STEINBICHLER 25 YEARS OF INSPIRING INNOVATION ABIS OPTICAL SURFACE INSPECTION

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Christopher Moore
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1 STEINBICHLER ABIS OPTICAL SURFACE INSPECTION 25 YEARS OF INSPIRING INNOVATION

25 YEARS OF INSPIRING INNOVATION EXPERTISE AND EXPERIENCE IN OPTICAL 3D MEASUREMENT TECHNOLOGY 25 years of experience and expertise in the field of optical measurement and sensor technology have

For example, with our ABIS sensors for surface inspection, we offer outstanding quality assurance tools We develop and manufacture all Steinbichler products at our central location that help to use

Using state-of-the-art technologies from Steinbichler, our customers ensure their product quality at the highest level. No less than 170 patents prove the innovative strength of our company.

2 25 YEARS OF INSPIRING INNOVATION EXPERTISE AND EXPERIENCE IN OPTICAL 3D MEASUREMENT TECHNOLOGY 25 years of experience and expertise in the field of optical measurement and sensor technology have shaped the success story of Steinbichler Optotechnik GmbH. The technical advantages of our systems also provide economic and ecological added value. For example, with our ABIS sensors for surface inspection, we offer outstanding quality assurance tools We develop and manufacture all Steinbichler products at our central location that help to use costly resources and raw materials in a highly efficient way. in Neubeuern. Thus, our customers benefit from the quality made in Germany. Using state-of-the-art technologies from Steinbichler, our customers ensure their product quality at the highest level. No less than 170 patents prove the innovative strength of our company. In close cooperation with renowned partners from science and industry, our highly qualified employees Our ABIS systems contribute to improving and maintaining a high level of product quality in various fields of application, EXPERTISE AND EXPERIENCE IN OPTICAL 3D MEASUREMENT TECHNOLOGY develop practical and user-oriented solutions for various applications and sectors. We set standards in optical 3D measurement technology, focusing on innovation and precision as well as flexibility and openness toward new approaches. particularly in safety-critical sectors such as the automotive industry. 2

ABIS - OPTICAL SURFACE INSPECTION OBJECTIVE AND EFFICIENT QUALITY CONTROL The surface quality of a product - particularly in the automotive industry - constitutes an important criterion for the

that are invisible to the eye while the surface is still unpainted.

3 ABIS - OPTICAL SURFACE INSPECTION OBJECTIVE AND EFFICIENT QUALITY CONTROL The surface quality of a product - particularly in the automotive industry - constitutes an important criterion for the customer and is generally seen in close relation to the quality of the overall vehicle. Even minimal inevitable disturbances in the early production stages prior to applying the paint work (e.g. in the press shop or body shop) may cause defects such as dents, bumps, sink marks, etc. that are invisible to the eye while the surface is still unpainted. On a high-gloss paint surface, however, even the slightest irregularities are clear to see with incident light from the proper angle, and constitute a reduction in quality that can only be remedied using costly corrective measures. The early, continuous and complete detection of surface defects with the objective, high-precision ABIS surface inspection system opens up new perspectives in quality assurance. Available in different versions and system concepts, the ABIS systems allow the fast, reliable and ultra-accurate detection of defects on sheetmetal parts or bodies-inwhite. Time-consuming and thus expensive rework in subsequent process steps, e.g. at the finish belt, can be efficiently reduced. Numerous renowned automobile manufacturers have implemented the ABIS surface inspection system with great success in a wide variety of custom concepts tailored to their press shop environments. These offline systems are ideal not only for ongoing auditing at regular intervals during the manufacture of a press lot, but also for checking the first sheet metal parts after a tool change. ABIS - OPTICAL SURFACE INSPECTION 3

EARLY DEFECT RECOGNITION FOR COST-SAVING AND RESSOURCE-EFFICIENT PRODUCTION The majority of

work steps such as paint work have been completed.

