Development of a Portable Quality-

Confirmation Inspection Unit for Automotive

Checking Fixture

Bastian Wibar Bin Momang

Supervisor: Ir. Dr. Hj Nik Mohd Zuki Bin Nik

Mohamed
 OUTLINE
• Introduction
• Objectives
• Scope
• Literature Review
• Experimental Setup & Procedure
• Results & Discussions
• Conclusions
 INTRODUCTION
 The checking devices is extensively used in
manufacturing industries.
 Production part inspection is important to
determine the quality of automotive parts.
 Surface quality of automotive panels and the
accuracy of the produced parts affects the
perceived valuation & quality of an automotive
part.
 Many CF devices in the marketplace are costly.
 OBJECTIVE
i. To develop a portable quality confirmation
inspection unit.
ii. To analyze the surface accuracy of the
automotive panel.
iii. To validate the system of portable checking
fixture devices.
 SCOPE
i. Fabrication of a portable checking fixtures
device .
ii. Development of system functionality
integration for the checking fixture device.
iii. Auditing the automotive panel specifically
focus on the surface accuracy.
iv. Data collection and compared with the data
obtained from Coordinates Measuring
Machine (CMM).
v. Arduino Mega 2560 used as DAQ card.
vi. GR&R study used to validate and improve
the measurement system.
 LITERATURE REVIEW

CF for RF Car Fender part (Jiang et

al., 2013)

Various Types of CFs (Shenmo, 2011)

Typical CFs (Boyle et al., 2010)

Defects at the Surface of Car
Panels
Springback

Wrinkles
 Electrical Components

Ultrasonic Distance Sensor

Arduino Mega 2560

Stepper Motor
 Start

Literature review

Development of portable
inspection unit system

Fabrication of portable
checking fixture

Identify the quality

checking procedure

System functionality
integration Research
System functionality testing

Data collection and analysis

Framework
Validation with actual
experiment and simulation

No
Confirmation

Yes

Thesis writing

End
EXPERIMENTAL SETUP &
PROCEDURE
 Gantry System Design
Sensor
Y-axis
Support
Y-axis
X-axis

Frame X-axis Sensor

Support

Sample Frame
Panel Sample
Panel
Platform Platform

Design 1 X-axis
Design 2
Y-axis

Sensor
Support

Frame

Sample
Panel
Design 3
Platform
 Y-axis
X-axis

Design 4

Sensor
Support

Sample Frame Hardware Implementation

Panel
Lateral Ball
Platform Supports Bearings

Frame
Synchronous
belt

Linear Synchronous
Motion
Platform
X-axis Belt Y-axis

Lateral
Supports Lateral
Supports

Toothed Sensor Ultrasonic Ball

Pulley Support Distance Sensor Bearing

Plastic
Stepper Brackets
Motor
Toothed
Brackets
Pulley

Stepper
Motors
Block Diagram
 Stepper Polulu Junction
Driver Shield Box

Arduino
Electronic system of
Mega USB
Cable sensor
Bread Potential
Board Meter
Power
Supply
LCD
Display
Ultrasonic
Distance
Sensor

Electronic system of Arduino

stepper motor Uno

USB
Cable
 Software Development

Software to control stepper motor

Software to control sensor

 Automotive Body Part
30
Point Time (s) Setting Value Tolerance (mm)

1 4 113.5
28 2 4 113.5
3 4 113.5
4 4 113.5
29 5 4 113.5
6 4 113.5

27 21 7 4 113.5
18 22 23 24 25 8 4 113.5
9 4 113.5
10 4 113.5
17
26 16 11 16 80.5
12 8 85.5

20 13 8 75.5
14 8 85.5

19 15 15 8 75.5
(+/-) 1.00
16 8 91.5
14 17 8 112.5
18 8 103.5
19 8 102.5
20 8 102.5
13
9 12 21 8 89.5
22 8 75.5
10 11 23 8 66.5
24 8 72.5
25 8 77.5

8 7 6 5 4 3 2 1 26 8 77.5
27 8 53.5

Sample panel
28 8 62.5
29 4 62.5
30 4 87.5
 RESULTS &
DISCUSSION

The result was “ACCEPT”

The result was “REJECT”

 Data Collection
Graph of Deviation (mm) vs Checking Point Graph of Deviation (mm) vs Checking Point
4 3

3 2

2 1
Deviation, mm

Deviation , mm
1st
1 0 1st
2nd
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29
0 3rd 2nd
-1
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 3rd
-1 -2

-2 -3

-3 -4
Checking Point Checking Point

Sample A Graph of Deviation (mm) vs Checking Point

Sample B
4

2
Deviation, mm

1
1st
0
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 2nd
-1 3rd
Sample C -2

-3

-4
Checking Point
 A
Graph of Deviation (mm) vs Checking Point B
C
3.0

2.5

2.0

1.5

1.0
Deviation, mm

0.5

0.0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
-0.5

-1.0

-1.5

-2.0

-2.5

-3.0
Checking Point

The portable CFs generates the quality analysis of automotive

body part that guides the operation of inspection.
 Graph of Number of Checking Point vs Judgement
25

20
Number of Checking Point

15

A
B
10
C

0
Accept Reject
Judgment

As a result, the surface quality points which are beyond the

controlled limit requires improvement and repairing should
be further investigated especially to the die surface.
 Data Validation
Checking area Checking time per
point (s)
Surface 7-9
Trim Line 5
Circle and Slotted 5
Hole

In this research, the average checking time for checking

one point using portable CFs at the surface of sample
panel is 6.67 seconds.
 GR&R Results

Sample A

Sample B
 Sample C

From GR&R study of the measurement

system, it is found that the measurement
system is acceptable because the
number of distinct categories was more
than five.
 CONCLUSION
• This research intended to introduce a
development of a portable quality-
confirmation inspection device for automotive
body part. In inventing a good portable
checking device, the characteristic of the
portable checking device and the design of a
gantry system need to be considered.
 CONTRIBUTIONS

i. A new CFs model for the checking device.

ii. Produce the design library of the portable

CFs design and surface accuracy data for
sample panels
 Journal
• Bastian Wibar Bin Momang and Dr. Hj Nik Mohd Zuki Bin Nik Mohamed,
Development Concept of a Portable Quality-Confirmation Inspection Device for
Automotive Body Parts, International Journal of Automotive and Mechanical
Engineering,ISSN: 2229-8649 (Print); ISSN: 2180-1606 (Online); Volume 11, pp.
2738-2746.
• Bastian Wibar Bin Momang and Dr. Hj Nik Mohd Zuki Bin Nik Mohamed, Design
Analysis of Front Fender Panels by Using Finite Element Method, Journal of
Mechanical Engineering and Sciences (JMES), In Press. (SCOPUS).

Conference
• Bastian Wibar Bin Momang and Dr. Hj Nik Mohd Zuki Bin Nik Mohamed,
Development Concept of a Portable Quality-Confirmation Inspection Device for
Automotive Body Parts, AiGEV 2014, Pahang Darul Makmur,Malaysia.
• Bastian Wibar Bin Momang and Dr. Hj Nik Mohd Zuki Bin Nik Mohamed, Design of
CF for Automotive Body Parts Based on Artificial Intelligent, 8th MUCET 2014,
UTeM, Melaka, Malaysia.
Thank You