Few areas of the manufacturing industry are as complicated as special vehicle construction. Vehicles such as government vehicles, stretch limousines and armored vehicles are highly specialized one-offs, which are often produced in batch size 1 and makes automation difficult. To meet these challenges, the special vehicle manufacturer IndiKar now relies on the IPG Mobile laser assistance system from EXTEND3D – Part of Atlas Copco Group.
Challenge
Manual and high-tech processes and tools are required in vehicle manufacturing
IndiKar, part of the WELP Group and a manufacturer of specialized vehicles such as armored vehiclesand stretch limousines, faced significant challenges in precision assembly due to the highly customized nature of their production. Traditional methods required costly, labor-intensive welding templates for accurately positioning bolts, screws, and other components. These templates were not only expensive to produce but also required additional storage space. Moreover, ensuring precise alignment and quality control was difficult, leading to potential rework and inefficiencies in the assembly process.
Solution
The IPG-L Mobile is provides real-time coordinate output during assembly of long sedans
To address these challenges, IndiKar implemented the IPG Mobile laser assistance system from EXTEND3D (part of Atlas Copco Group). Mounted on a mobile tripod, the system projects precise laser guides (crosshairs or design lines) onto vehicle surfaces for bolt placement, screw point positioning, and alignment of extended vehicle bodies, such as long sedan doors. This digital system eliminated the need for physical templates and allowed workers to align components dynamically using real-time data and projections.
Key features included:
- Integration with CAD for precise projections.
- Adaptive projection to account for surface defects.
- A user-friendly interface requiring minimal training.
Result
- Cost Savings: IndiKar significantly reduced production costs, saving several thousand euros per vehicle by eliminating the need for welding templates and associated storage and modification expenses.
- Enhanced Quality Control: Real-time projections allowed workers to perform accurate assembly and immediate quality checks, reducing the need for rework, such as repainting misaligned doors.
- Scalability: The knowledge gained with each use expanded the system’s applications, paving the way for future enhancements, like directly transferring drawing data, and projecting bending lines onto components.
“The new IPG-L Mobile system saves us the production of time-consuming and expensive stencils.”
Sascha Dorst Technical Project Manager at IndiKar