The costs of removing these defects increase drastically with the progress of work Hubert

fully accepted by our customers as an efficient measurement tool in press shops and body

Featuring a high measurement repeatability and providing objective inspection results (defect

compared to manual audits and offer high performance for design-oriented, complex surface

Consequently, particularly the rework of defects that have been propagated throughout the

Quality control with ABIS substantially optimizes the sustainability of the production

4 EARLY DEFECT RECOGNITION FOR COST-SAVING AND RESSOURCE-EFFICIENT PRODUCTION The majority of defects that can occur during the production process are invisible at the early stages of manufacture. These minute surface defects become visually perceptible later on, however, when subsequent work steps such as paint work have been completed. At that time, they can only be remedied using expensive corrective measures. The costs of removing these defects increase drastically with the progress of work Hubert Lechner Sales Surface Inspection The ABIS surface inspection system has been approved and fully accepted by our customers as an efficient measurement tool in press shops and body shell work. Featuring a high measurement repeatability and providing objective inspection results (defect classification), the systems also score high with the extremely short measuring times compared to manual audits and offer high performance for design-oriented, complex surface shapes. within the production cycle (press shop, body shop, paint shop, final assembly). Consequently, particularly the rework of defects that have been propagated throughout the production process constitutes a substantial factor with regard to manpower and time. Quality control with ABIS substantially optimizes the sustainability of the production processes by significant savings of work ressources and raw materials such as sheet metal and coatings - environmentally friendly and economically efficient high-end technology. LATE DETECTION AND CORRECTION OF SURFACE DEFECTS CAUSE HIGH COSTS factor 1000 PAINT SHOP EARLY DEFECT RECOGNITION 4 COSTS PER DEFECT factor 10 factor 100 PRESS SHOP BODY SHOP PROCESS CHAIN

DETECTION OF ALL RELEVANT DEFECT TYPES WITH ABIS II OBJECTIVE AND FAST

sink marks, waviness, constrictions, cracks, etc.

production of sheet metal parts and bodies-in-white.

5 DETECTION OF ALL RELEVANT DEFECT TYPES WITH ABIS II OBJECTIVE AND FAST MEASUREMENT WITH MODULAR SENSORS With the ABIS II sensors, a wide range of defect types can be detected. Featuring a reliable, early recognition and classification of dents, bumps, sink marks, waviness, constrictions, cracks, etc., the systems represent the perfect quality control instruments for the production of sheet metal parts and bodies-in-white. Users especially benefit from the high precision and extremely short cycle times. The modular sensor technology of ABIS II offers an exceptionally high flexibility. With the optional integration of the contrast sensor, the detection of contrast-sensitive defects such as adhesive residues, scratches and dirt, is also possible. EXAMPLES FOR CONTRAST-SENSITIVE DEFECTS: ADHESIVE RESIDUES SCRATCHES DIRT EXAMPLES FOR 3D DEFECTS: BUMPS DENTS SINK MARKS WAVINESS CONSTRICTIONS CRACKS DETECTION OF ALL RELEVANT DEFECT TYPES 5

ABIS II - CONTINUOUS ANALYSIS OF THE SURFACE QUALITY THROUGHOUT THE COMPLETE PROCESS CHAIN Many users in the automotive industry rely on an integrated surface quality analysis across the entire

After each of the process steps Single Part, Assembly and Cathodic Dip Painting, the individual parts are examined again by same inspection application to identify any surface defects that might

Practical experience in production shows that the relevance of a surface defect can increase or decrease after a process step.

6 ABIS II - CONTINUOUS ANALYSIS OF THE SURFACE QUALITY THROUGHOUT THE COMPLETE PROCESS CHAIN Many users in the automotive industry rely on an integrated surface quality analysis across the entire process chain. After each of the process steps Single Part, Assembly and Cathodic Dip Painting, the individual parts are examined again by same inspection application to identify any surface defects that might affect the top coat quality. The development of a defect is documented after each process step. Practical experience in production shows that the relevance of a surface defect can increase or decrease after a process step. Based on a process-wide quality analysis, the required rework is done precisely at the required location on the part and at the required process steps. This increases the efficiency in the finishing area and results in a significant cost saving. Besides the development of a surface defect across the process chain, the time-related changes within a production period also give users important information on the quality changes. For example, when the audit value deteriorates, corrective action (e.g. regarding press parameters or tool surfaces) can be taken at an early stage before producing parts with defects that will later require rework. ABIS - CONTINUOUS ANALYSIS OF THE SURFACE QUALITY THROUGHOUT THE COMPLETE PROCESS CHAIN SURFACE INSPECTION WITH ABIS II THROUGHOUT THE COMPLETE PROCESS CHAIN Single Part Assembly Cathodic Dip Painting 6

