Dimensional Gauging of Automotive Parts Using Robot-Mounted 3D Sensors

Dimensional gauging is a key 3D scanning and quality control process for detecting sizing errors in automotive parts. Such errors are common and occur when the actual dimensions of the machine-worked part are different from their nominal value.

In the automotive industry size discrepancies must fall within tight tolerance requirements or the part has to be rejected. For this reason, manufacturers require advanced inline inspection systems that can quickly and accurately identify dimensional errors and execute the proper pass/fail decisions to ensure the highest levels of product quality.

What Dimensional Gauging Systems Measure

Dimensional gauging systems provide 2D and 3D measurements of important automotive part features including holes, slots, surface, edges, studs, clips, and gap and flush. Such features are found on the body in white, underbody, body sides, doors, hoods and decklids, frames, suspension cradles, instrument panel beams, motor compartments and more.

When a part is found to be outside the predetermined tolerance, it gets flagged/rejected, at which point the inspection system has to be able to provide the user with root cause analysis on the particular fail decision made, combined with accurate supporting data.

Dimensional Gauging Systems In The Field

Bluewrist Robot & Vision Solutions designs both stationary and robot-mounted dimensional gauging systems that use 3D sensors as their optical and data processing backbone.

Automotive manufacturers deploy these systems in their quality control assembly lines for fast, accurate and reliable non-contact inspection of automotive parts (and other manufactured components) in real-time. Technicians also pair these inspection systems with secondary monitoring systems that can alert line-workers of production issues using an interactive user-interface with real-time data processing and detailed reports.

3D Inspection System Features:

  • High-density point cloud data of parts and other manufactured components, including automatic alignment of point clouds with CAD models and noise filtering

  • Ability to mount multiple scanners to increase scan coverage

  • Complete robot calibration to maximize measurement stability and accuracy in a thermally changing environment

  • Full integration with line PLCs and robots for alarm triggering and decision making

  • Data management software with reporting capabilities that include dimensional results, historical charts and process performance analysis

  • Networking capability that allows data-sharing between systems

To see what a dimensional gauging system looks like in operation, watch this short video.

Advantages of 3D-Based Inspection Systems

Aside from assuring greater product quality, effective dimensional gauging systems provide a number of important business advantages. These benefits include faster scan times, more comprehensive and accurate data, reduced setup complexity, less downtime and increased throughput, faster time to market and lower manufacturing costs –– all of which contribute to increased productivity and profitability.

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