Case Study 132
2021
Skoda Auto - Modernisation and Improvement of Coordinate Measuring Machines (CMMs)
Automated optical measurement as an engine of modernisation and innovation
HxGN-Robotic-Auotmation-Skoda-Software-and-Tracker
Hexagon and ŠKODA AUTO have been measurement partners for decades. At the end of 2018, the companies concluded an agreement to reconfigure inspection processes for 3D optical systems instead of tactile measurement. This programme has resulted in a significant increase in measurement capacity and quality, as well as the digitalisation of outputs from measuring devices.
This was achieved through the modernisation of several installed coordinate measuring machines (CMMs). It also resulted in a unique installation of two fully automated smart measuring cells for the measuring centre in Mladá Boleslav.
In terms of software, the measuring cell is equipped with Hexagon’s leading metrology platform PC-DMIS. The use of a single software platform across the factories has a number of practical advantages, such as the uniform integration of VW Group measuring principles directly into PC-DMIS. It has also added technical value in the possibility for the offline preparation of measuring programs.
A significant shift in the development of PC-DMIS in recent years has made it possible to take full advantage of offline programming. The operators of the new measurement cells in Mladá Boleslav have been able to make the most of this capacity, which allows them to start measuring very quickly when the production of new parts is launched.
In the new HxGN Robotic Automation software, which Hexagon officially launched in 2021, this offline programming functionality within PC-DMIS can now be more fully taken advantage of in the context of optical robotic measurement.
HxGN-Robotic-Auotmation-Skoda-Case-T-Scan-5
“The HxGN Robotic Automation software significantly reduces the time required for the offline programming of robotic measurement and the debugging of measurement programs. ”
“Hexagon’s fully robotic measuring cells are the first embodiment of “The HxGN Robotic Automation software" in the field of optical measurement. It is is just the beginning. More projects will follow as soon as possible to use the HxGN Robotic Automation Software for in-line and at-line measurement.
Tailor-made smart solution
The measuring cell itself is based on robotic absolute measurement powered by the large-volume measuring capabilities of Hexagon’s advanced laser tracker and 3D laser scanner technology. “The Leica Absolute Tracker AT960 is capable of six degrees of freedom (6DoF) measurement as standard, allowing the use of a 3D laser scanner or probe from up to 60 metres away."
Magnetic fixturing system “Ensuring fully automated control of the dimensions, shapes and positions of measured elements is then just a matter of programming using a unique combination of integrated Hexagon accessories within the cell – from interconnected metrology and programming software, selected rotary tables and flexible fixtures to the new cell control system architecture. The system as configured ensures fast data exchange between all peripherals and therefore enables the automatic creation of measuring programs based on CAD data of parts and jigs, as well as measurement simulation, the precise positioning of clamping jigs according to reference points, and last but not least the fast evaluation of large volumes of scanned data into graphically presented measurement results.”
The robotic measuring cell concept now in place in Mladá Boleslav arose from close cooperation between ŠKODA AUTO and Hexagon, and the resulting solution that was installed within a few months is a prototype tailored specifically to the needs of the measuring centre in this location. The system was designed to deliver the versatility the centre needed, with an installed tool changer unit allowing for direct automated switching between high-speed scanning and more accurate tactile measurement. This variability means the system will always be able to perform measurement of difficult-to access areas, such as openings, in a way that would simply not be possible for a less bespoke solution.
Extended use for the FIVE U-nique fixturing system
The smart cells also contain two workstations with rotary tables that use the flexible magnetic FIVE U-nique fixturing system, which allows accurate fixtures to be rapidly built for an unlimited number of part configurations to provide support and reference to the workpiece. The FIVE U-nique system provides considerable flexibility to automated measurement processes due to its reduced installation time, allowing for fast changes between configurations.
The reference position of each part-holding fixture is automatically determined from the CAD data of the part. The robot enters this position with a special tool from the tool changer and thus determines the final position and height of the fixture for the location. Thanks to this, a quick readjustment of the jigs for all measured parts is ensured, which significantly reduces the financial demands of acquiring and storing individual fixed configuration jigs for every part.
The accuracy of the jig placement is defined by the accuracy of the measuring system, in this case a high accuracy laser tracker and scanner. This system measures the position of the robot as it positions the part-holding fixtures, and subsequent iteration ensures zero deviation from the reference position. The well-established FIVE U-nique system has previously been used to position parts exclusively in coordinate measuring machines, but this new concept developed especially for ŠKODA AUTO demonstrates how this trusted solution can still play a role in the world of smart manufacturing.
Service and support as standard
Following this successful implementation, ŠKODA AUTO continues to credit their strong partnership with Hexagon to the constant support of Hexagon’s service technicians and application engineers, supported by an accessible and user-friendly training system.
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