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Control of the EGR Pipe Geometry in a 3D Space

    MV Center Systemy Wizyjne Sp. z o.o.

Even complex 3D geometry inspections might be performed automatically, resulting in reducing the number of complaints and increasing the certainty of inspections by eliminating the mechanical gauges often used in the geometry inspection process.

The engineers at MV CENTER SYSTEMY WIZYJNE SP Z O.O. have designed and delivered an inspection stand for automatic control of the EGR pipe geometry. The station was equipped with a rotary table using a mounting socket and a cage for a precise (+/- 0.02 mm positioning accuracy) MITSUBISHI RV-7FLM robot. The measuring system was based on the GOCATOR 2340 3D scanner and installed on the robot effector.

Scope of the inspection:

  • Quality control of the input and output flange of the pipe (including flatness inspection)
  • Position of the embossing on the pipe in relation to the measurement base (input flange)
  • Control of the position of mounting elements (hooks, handles, pressure probe) in the 3D space in relation to the same base
  • Control of the position of the input flange surface in relation to the output flange

The most challenging part of the project was developing a methodology for matching the measurement points specified by the customer on the CAD model of the product to the actual arrangement of the detail in the inspection base. The product is positioned on the station by the operator, so its position may vary by several millimeters in each plane.

The task of correcting the robot's trajectory and transforming the position from the CAD model into real positions was solved by combining two software environments - Aurora Vision Studio (inspection software) and MELFA (robot software).

Thanks to the active support of Adaptive Vision engineers, the Aurora Vision Studio libraries have been expanded with advanced 3D operation tools required for solving this case problem.

Hard work has paid off - we were able to achieve impressive measurement accuracy of 0.2 mm and repeatability of 0.05 mm. Taking into account the high degree of complexity of the system and the reflectivity of the products, achieved result is richly satisfying.

The station cycle time is approx. 60 seconds, during which measurements are made at over 20 reference points and 3 surfaces are scanned (flanges + handle). The station supports 3 references, each detail is marked with an individual QR code and the measurement report is generated in the CSV file format. The NOK parts are locked in the SAP system and must be deposited by the operator in a special scrap area.