Product category:
Non-contact, Optical and Laser measurement systems
News Release from: Metris | Subject: Modelmaker D scanner at PSA
Edited by the Manufacturingtalk Editorial
Team on 11 June 2008
Car builder quadruples scanning
productivity
Using a Metris Modelmaker D scanner for non-contact 3D measurement of large vehicle parts, a French automotive plant has quadrupled its scanning productivity.
After upgrading optical metrology equipment with a handheld Metris ModelMaker D (MMD) scanner for non-contact 3D measurement, PSA in France has radically increased its scanning productivity, reported Metris The MMD features 100mm laser stripe width and all-digital operation to enable PSA metrology engineers to complete detailed geometric scans of small to large vehicle body parts in record time
This article was originally published on Manufacturingtalk on 2 Oct 2008 at 8.00am (UK)
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The engineers take the portable systems to any location or site, set it up and measure parts on the spot.
The perfect interaction between localiser, scanner and software speeds up scanning throughput and trims down post-processing and analysis work.
Metris told manufacturingtalk that fast turnaround scanning additionally enables PSA to systematically digitise body frames, doors, windscreens and other parts, and use the acquired data to validate numerical calculations, ultimately contributing to fewer mechanical prototypes.
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* One system suits many metrology tasks - PSA has a history with digitising since 2001.
PSA has gained significant experience in applying laser scanning to digitise the geometry of vehicle body parts of prototype or early production vehicles.
PSA Poissy's metrology department said that dimensional accuracy is of prime importance in vehicle body assembly.
For example, during the assembly process of a trunk (boot) lid, the geometry of the lid slightly changes due to the mechanical interaction between frame, glass, trim, lock, etc.
When PSA prototypes vehicle body parts, it closely monitors geometry using Metris MMD to ensure assembled body elements will fit perfectly.
The use of a wide variety of materials - including composites and plastics - sets specific manufacturing and measurement challenges, and increases the need for reliable and efficient metrology systems.
* Body-in-white measurement - physically the largest part that PSA metrology engineers scan using the handheld Metris MMD is a body-in-white (BIW) structure.
Positioning the articulated measurement arm at one or two locations is sufficient to digitise a hood (bonnet) or the entire rear of a vehicle body.
Metrology engineers at PSA also use Metris MMD to scan interior trim parts, light units and various other parts.
To deliver top data quality for different surface types even under difficult lighting conditions, the Metris MMD scanner features ESP (Enhances Sensor Performance).
ESP is an algorithm that automatically adapts camera and laser settings to accommodate varying surface shape, colour and reflectivity.
Metris said that it helps PSA engineers accurately deal with sheet metal, composites and plastics - without having to apply spray or other preparation measures.
With a laser line that counts as many as 1028 measurement points, the scanner reliably digitises free-form surfaces as well as the edges of individual features.
Another reason why PSA opted for a non-contact scanning system, said Metris, is the capability to reliably digitise softer trim material, eliminating the risk to scratch fragile components or press flexible parts.
On finished cars, the system serves as an optical gauge for flush and gap inspection between body panels.
* Reducing scanning throughput time and post-processing tasks - when scanning a vehicle body part, a PSA engineer operates the laser scanner while the scanned surface takes shape in real time on the laptop screen.
The displayed information provides instant feedback regarding scanning speed, coverage and progress.
Scanning takes place at a relentless pace, thanks to the scanner's extra large laser stripe and fast digital signal processing.
A PSA scanner user explained that the result of the scan is a cloud of hundred thousands or even millions of measured surface points.
After filtering the point cloud to eliminate excess points, a polygon surface mesh is generated and optimized and the entire process is smoothly managed by Metris KUBE.
The tight integration between scanner software and hardware not only streamlines the scanning process, but also cuts the remaining post-processing effort in half when compared with the previous scanning system used, said the operator.
According to PSA Poissy's metrology department, the metrology team represents a centralised unit that runs measurements at PSA sites across France to support vehicle development from prototype to release.
Regardless whether measurements are scheduled to take place in the PSA Poissy facilities, or at PSA sites in Rennes or Sochaux, for example, metrology engineers take the portable system with them and start scanning right away.
This pragmatic approach offers maximum measurement flexibility and saves on logistics by reducing transportation of vehicle body (parts) to a centralised metrology laboratory.
* Scanning jobs performed four times - besides monitoring the geometric quality of vehicle body parts - Metris laser scanning forms an essential step in verifying numerical calculations PSA performs as part of virtual simulation.
Metrology engineers at PSA systematically use the Metris MMD scanner to acquire digital 3D copies of structural components such as body frames, doors, windscreens and other parts.
This touch with reality increases simulation accuracy and helps reduce the number of lengthy and costly physical prototype cycles.
PSA said that overall, when using the all-digital Metris laser scanner with wide laser stripe, operators are able to complete scanning jobs four times faster than before.
Productivity improvements of this degree enable PSA to take on additional metrology assignments and yet increase the level of data quality, all within the current capability of its metrology team. Request a free brochure from Metris ...
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