ABISII 03-2011 English Screen Version SmallFile

8/3/2019 ABISII 03-2011 English Screen Version SmallFile

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ABIS IISURFACE INSPECTION


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The surace quality o a product - particularly in the automotive industry -

onstitutes an important criterion or the customer and is generally seen in

lose relation to the quality o the overall vehicle.

ven inevitable disturbances at the early p roduction stages prior to applying

he paint work (e.g. in the press shop or body shop) may cause deects such

s dents, bumps, sink marks, etc. which might not be visible to the eye while

he vehicle is still unpainted. On a glossy paint surace, however, even the

ightest irregularities are clear to see with incident light rom the proper

ngle, and constitute a reduction in quality. Particularly the intense com-

etition among manuacturers demands an increase in the surace quality

n conjunction with continuously decreasing production costs. The target

reedom rom deects is time-consuming and labor-intensive to achieve or

utomobile manuacturers. It is not 100 % possible through conventional

means so that deects that have gone unnoticed during the production pro-

ess generate very high rework costs.

Now, the early and complete detection o surace deects with the eective

ABIS II high-precision surace inspection system opens up new perspectives

n quality assurance.

2

DEFECT RECOGNITION

DURING PRODUCTION PROCESS

Many relevant surace deects on sheet-

metal parts or bodies-in-white are not

visible to the human eye.

Depending on individual type, characte-

ristics, and illumination conditions, some

quality-relevant deects can be detected

ater e-coating.

Ater application o the top coat, previously

unrecognized surace deects become

clearly visible and require time-consuming

corrections.

ABIS II:

OPTICAL

SURFACE INSPECTION

3

SIGNIFICANT INCREASE OF COSTS

FOR LATE CORRECTION OF SURFACE

DEFECTS

HL: Anrage AUDI neue Bilder;

>> alls negativ, weiter verwenden

PROCESS CHAIN

PRESS SHOP

BODY SHOP

PAINT SHOP

COSTSPERDEFECT

factor10

factor100

factor1000

?

? ?


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The majority o deects that can occur during the production process are

invisible at the early stages o manuacture. These minute surace deects

ecome visually perceptible late r on, however, when subsequent work steps

uch as paint work have been completed. At that point in time, they can only

e remedied using expensive corrective measures.

To achieve a high surace quality under the aspect o cost optimization, a

wide range o deect types needs to be detected. The reliable and early

etection combined with an objective evaluation and classication o de-ects, such as dents, bumps, sink marks, waviness, constrictions, cracks, etc., is

ecessary since the costs o removing these d eects increase drastically with

he progress o work within the production cycle (press shop, body shop,

aint shop, nal assembly). Consequently, particularly the rework o deects

hat have been propagated throughout the production process constitutes a

ubstantial actor with regard to m anpower and time. It thus has a consider-

ble infuence on the economic eciency o the manuacturing process.

ABIS II:

DETECTION OF ALL RELEVANT DEFECT TYPES

5

ABIS II an optical sensor system that is

available in dierent versions and system

concepts allows the ast, reliable and ultra-

accurate detection o not only 3D deects

on the inspected par t (e.g. dents, bumps, sink

marks, waviness, constrictions or cracks), but

also o contrast-sensitive deects (e.g. scrat-

ches, adhesive residues, dust and dirt) using

the new contrast sensor upgrade.

Time-consuming and thus expensive re-

work in subsequent process steps, e.g. at

the nish belt, can be eciently reduced.

4

3D DEFECTS:

BUMPS DENTS SINK MARKS WAVINESS CONSTRICTIONS CRACKS

EXAMPLES FOR CONTRAST-SENSITIVE DEFECTS:

ADHESIVE RESIDUES SCRATCHES DIRT


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6

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ABIS II is a fexible system concept that comes in three dierent versions.

Users can thus choose the sensor system that best meets their application

equirements.

ABIS II Ofine allows data acquisition and evaluation at an automatic test

tand and is excellently suited or accompanying production monitoring.

ault catalogs and classication criteria that have been compiled during the

lanning stage can be extended and modied. The ABIS II Ofine cell can be

ongured or both mobile use and stationary installation at a xed position

n the press shop. The mobile Ofine version eat ures one or more portable

latorms, on which the system components are mounted.

With ABIS II Inline, a ully automatic inspection and as sessment can be per-

ormed by direct integration o the system concept into the manuacturing

nvironment o the body shop or press shop. According to the customers

pecications, the ABIS II Inline system can be congured or either 100%

nspection o all parts or or the inspection o certain object areas and de-

ed zones on the test part. The achieved complete or partial inspection o

odyshells and sheet metal parts sets highest standards in quality assurance

nd auditing.

