AUTOMOTIVE – 3D MEASUREMENT APPLICATIONS
From the production line of major automotive manufacturers to the shop floor of car builders and custom car companies, carrying out inspection at all points of the design and production process is extremely important. With easy and convenient inspection methods facilitated by tools such as 3D white light scanners, you can create efficiencies and improve the quality of the final product.
NUB3D’s SIDIO white light 3D scanners are used on a day-to-day basis for applications including:
To speed up the final car design process
Currently, most of the work required to create a rough vehicle shape is done virtually. However, clay models are a good method to use when applying the finishing touches.
Ongoing changes between physical and virtual environments are often required.
Moreover, to improve final car design it is often necessary to replicate and scale models to actual size during the design phase and/or to create multiple replicas in order to test different design concepts or model variations.
Use SIDIO systems to create a digital model of the clay design by scanning all of the surfaces. From that data, you can reproduce models (for instance, direct machining), quickly determine dimensions, scale to any desired size, switch to any desired material and obtain Class A surfaces through reverse engineering.
Reproduction times are drastically reduced because the full geometry of parts, from small to large in size, can be captured quickly and easily.
The part can be adapted to the required size without damaging the original design thanks to the high accuracy that SIDIO systems deliver.
Also through reverse engineering, moving from physical to virtual models is done faster and more accurately.
To ensure design and production processes are adequate for optimal car robustness.
It is imperative that you understand and test how car and its components will behave in different environmental conditions once the car is on the road.
Changes in design will have to be made if you find that elements’ geometry change or that they are affected more than had been expected.
Common tests performed on a car include:
- Hail Impact Testing: To determine the impact that hail has on the element deformation of a part by simulating the impact of numerous nylon balls with known speed, weight and diameter.
- Crash Test: To analyze the deformation of the bumper and body in a crash, and, most importantly, to determine which parts of the motor may be affected at any given crash speed. Crash testing can also include running data analysis of the effect the impact of a car (frontal, semi-frontal or rear) has against a static element.
- Assembly: To determine if undesired interactions have occurred while assembling various elements, even though individual pieces may have been manufactured correctly. Gauges and fixtures can affect the shape of the part as can the welding process between different parts.
- Weather-stripping Analysis To determine the behavior of the door gasket when the door is closed. The purpose of this study is to quantify the amount of clearance between the rubber and the rest of the doorframe when the door is closed, and to determine if the same amount of contraction exists around the entire door.
- Door Sag: To test car door endurance. To check door sag after heavy usage, both with and without load. If there is door sag, further analysis will be required to find out which parts are sagging (door, door hinges, hinge pillar, etc.).
Use SIDIO Systems to digitize the part both before and after testing. Once both results are obtained, run a comparison analysis to identify if there are any distortions between the surfaces.
Fast acquisition of the full surface of the part allows you to considerably reduce time dedicated to the project. Direct access to the high-quality results of both tests facilitates an easy and complete analysis so you can understand the tests effects even better.
Having such information allows you to improve the tests handled (e.g., virtual assembly, flush & gap, hail impact testing, fatigue testing, and more) and to verify whether these areas meet the defined specifications.
Therefore, you can make any necessary changes to the design or production process in order to achieve a finished part that fulfills the requirements.
To optimize the aesthetic aspect of the car’s interior.
The driver is the car’s most important user, so it’s critical that everything he sees looks perfect. The driver’s view of the car will determine his perception of the car’s quality.
How two different parts match up is very important. It’s imperative to ensure that there are no gaps and the transition between the parts is smooth. To do so, all interior elements must be measured and controlled.
Obtaining the complete geometry of these areas by scanning them with SIDIO Systems allows to measure the flush & gap between the different elements. Then, use this information to both analyze how these elements interact once the parts are assembled and to determine whether any resulting deformations affect the aesthetics once assembled.
From the robust information gathered, you can verify whether these areas meet the defined specifications.
Then you can make any necessary changes to the design or production process in order to achieve a finished part that fulfills the requirements.
To ensure that parts are correctly assembled and fit within the defined requirements for obtaining a valid final part.
Flush & gaps inspection between assembled automotive doors and bodies is a critical factor in modeling a car’s aerodynamic performance and, in turn, determining complete efficiency.
It is also very important to the aesthetic appearance of the car that the flush & gap is within the tolerance accepted by car manufacturer.
Use your SIDIO system to scan the places where different parts of the car interact (hood and front fender, door and side pillar, headlight and body, etc.). Color-coded visual reports that graphically illustrate how the flush & gap evolves along the edges are generated.
Final positioning of the parts can be adjusted to increase the quality of the assembly process, and, thus, the manufacture of the final products. As a result, the overall car design is improved.
To guarantee gauges do not affect negatively the parts shape.
Incorrect gauges and tools can affect the assembly because they emulate the final position where the mounted elements are to fit. It is therefore essential to verify that gauges and tools have the adequate dimensions.
Using SIDIO systems, you can quickly and accurately check the gauges to ascertain whether or not they are manufactured according to the defined tolerances.
Identifying whether or not the gauges are well manufactured is important in order to avoid confusion and future assembly issues. Detecting faulty gauges in time will improve the production process thanks to the ability to adjust the gauges before beginning a production round on which they are based.
To avoid standstill time due to defective supplier parts, which can lead to costly downstream production defects.
Reworks cause delays in production and generate higher costs. Furthermore, revision campaigns have a direct negative impact on the manufacturer’s brand and affect future revenue.
By using SIDIO AIRUS to automatically measure parts and pieces, you can detect dimensional errors in specific areas or over the entire piece. The SIDIO AIRUS inspection cell can be installed on the shop floor, allowing operators to analyze a large quantity of parts automatically. One single cell can have many different parts programed into it.
This way, all supplier parts can be monitored to ensure that 100% of them are within the specified manufacturing tolerances.
The operator will see a report and a color map that visually displays geometrical deviations between the part and the CAD file to help him decide whether or not the part is up to standard.
Automatic measurement, along with the report chart, ensures that all the pieces received from suppliers are within the required specifications.
Through a complete report, the OEM is able to identify defective supplier parts and avoid production line stops. The number of reworks needed is reduced; costly revision campaigns and subsequent factory recalls are avoided.
At the same time, process automation reduces measurement times, thereby making production faster.