USER-FRIENDLY SENSOR TECHNOLOGY, SOFTWARE AND AUTOMATION FOR TOOL MAKING, PRESS SHOP, AND COMPLETE BODYSHELL WORK ABIS II offers the highest standards in terms of suitability for industrial

Thanks to the high-speed inspection and evaluation capacity, a report of the inspection result will be available in minimum time. The entire operation of e.g. an offline system is done very simply by selecting the relevant part inspection processes on the touch screen.

7 USER-FRIENDLY SENSOR TECHNOLOGY, SOFTWARE AND AUTOMATION FOR TOOL MAKING, PRESS SHOP, AND COMPLETE BODYSHELL WORK ABIS II offers the highest standards in terms of suitability for industrial applications as well as expandability, defect detection and easy use. To inspect a part, all the user has to do is select the part on the touch screen and start the test sequence. Thanks to the high-speed inspection and evaluation capacity, a report of the inspection result will be available in minimum time. The entire operation of e.g. an offline system is done very simply by selecting the relevant part inspection processes on the touch screen. When programming additional test sequences for new parts, the user is systematically supported by the easy-to-use ABIS-TeachIn software. The classification criteria and threshold values for a subsequent automatic evaluation of the defects are always based on the customer s specifications. In addition, the Horst Winterberg Group Leader Development Surface Inspection Our long-term experience in optical measurement technology and image processing, paired with the know-how of our customers, are the basis for the success of our unique ABIS surface inspection systems. system applies the customer s internal audit note standards and defect names. The specified threshold values can be flexibly adapted to the relevant production stage at any time (floating audit). Efficient, highly precise quality control Objective classification and documented surface quality Easy operation & fast evaluation Fully automatable process Less rejects and complaints Reduction of rework costs Sustainable optimization of production processes USER-FRIENDLY SENSOR TECHNOLOGY, SOFTWARE AND AUTOMATION 7

ABIS - SYSTEM VARIANTS FROM PORTABLE SENSOR AND OFFLINE SYSTEM TO FULLY INTEGRATED UNIT ABIS II is a flexible system concept that comes in three different versions.

The flexible, compact and highly precise ABISoptimizer sensor system has been developed especially for applications at an early stage of the manufacturing process.

ABIS II Offline allows data acquisition and evaluation at an automatic test stand and is excellently suited for accompanying production monitoring.

8 ABIS - SYSTEM VARIANTS FROM PORTABLE SENSOR AND OFFLINE SYSTEM TO FULLY INTEGRATED UNIT ABIS II is a flexible system concept that comes in three different versions. Users can thus choose the sensor system that best meets their application requirements. The flexible, compact and highly precise ABISoptimizer sensor system has been developed especially for applications at an early stage of the manufacturing process. Due to its high mobility, the system allows for an easy change of the location for concurrent and focused, punctual inspection measurements in production. ABIS II Offline allows data acquisition and evaluation at an automatic test stand and is excellently suited for accompanying production monitoring. Defect catalogs and classification criteria that have been compiled during the planning stage can be extended and modified. The ABIS II Offline cell can be configured for both mobile use and stationary installation at a fixed position in the press shop. The mobile Offline version features one or more portable platforms, on which the system components are mounted. With ABIS II Inline, a fully automatic inspection and assessment can be performed by direct integration of the system concept into the manufacturing environment of the body shop or press shop. According to the customer s specifications, the ABIS II Inline system can be configured for either 100 % inspection of all parts or for the inspection of certain object areas and defined zones on the test part. The achieved complete or partial inspection of bodyshells and sheet metal parts sets highest standards in quality assurance and auditing. ABIS - SYSTEM VARIANTS 8

VIRTUAL DESIGN INDIVIDUAL SYSTEM CONFIGURATION PERFECT FOR INTEGRATION INTO PRODUCTION PROCESSES Before an ABIS II surface

Simulation programs help to select the specific robot and its position with reference to the part under test.