ABIS II:

SYSTEM CONCEPTS

Beore an ABIS II surace inspection system is installed, a virtual system concept is

always created rst. Simulation programs help to select the specic robot and itsposition with reerence to the part under test. This ensures that the sensor will

be able to reach all the positions required or inspection.

How many sensors and data analyzers the nal system concept provides de-

pends on the part size(s) (rom small bodyshell parts to the complete car body

/ body-in-white) and on the specied maximum inspection time per part (cycle

time). The security concept and the construction o the sys tem are designed and

implemented in accordance with user guidelines. Customers can choose to do

this themselves or order a complete, end-to-end surace inspection solution.


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Numerous renowned automakers have

mplemented the ABIS II surace inspection

ystem with great success in a wide variety

o custom concepts tailored to their press

hop environments. The ABIS II ofine sys-

em is ideal not only or ongoing auditing at

egular intervals during the manuacture o

press lot, but also or checking the surace

uality o the rst sheet metal parts atertool change.

Machine operators can very quickly obtain

n objective evaluation o the surace qua-

ty o a pressing. An automated central au-

it station with appropriate conveyor belts

s provided or eciently inspecting large

uantities o bodyshell parts.

ABIS II:

REFERENCE SYSTEMS

8

By courtesy o AUDI AG, BMW AG, Daimler AG, KIA Motors


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EVALUATION AND

VISUALIZATION

SOFTWARE

10

11

Many users in the automotive industry rely on an integrated surace quality

analysis across the entire process chain. Ater each o the process steps

Single Part, Assembly and Cathodic Dip Painting, the individual parts are

examined again by same inspection application to identiy any surace de-

ects that might aect the top coat quality. The development o a deect is

documented ater each process step. Practical experience in production

shows that the relevance o a surace d eect can increase or decrease ater a

process step. Based on a process-wide quality analysis, the required rework

is done precisely at the required location on the part and at the required

process steps. This increases the eciency in the nishing area and results in

a signicant cost saving.

Besides the development o a surace deect across the process chain, the

time-related changes within a production period also give users important

inormation on the quality changes. For example, when the audit value dete-

riorates, corrective action (e.g. regarding press parameters or tool suraces)

can be taken at an early stage beore producing parts with deects that

will later require rework. Statistics programs provide distribution charts that

show the user which component positions and which steps o the produc-

tion process oer a potential or cost-saving optimization.

ABIS II oers the highest standards in terms o suitability or industrial appli-

cations as well as expandability, deect detection and easy use. To inspect a

part, all the user has to do is select the part on the touch screen and start

the test se quence. Thanks to ABIS IIs high-speed i nspection and evaluation

capacity, a report o the inspection result will be available in minimum time.

With an ofine system, or example, the user will receive a complete test

report, including auditing, in less than 40 seconds ater starting the inspec-

tion o the sliding door shown in the picture on the let. The entire ofine

system can be operated simply by selecting the relevant part inspection

processes on the touch screen. When programming additional test sequen-

ces or new parts, the user is systematically supported by the easy-to-use

ABIS-TeachIn sotware. Ater dening the individual inspection positions on

the part, the user assigns the required quality level to each object area. The

latest version o the TeachIn sotware eatures a vir tual toolbox or auditing.

The toolbox comprises whetstones in dierent s izes that can be used accor-

ding to the dimensions o the individual surace deect. Short whetstones in

the TeachIn sotware allow inspecting critical positions on parts (e.g. door

handle recesses, tight concave surace contours), which cannot be acces sed

using real whetstones. Additional unctions or detecting skid and impact

lines, cracks and holes are also easy to activate . The classication criteria and

threshold values or a subsequent automatic evaluation o the deects are

always based on the customers specications. In addition, the system applies

the customers internal audit note sta ndards and deect names. The specied

threshold values can be fexibly adapted to the relevant production stage at

any time (foating audit).

PROCESSCHAIN

SinglePart

Assembly

CathodicDipPainting


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EVALUATION AND

VISUALIZATION SOFTWARE

12

13

ABIS II sets standards in optical surace in-

pection. Independently o ofine or inline

operation, the inspection system can iden-

y all relevant types o deect - in both the

D image and the contrast image. Dents,

umps, sink marks, pits, waviness, constricti-

ons, cracks, scratches, dust and dir t, etc. are

uickly and reliably detected and analyzed

t a high resolution.

required, the inspection report can inclu-

e the associated quality image o a surace,

howing the part as i a virtual whetstone

ad been used.

