Increasing the degree of automation and digitization of manufacturing processes in industry is becoming increasingly important. Even though numerous processes are already highly automated, there are still process steps in particular in quality control and rework that require manual intervention by production employees. One example is the rework of painted surfaces where features such as nibs or craters need to be sanded and polished. To facilitate this process, automatic optical surface inspection systems identify and classify those features and subsequently guiding the operator by means of a laser-marking system. This combination of automated inspection and guidance considerably reduces the inspection effort and at the same time makes a significant contribution to the ergonomics of the workplaces.
Challenge
Manual inspection and rework of large, complex 3D components in industries with particularly short cycles posed significant challenges, including time inefficiency, physical strain on workers, and inconsistent quality. Existing systems for automated surface inspection required further enhancement to optimize ergonomics, precision, and integration into existing production processes.
Solution
EXTEND3D – Part of Atlas Copco developed the dynamic laser projection technology. The key innovation is a smart software, which can be flexibly tailored to inline application scenarios. The solution integrates CAD data and automated surface inspection results to guide the operator to relevant features for rework intuitively. For this, the IPG Precision laser projectors show markings directly on the workpiece. This works even for moving parts and allow operators to identify the features quickly and reliably. The software adapts to customer-specific needs, handles complex lighting conditions, and ensures visibility across all surface types. In practice, the system autonomously coordinates multiple projectors to handle large, 3D surfaces.
Impact & Key results
The laser projection method simplifies and accelerates inspection and rework processes, reducing manual intervention and physical strain for workers formerly spent on the tedious and tiring manual search for potential feature. It enhances production efficiency, improves the quality of the finish process, and optimizes workplace ergonomics. For employees in particular, work processes are much simpler, faster and, above all, more convenient. By combining laser projection with automated surface inspection, industries achieve significant process excellence and cost reduction while maintaining high precision and employee comfort.
Download the full success story
- BMW Success Story IPG laser.pdf 1.6 MB, PDF