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Automatic surface defect inspection system for sprayed car parts
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January 2008
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BMW is currently working closely with sensor system specialist Micro-Epsilon, developing and testing complete surface defect detection systems.
These systems can operate as stationery test rigs or by using robot arms, which scan multiple inspection points on car body parts, automatically identifying and marking any surface defects. System such as these will enable complete car bodies to be inspected in less than 90 seconds typically. By introducing this at various stopping points in the assembly line, production delays will therefore be avoided.
Franz Hochwimmer, sales engineer at Micro-Epsilon’s Systems Division explains: “Since 2005, we’ve been working closely with BMW, initially developing systems to detect surface defects on small, plastic and rubber components on the car. This involved the inspection of components such as car bumpers, mudguards and cylinder heads – but not the complete body of the car. At the end of 2005, Micro-Epsilon supplied a system for BMW’s Dingolfing plant, to automatically detect surface defects on the sides of the car, including front and rear mudguard areas and the doors.”
Micro-Epsilon’s reflectCONTROL ‘deflectometry’ system has been developed to such an extent that it can now be used in industrial production. In order to ensure reproducible, well-structured surroundings – the reflected image of which is to be recorded and evaluated – a striped pattern is shown on a display. Cameras record the reflected image of the display and pass the data to an industrial PC for evaluation. The complete system set-up is mounted on a robot arm. It is then possible to move the system around the object to be inspected, for example, a car body. Alternatively, a stationary installation is also possible, in which the parts are placed on a measuring table.
Hochwimmer adds: “More recently, we installed reflectCONTROL on a robot arm, which inspected around 36% of the car body for defects. BMW Dingolfing has evaluating these results now with a view to installing a complete, four-robot arm detection system shortly, which will inspect complete car bodies across two vehicle assembly lines.”
The reflectCONTROL measurement system is also suitable for other applications. The method can be employed anywhere where shiny or reflecting surfaces need to be checked for defects. Examples can be found in the manufacture of clear-coated display covers, glass surfaces or mirrors.
Due to the success of the joint development at BMW, Micro-Epsilon is currently seeking other new development partners. For more information on Micro-Epsilon’s reflectCONTROL system, please call the Micro-Epsilon UK sales department on 0151 260 9800
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Author
Chris Rowlands
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