which the production quality of mounted parts for the new Golf 7 is automatically controlled. In each production line an ATOS optical 3D scanner is fully automatically monitoring the quality of the engine hoods, tail gates and doors. The measurement results are available during the production and allow processes to be quickly and accurately targeted and optimized.

Volkswagen pursues accident research. Numerous accident statistics and local accident surveys have been analyzed statistically to gain knowledge of the accident event. The goal is to improve vehicle safety. 

In 2007, Volkswagen presented on their automated ATOS scanning robotic solution for the inspection of their suspension parts.  

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