Sensor technologies enable more complex robot inspection measurements

23 August, 2019

For defect detection on diffuse reflective surfaces, Micro-Epsilon has developed the surfaceCONTROL measurement system. This technology uses structured light projection to detect and analyse local shape defects on surfaces that deviate by micrometres from their target measurements. The system also operates reliably on textured surfaces, such as interior automotive parts.

The surfaceCONTROL offers a variety of measurement areas ranging from 150x100mm2 to 600x400mm2, and it takes only a few seconds to capture 3D data for a surface.

Various evaluation procedures are available, depending on the nature of the shape deviations being investigated. The 3D data can be used to calculate a flawless virtual cover, or a digital whetstone can be used, similar to a whetstone in a press shop. These methods provide repeatable, objective assessments of deviations from around 5μm to 20μm, depending on the surface. The structured light projection procedure is suitable for all surfaces that diffusely reflect at least part of the light, including steel, aluminium, plastics and ceramics.

Robot integration

Alternatively, for detecting paintwork defects on entire car bodies, the reflectCONTROL system can be integrated to the robot. Using deflectometry, the surface is examined to micrometre accuracy. A robot continuously adjusts the position of the system to help complete measurements within a very short timeframe. The defects are measured laterally and in depth and classified to enable follow-up work and process improvements to be performed precisely as required and easily. The technology provides objective 100% inspection of all vehicles manufactured and enables employees to concentrate on remedying critical defects rather than identifying them.

Not only does the system reduce defects, it also means that where defects are detected, this happens immediately after the painting booth when they can still be easily reworked. This reduces costs and reduces the number of rework lines required.

An increasing number of sensors are being integrated with robots because these systems can complete many tasks independently and travel distances are expected to be found dynamically, as the use of specified travel ranges is set to decrease over time.

www.micro-epsilon.co.uk