ABIS-SystemProcessManager

Start and administration of all single processes Automatic control and display of system diagnosis messages

ABIS-SystemProgressInfo

Automatic display of processing progress of a measurement,

divided into measurement positions and processes

ABIS-SystemOfineUI

Selection and start of measurements Touchscreen functionality Conguration of menu buttons and letterings via ABIS-TeachIn Easy communication with robot control via I/O interface

ABIS-AcquisitionSensor

Automatic image acquisition Possible simulation of a series of measurements

ABIS-AcquisitionPreprocessing

Automatic correction function for the compensation of minimummeasurement position deviations

Automatic preprocessing of images for defect analysis

ABIS-Analysis

Automatic detection and analysis of defect regions Possible consideration of different areas of relevance and quality standards

ABIS-SystemDefectManager

Automatic registration of classication data acquired with ABIS-Analysisinto a central database

ABIS-SystemMarker

Automatic display of defects acquired with ABIS-Analysis in a CAD displayof the test part - I.O. / N.I.O. display

Individual conguration possibilities for defect display Subsequent loading and display of classication data from a database Print functions

ABIS-TeachIn

Comfortable setup and teaching of components/test parts Clear and methodic processing of the single teaching steps Selection of various defect algorithms Selection of different virtual whetstones Individual classication of all detected features/characteristics Conguration and modication of all acquired measurement data

FUNCTION OVERVIEW

ABIS II SOFTWARE COMPONENTS

The ABIS II sotware enables users to enter

individual deect characteristics and severity

levels based on the auditors experiences.

This allows including the experience o

the quality assurance sta directly into the

systems classication and tolerance criteria,

which in turn can be customized to the indi-

vidual state o production.


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14

15

CONTRAST

SENSOR

ABIS II:

SENSOR SYSTEMS

Neue Bilder Anlage Zur Schanz

ABIS II SENSORABIS IICONTRASTSENSORIk

Dimensions (mm) 670 x 80 x 100755 x 160 x 460incl. ABIS II sensor

Weight (kg) 4.714.8incl. ABIS II sensor

Image Acquisition Time 0.1 msec 0.1 msec

Robot Capability yes yes

Field of View 220 x 300 mm 220 x 300 mm

Data Interface CamLink CamLink

Resolution CCD Camera(Pixel)

1200 x 1600 1200 x 1600

3D Defect Size Resolution(Depth)

10 m (min.)surface dependant

-

Lateral Defect Resolution1.5 mmsurface dependant

10 m

Stand-Off Distance 432 mm +/- 20 mm 432 mm +/- 20 mm

Light Source Xenon ash lamp LED

Lifetime of Light Sourcemin. 106 ashesat 1 Hz repetition frequency

unlimited

The addition o the new ABIS II contrast sensor system allows quickly and

easily extending the range o detectable deects to include surace characte-

ristics that are not visible in the 3D image. With the contrast sensor system,

bar-shaped LED lines and the camera are customized or the eld o view

and the measurement distance o the ABIS II sensor. The images are captured

almost simultaneously by the ABIS II sensor and the contrast sensor system

(time dierence 0.1 msec), so that the overall inspection time or component

testing is not prolonged when using the contrast sensor system.

To ensure exact positioning o the par t under test, an optional laser beamer

can indicate the parts contour on the measuring table o an ABIS II Ofine

system (see bottom picture on page 14). The position o the part on the

table can be determined using an optical position recognition system. This

data is then use d to correct the robot path during the tes t procedure. The

camera o the position recognition system can be installed either above the

measuring table or directly to the robot.

The robust, industrial strength design o the sensor s ensures a reliable, high-

speed measurement data acquisition in press shop and body shop envi-

ronments: The ABIS II sensors are not aected by high acceleration loads,

vibration, hall lighting, fuctuating temperatures, etc., which they are e xposed

to on site every day.


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SteinbichlerOptotechnik

GmbH

03_

2011

Steinbichler Optotechnik GmbHGeorg-Wiesbck-Ring 12, 83115 Neubeuern

phone +49-8035-8704-0, ax [email protected]

www.steinbichler.com

Steinbichler Vision Systems, Inc.46995 Five Mile Road, Plymouth, MI 48170

phone +1-248-994-2204, ax +1-734-927-1549ino@steinbichler-vision.comwww.steinbichler-vision.com

Steinbichler do Brasil Ltda.Alameda Amazonas, 686, Lateral A

Alphaville Empresarial, Barueri SP CEP 06454-070phone / ax +55-11-4195-4495

[email protected]

www.steinbichler.com.br

S&S Optotechnik (Beijing) Co., Ltd.No. 1217 Zhong Kun Plaza

59 Gao Liang Qiao Byway, Haidian District100044 Beijing


Steinbichler Vision Systems Pvt. Ltd.68, Chinnappa Garden Link Road

Nandidurga Road, Jayamahal ExtensionBangalore - 560046

phone +91-80-409098-40/-38/-39, ax [email protected]

www.steinbichler.in

Steinbichler Portugal Lda.Edicio OPEN, Zona Industrial da Marinha GrandeRua da Blgica Lte 18, 2431-901 Marinha Grande


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ABISII 03-2011 English Screen Version SmallFile