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Case Studies

Learn how stamping 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

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.

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.

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

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.  

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.

This presentation from 2007 covers how Infinity utilizes TRITOP and ATOS are used for sheet metal inspection and forming analysis.

Mitsubishi Heavy Industries explains the importance of using ATOS structured blue light 3D scanner for precision digital manufacturing - aircraft skin panel production, dimensional analysis, spring back analysis, dies, assembly jig and checks.

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.  

This presentation delivered by Renault showcases varies examples of ATOS 3D scanning, TRITOP photogrammetry, and robotics to measure and analyze sheet metal and forming applications.

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.

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.

Yaris Kabin gives an overview on their manufacturing process as well as how ATOS and TRITOP have been implemented for dimensional analysis and checking of parts for inspection and reverse engineering applications on their industrial equipment. 

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