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InRob was a Vinnova (swedish government) funded project. It was to deliver proof-of-concept that an in-line robotic inspection system could be deployed in a fully automated / off-line programmed way. The platform used was Nikon Metrology's robot integrated laser scanner.
InRob was a Vinnova (swedish government) funded project. It was to deliver proof-of-concept that an in-line robotic inspection system could be deployed in a fully automated / off-line programmed way. The platform used was Nikon Metrology's robot integrated laser scanner.
InRob was a Vinnova (swedish government) funded project. It was to deliver proof-of-concept that an in-line robotic inspection system could be deployed in a fully automated / off-line programmed way. The platform used was Nikon Metrology's robot integrated laser scanner.
Background InRob was a Vinnova (Swedish Government) funded project with Volvo Car Corporation, Scania, LK Scandinavia, Fraunhoffer Chalmers Gothenburg, Chalmers and Linkoping University, supported by Nikon Metrology UK.
The project outline was for future production control in Body In White, Coordinate Measurement machines (CMMs) are perceived as too slow, too accurate, and too expensive for in-line inspection. This project was to deliver proof-of-concept that an in-line robotic inspection system could be deployed in a fully automated / off-line programmed way, and meet the needs of accuracy and repeatability in Body In White assembly. The platform used was Nikon Metrologys robot integrated laser scanner (MMDx100).
3D CAD to nominal features and robot program
Starting with CAD nominal design (in this case CATIA V5) Nikon Metrology supplied Chalmers with details of its proprietary feature definition format. This gave a very fast, open and simple transfer from Volvos own metrology planning toolkit (GD&T) into Nikons analysis software (Focus 10).
Fig 2. Off-line robot program
Working closely with Linkoping University and LK Scandinavia, Nikon developed best practice guides including optimal approach and angles for laser scanning. This was used by Chalmers to optimise the measurement sequence and give base robot program for final verification in either a robot vender specific simulation system or generic 3D CAD based simulation system (using Realistic Robot Simulation technology). In this project both ABBs Robot Studio and Dassaults Delmia V5 were successfully used, providing a simple method of creating robot programs and proving them off-line.
Scanner technology
For on-line inspection Nikon Metrologys MMDx100 laser scanner was used including its Enhanced Sensor Performance (ESP) technology, changing the laser power real-time for consistent data acquisition on shiny and matt surfaces without data loss.
a) With ESP b) Without ESP (data loss) Fig 3 Enhanced Sensor Performance (ESP)
Combined with its anti-reflection filters this gives outstanding data acquisition even on highly reflective sheet metal.
Fig 4 Shiny surface
a)Reflection Filter On b) Reflection Filter Off Fig 5 Reflection Filter on shiny bowl
Working within the K-Series optical CMM working volume, the scanner only acquires data where needed, in any robot orientation in one unified coordinate system. This gives great accuracy with low data sets, meaning fast processing.
Fig 6 Nikons K-Series optical CMM dynamic tracking laser scanner by IR LEDS on scanner housing in robots working volume
Point Cloud Data
The point cloud data is acquired within the robots reach inside the large volume of K-series optical CMM.
Fig 7 Raw scan data
For ultra-high speed inspection the acquisition can be taken on one PC and the analysis on another. In this case the analysis can take place at the same time as the next scan. This also facilitates multi-robot inspection in a single station; with each robot doing its own aquistion but then passing the data to station PC to do multi-robot inspection analysis.
Analysis
The analysis is run as an automated script which is programed once off-line, as a simple sequence within Nikons Focus software.
Fig 8 Raw point Cloud imported into Focus analysis software
Fig 9 Automatic filtering; further simplifying data set
The nominal features are then compared to the filtered point cloud. This starts as an alignment based off scanned tooling balls on the jig. This puts all the measured features in the same coordinate system as the car. Then the rest of the features are auto-detected to CAD nominal.
Fig 10 Auto-inspect 2D shapes (circle above)
Fig 11 Auto-inspect 3D shapes (ChristmasTree above)
Putting this all together we successfully demonstrated the automated workflow shown schematically below, with the Nikon Metrology Automation Software at the hub of the robot cell
Fig 13. Workflow
There is an automated route from CATIA, through the metrology planning toolkit (GD&T) into Nikons proprietary feature definition format (.mff) over local network. Rules for scanner orientation angle, speeds, directions are preset-based on best practice. These are used in Chalmers software to optimize measurement sequence, outputting to standard robot simulation package to complete all programs off-line again transferring full syntax programs over local network to robot cell. On starting a robot program the Nikon Automation Software manages the interface between robot and
metrology system, based on its Adaptive Robot Control (ARC) technology. The acquired point cloud is then automatically processed filtering, auto defining alignment features, aligning, and automatically comparing point cloud to nominal features. Features inspected were a range of 2D holes/slots; surface intersect points, and 3D weld bolts, Christmas trees and T-Studs. Locally the features are checked against tolerance warning limits for local cell alerts, and output over local network in PCDMIS format for bodyshop Statistical Process Control system
Accuracy The repeatability of measurements was 60m 3; with spatial accuracy within 100m within the robots working volume. Final inspection accuracy compared to CMM touch probing was 150m for 2D features such as circles and slots; and 400m for weld bolts and Christmas trees again all 3. This was all achieved in single pass at high speed. Of course more passes and slower speeds improve accuracy but the trade-off is longer cycle times. In this deployment inspection times were approximately 2 seconds/feature.
Fig 14 Repeatability
Future The solution is available today on any robot platform. Using Nikons ARC technology its possible to port to any robot in less than two weeks. Currently there are fully working interfaces with Fanuc, ABB, KUKA, and Siemens PLC. Nikon continues to develop its fitting algorithms which are shared across all technology platforms.
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