100% Quality Assurance with 3D machine visionMapvision production line measurement systems are installed directly on the production line after the manufacturing equipment, where they inspect 100% of the manufactured parts in real time. With the 3D systems, no defective component continues in the manufacturing process or goes to the customer. Predictive Manufacturing Process Control Mapvision production line measurement systems provide real time reports on the trend of the manufacturing quality which enables immediate corrective action. Therefore, dimensions never exceed set tolerance limits. This kind of predictive control reduces the amount of scrap and set-up costs dramatically. Traditional measuring methods produce the process critical information in the post-production environment, when it is too late to correct the manufacturing process. The benefits of production line measurement are as follows:
Flexibility Mapvision eliminates the need for expensive product specific measuring gauges and accelerates product changes and ramp ups. The system is designed to be flexible. The camera set up is designed to meet manufacturing process specifications, not to measure only one type of part. Because the orientation of the cameras is free in relation to the objects to be measured, it adapts to the process specifications, not to the geometry of the part to be measured. This unique design allows Mapvision production line measurement systems to measure different kinds of products on different manufacturing lines with no mechanical set up. Since there are no moving parts in the measuring system, changing the product on the production line is fast and easy. First true 3D machine vision Mapvision is the first flexible and truly 3D machine vision system. All of the traditional 2D machine vision applications, including dimensional measurement, deformation analysis, robot guidance, process control, quality control, flaw detection, and others have now become 3-dimensional. Reliability Mapvision measuring systems are composed of optics, electronics and software. Mechanical components play a non-critical role in the system. This guarantees great reliability even in the toughest factory conditions. Feature recognition method
Mapvision production line measurement system measures details such as bolt holes, corners, edges, grooves, etc., which can be seen by the cameras. The measuring systems use predefined pattern images to search and locate corresponding object features. After measuring at least three details, the system can accurately define the 3D position of the object. This means reliable, fast and flexible object positioning in three dimensions while eliminating the need for product specific jigs and fixtures. By recognizing more details, the part can be measured and thoroughly examined and then quickly positioned for the next operation on the production line. Reference dimensions are communicated to Mapvision system by reading a master part or 3D CAD model. Programming of the system is easy. A user can either mouse click the points to be measured or use arrow keys to position the point at the desired location, or let the system read the measuring locations directly from a 3D CAD file. Both methods, feature recognition and 3D contour scanning can be used simultaneously.
 Real-time measurement provides many advantages. It is a non-contact process which is suitable for hostile objects. Many points can be measured simultaneously, and the results stored for post?processing and analysis. Statistical data can be collected for long-term tracking and analysis of the production process in on-line applications. Real-time measurement provides fast feedback and therefore helps to minimise production losses. Mapvision4D systems provide accurate measurement and feedback on the reliability of the measurement process. The resulting three-dimensional data can be used in off-line applications to make complete surface models and perform comparisons with existing CAD models. Automotive industry case At Valmet Automotive, Mapvision production line measuring systems are used to measure the shape of Porsche car bodies and their precise positioning in front of the robots. The system is superior to any other positioning device because it can handle different car body types on the same production line. The systems measure on-line without getting in the way of the robots.
The non-contacting method ensures that there is no damage to painted surfaces. Product changes can be implemented by simple re-programming without any mechanical changes on the production line. This saves both time and money.
  Two measuring modes, Development Mode and Production Mode When ramping up the production process, the production line measurement system is used in Development Mode. A large amount of measurement data is gathered for complete analysis of all dimensions. Typical deviation analyses are done by comparing the measured 3D points to a 3D CAD model. The deviation between the measured dimensions of the actual part and nominal dimensions of the 3D CAD model are colour plotted for rapid and thorough understanding of the measured part compared to the CAD model. Mapvision provides a variety of ways to help users understand the differences between the measured part and the nominal dimension of the 3D CAD part. In Development Mode the user gets valuable information which allows him to quickly fine tune the process parameters and minimize the length of the ramp-up. The use of Development measuring mode is shortening ramp-up times in injection moulding processes, in automotive glass and sheet metal manufacturing, in foundries and in woodworking industries. Production Mode provides 100% inspection because every part is measured. Typically the functional and critical dimensions are measured. 100% measuring ensures that no defective component or semi-finished part makes it through the process. Real time measurement within the process cycle enables immediate corrective feedback to process control completely eliminating the manufacture of defective parts. 
Automotive glass measuring system is assembled directly
on the production line
|