How many sensors and data analyzers the final system concept provides depends on the part size(s) (from small bodyshell parts

Corresponding accessibility studies and cycle time simulations build the basis for optimal customer-specific system

9 VIRTUAL DESIGN INDIVIDUAL SYSTEM CONFIGURATION PERFECT FOR INTEGRATION INTO PRODUCTION PROCESSES Before an ABIS II surface inspection system is installed, a virtual system concept is always created first. Simulation programs help to select the specific robot and its position with reference to the part under test. This ensures that the sensor will be able to reach all the positions required for inspection. How many sensors and data analyzers the final system concept provides depends on the part size(s) (from small bodyshell parts to the complete car body / body-in-white) and on the specified maximum inspection time per part (cycle time). Corresponding accessibility studies and cycle time simulations build the basis for optimal customer-specific system configurations. The safety concept and the construction of the system are designed and implemented in accordance with user guidelines. Customers can choose to do this themselves or order a complete, end-to-end surface inspection solution. VIRTUAL DESIGN 9

TESTIMONIALS / REFERENCES The optical surface inspection system must be ready to run day and night.

Uwe Walcher System Operator Press Shop III Audi AG Ingolstadt The ABIS system enables us to objectively analyze the surface quality in the individual

For the good business relationship with our customers for bodyshell panels, the ABIS system is an excellent inspection system for the objective

With the Zwickau plant, the first TOWER Automotive press shop now utilizes the ABIS II system for objective surface inspection of body shell parts.

10 TESTIMONIALS / REFERENCES The optical surface inspection system must be ready to run day and night. It now replaces the whetstone formerly used by the QA staff. Thus, we can check more parts and classify them objectively in the same time period. Uwe Walcher System Operator Press Shop III Audi AG Ingolstadt The ABIS system enables us to objectively analyze the surface quality in the individual process steps from the single part through to assembly and cathodic dip painting and take targeted measures. For the good business relationship with our customers for bodyshell panels, the ABIS system is an excellent inspection system for the objective documentation of surface quality. Quality control and customer satisfaction are top priorities at TOWER Automotive. With the Zwickau plant, the first TOWER Automotive press shop now utilizes the ABIS II system for objective surface inspection of body shell parts. Thus, the surface quality of complexshaped body shell parts is now fully documented for our customers very quickly and clearly. Dietmar Leichsenring MGR Equipment & Facility Realisation Europe TOWER Automotive Jorge Palenzuela Head of Quality Assurance Russia Gestamp Automation TESTIMONIALS 10

Since our company s foundation, a central REFERENCES part of our business philosophy has been

For more than two decades now, customers from all over the world benefit from our innovative

Audi AG BMW AG Daimler AG General Motors Gestamp Honda KIA Slovakia For the complex automated

11 Since our company s foundation, a central REFERENCES part of our business philosophy has been focused on an international orientation of our sales and support activities. For more than two decades now, customers from all over the world benefit from our innovative metrology solutions and corresponding technical support services. Audi AG BMW AG Daimler AG General Motors Gestamp Honda KIA Slovakia For the complex automated surface inspection units, professional local support is guaranteed by highly qualified service technicians. Having established numerous international PSA Peugeot Citroën Tower Automotive Toyota Volkswagen AG Zwick-Roell subsidiaries and a worldwide distribution network, we offer our high-end products and services across all continents. REFERENCES 11

Steinbichler Optotechnik GmbH 11_2013 STEINBICHLER OPTOTECHNIK GmbH Georg-Wiesböck-Ring 12 83115 Neubeuern Germany Tel.

12 Steinbichler Optotechnik GmbH 11_2013 STEINBICHLER OPTOTECHNIK GmbH Georg-Wiesböck-Ring Neubeuern Germany Tel.: Fax: International Subsidiaries: USA BRAZIL P.R. CHINA INDIA FRANCE PORTUGAL UK AUSTRIA RUS

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