ABIS II SURFACE INSPECTION

The surface quality of a product - particularly in the automotive industry - constitutes an important criterion for the customer and is generally seen in close relation to the quality of the overall vehicle. Even inevitable disturbances at the early production stages prior to applying the paint work (e.g. in the press shop or body shop) may cause defects such as dents, bumps, sink marks, etc. which might not be visible to the eye while the vehicle is still unpainted. On a glossy paint surface, however, even the slightest irregularities are clear to see with incident light from the proper angle,...

DEFECT RECOGNITION DURING PRODUCTION PROCESS Many relevant surface defects on sheet-metal parts or bodies-in-white are not visible to the human eye. Depending on individual type, characteristics, and illumination conditions, some quality-relevant defects can be detected after e-coating. After application of the top coat, previously unrecognized surface defects become clearly visible and require time-consuming corrections. 3 SIGNIFICANT INCREASE OF COSTS FOR LATE CORRECTION OF SURFACE DEFECTS PROCESS CHAIN PRESS SHOP BODY SHOP PAINT SHOP COSTS PER DEFECT factor 10 factor 100 factor 1000 ? ? ?

The majority of defects that can occur during the production process are “invisible” at the early stages of manufacture. These minute surface defects become visually perceptible later on, however, when subsequent work steps such as paint work have been completed. At that point in time, they can only be remedied using expensive corrective measures. To achieve a high surface quality under the aspect of cost optimization, a wide range of defect types needs to be detected. The reliable and early detection combined with an objective evaluation and classification of defects, such as dents, bumps, sink...

5 3D DEFECTS: BUMPS DENTS SINK MARKS WAVINESS CONSTRICTIONS CRACKS EXAMPLES FOR CONTRAST-SENSITIVE DEFECTS: ADHESIVE RESIDUES SCRATCHES DIRT

6 ABIS II is a flexible system concept that comes in three different versions. Users can thus choose the sensor system that best meets their application requirements. ABIS II Offline allows data acquisition and evaluation at an automatic test stand and is excellently suited for accompanying production monitoring. Fault catalogs and classification criteria that have been compiled during the planning stage can be extended and modified. The ABIS II Offline cell can be configured for both mobile use and stationary installation at a fixed position in the press shop. The mobile Offline version features...

7 Before an ABIS II surface inspection system is installed, a virtual system concept is always created first. Simulation programs help to select the specific robot and its position with reference to the part under test. This ensures that the sensor will be able to reach all the positions required for inspection. How many sensors and data analyzers the final system concept provides depends on the part size(s) (from small bodyshell parts to the complete car body / body-in-white) and on the specified maximum inspection time per part (cycle time). The security concept and the construction of the...

Numerous renowned automakers have implemented the ABIS II surface inspection system with great success in a wide variety of custom concepts tailored to their press shop environments. The ABIS II offline system is ideal not only for ongoing auditing at regular intervals during the manufacture of a press lot, but also for checking the surface quality of the first sheet metal parts after a tool change. Machine operators can very quickly obtain an objective evaluation of the surface quality of a pressing. An automated central audit station with appropriate conveyor belts is provided for efficiently...

9 By courtesy of AUDI AG, BMW AG, Daimler AG, KIA Motors

EVALUATION AND VISUALIZATION SOFTWARE 10 Many users in the automotive industry rely on an integrated surface quality analysis across the entire process chain. After each of the process steps Single Part, Assembly and Cathodic Dip Painting, the individual parts are examined again by same inspection application to identify any surface defects that might affect the top coat quality. The development of a defect is documented after each process step. Practical experience in production shows that the relevance of a surface defect can increase or decrease after a process step. Based on a process-wide...

11 ABIS II offers the highest standards in terms of suitability for industrial applications as well as expandability, defect 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 sequence. Thanks to ABIS II‘s high-speed inspection and evaluation capacity, a report of the inspection result will be available in minimum time. With an offline system, for example, the user will receive a complete test report, including auditing, in less than 40 seconds after starting the inspection of the sliding door shown in the picture on the...

EVALUATION AND VISUALIZATION SOFTWARE 12 ABIS II sets standards in optical surface inspection. Independently of offline or inline operation, the inspection system can identify all relevant types of defect - in both the 3D image and the contrast image. Dents, bumps, sink marks, pits, waviness, constrictions, cracks, scratches, dust and dirt, etc. are quickly and reliably detected and analyzed at a high resolution. If required, the inspection report can include the associated quality image of a surface, showing the part as if a virtual whetstone had been used. The ABIS II software enables users...

13 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-SystemOfflineUI • Selection and start of measurements • Touchscreen functionality • Configuration 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...