Automated Inspection Of Cockpit Modules

Our customer necessitated that we capture the data of the modules specifically for the production of the new VW ID.3 cockpits and for ensuring compliance with quality standards. “During operation, we take random cockpits from the main production line to check them for any material defects. We then carry out a product audit and scan the component. Once this process has been completed, we reintroduce the cockpit into the production process,” explains Uwe Schulz, metrology engineer at SAS Autosystemtechnik GmbH. During the normal production process, we only have 20 minutes for this inspection. As a rule, we carry out at least five scans per shift – i.e., at least 15 scans per day in addition to measuring procedures in line or in series. The first article inspections come on top.

As a first step, Uwe Schulz prepares a measurement plan for his employees which they will use in the Kiosk Interface – a special user interface for a simplified operation of the ATOS ScanBox. “The Kiosk Interface is so intuitive that even colleagues without background knowledge can easily perform analysis measurements,” explains Uwe Schulz. The software handles the entire process control and automatically executes measuring and inspection procedures. It significantly minimizes any operator influence and is thus part of a reliable solution that meets the most demanding requirements where precision and data quality are crucial. “Another major advantage is that we have tied the Kiosk Interface to our product audit. It covers the entire reporting process. Any defects or the corresponding missing parts that are identified, are described in one of the input fields and then become part of the measurement report.

After having captured the data of the assembled cockpits, Uwe Schulz checks their surfaces against their CAD data. The scanned parts are visualized and evaluated in a color plot where the operator can identify deviations and material defects at a glance. If components, such as the glove compartment, are warped or if the installation gaps for the decorative stitching of the passenger airbag do not match the CAD, SAS initiates immediate corrective action until the component meets the predefined standard. “We are now able to capture all inspection characteristics and functional dimensions of our components. It is especially the fact that we can combine our processes with the preinstalled ZEISS INSPECT software and its ease of use that makes our daily routine so much simpler,” summarizes Uwe Schulz.