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No. 605, 01.07.2016 Nicole Rüffer [email protected] +49 (6151) 948-192

Automatic inline surface inspection of all painted car bodies within a production run Fastest paint inspection on the fly: Flawless surfaces in shortet cycle times

Ever-growing quantities and high standards in paint quality are

presenting automotive manufacturers with new challenges. A new

robot-guided sensor inspects the paint surface of vehicles even in motion. All defects are detected immediately after drying, clas-sified and can – as an option – be marked automatically if re-

quired. Users can measure topographical defects in three dimen-

sions and gain comprehensive information that enables them to

systematically optimize production in next to no time.

The purpose of car paint is to protect car bodies from corrosion. But

looking good is no less important: impeccable paintwork ranks among

the top selling points for vehicles. With its Car Paint Vision solution,

ISRA VISION offers automatic and highly-flexible inline inspection of all

painted car bodies using four robot-guided sensors within a production

run. The system’s high automation potential also means a fast return

on investment. All relevant defects – including e.g. defects in coating

and pigmentation, inclusions and craters, scratches and indentations –

are reliably detected and classified.


On-the-fly inspection possible

Inspecting all paint surfaces objectively and consistently using the au-

tomated solution offers crucial advantages over visual inspection by

human eye – with direct cost benefits. In addition, the solution supports

process optimization based on reliable statistical data. The precise

marking of defect locations reduces reworking, and the complete in-

spection of the entire vehicle using four sensors only takes about 60

seconds.

PAINTSCAN combines two surface inspection methods in one hybrid

sensor head. Combining these complementary processes ensures re-

liable detection of all topographical and non-topographical paint de-

fects. Every point on the car body is inspected multiple times. The

camera technology is directly connected to the integrated, high-

performance computing units. Inspection can be done on the fly, re-

ducing cycle times. The system can be easily retrofitted to existing

plants.

The deflectometry method

Alternatively, the PAINTSCAN solution is also available with deflec-

tometry sensors, with phase-measuring deflectometry integrated into

one of the sensor heads. The method requires only a single image to

identify defects. The system analyzes the evenness of a surface’s

bending to unambiguously classify defects in the lacquer. The inspec-

tion is done while the car body is at a standstill.

Extremely powerful technology components are used in both sensor

systems, including high-resolution cameras, state-of-the-art processors

and special LED matrix lighting. These technologies form the basis of

highly-accurate 3D paint inspection at maximum speed. The intuitive


software supports users in commissioning the system quickly, e.g. by

guiding them through setup and sensor calibration step by step.

Statistical data for process surveillance

Detailed information on defects is available almost in real time, also

making it possible to adjust parameters as needed – besides signifi-

cantly reducing the time for rework. The painting process can be sys-

tematically optimized based on the statistical data obtained in order to

further reduce the need for reworking. The Car Paint Vision system

with PAINTSCAN ensures reliable 100% quality control at significantly

reduced inspection times. ISRA’s solution makes it possible to in-

crease quality while maintaining production quantities and process

stability, resulting in enhanced efficiency throughout the entire painting

process.


Images

605_1.jpg In his flat casing, PAINTSCAN unites state-of-the art-processors, high resolution Gig-E camera components and specialized LED matrix illu-mination

605_2.jpg The technology combines the precision of deflectometric 3D measuring with the speed of 2D surface inspection. This creates the in-line deflectometry a highly innovative and globally unique and highly precise method, setting new standards in process in-tegrated quality assurance.


605_3.jpg Fast data capturing enables reliable inline 3D measurements for defect detetection.

605_4.jpg Through the Windows 10 system, PAINTSCAN can be operated easily and intuitively.

fastest paint inspection on the fly: flawless surfaces in ... · fastest paint inspection on the...

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