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, or with the compact reflectCONTROL PSS 8006.D for smaller parts such as panels. 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.

PSS 8005.D

Data sheet reflectCONTROL for automated paint inspection (PDF, 1.14 MB)

The reflectCONTROL PSS 8005.D system uses robot-controlled sensors that inspect lustrous 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

PSS 8006.D

Data sheet reflectCONTROL for automated paint inspection (PDF, 1.14 MB)

The reflectCONTROL PSS 8006.D system possesses all the components necessary for immediate integration into the production process, in one compact unit. A freely controllable measurement table under the deflectometry unit makes it possible to move the workpiece into any number of measuring positions for complete examination.

Special features:

Measures the curvature and reflectance of the surface
Suitable for defects of a lateral size of 200 µm and more
Can be adapted to different surface characteristics and reflectivities
Table controlled by stepper motor allows detection of the surface at an angle of ± 18°
Inspection time <1 s per robot position

LPS 8005.T

Data sheet automationCONTROL (PDF, 626 KB)

By scanning in a scanning cabin, the location and geometry of the objects to be processed can be recorded digitally. On the basis of this data, the robot programme is adapted by the system to each object, and then processing is performed by the processing robot. The process is carried out automatically, without any manual intervention.

Benefits: