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Advanced measuring equipment in high-precision body manufacturing
Creating a high-quality car body is the most visible representation of a vehicle’s design and manufacturing excellence. A highly precise body-in-white (BIW) is essential not only for achieving an aesthetically pleasing appearance but also for reducing labor time and improving production efficiency. In the 1980s, Japanese automakers successfully entered global markets by combining fuel-efficient engines with elegant designs. Today, Dongfeng Honda is focusing on building a 1mm-level BIW, emphasizing the importance of precision in automotive manufacturing.
To achieve this level of accuracy, advanced and reliable **measuring** instruments are crucial. A three-coordinate **measuring** system has become an integral part of the production process, enabling real-time inspection and ensuring consistent quality. The author explores how coordinate **measuring** machines play a vital role in equipment installation, fixture calibration, daily analysis, and maintaining the integrity of the body during production.
**Laser Tracker**
The accuracy and stability of production line equipment significantly impact the precision of the vehicle body, as well as the efficiency and consistency of mass production. To ensure this, it's necessary to adjust the equipment’s accuracy before introducing specific vehicle fixtures.
One key step is the leveling of the equipment base. Traditional tools like bubble levels have limitations in terms of accuracy and efficiency, often requiring skilled personnel and lengthy adjustments. In contrast, the Leica AT901 series laser tracker allows two **surveyors** and one construction worker to complete the task quickly and accurately. This device offers high repeatability, real-time temperature compensation, and can measure surfaces made of different materials, achieving a base accuracy of ±0.05mm.
When adjusting large welding fixtures, traditional **measuring** methods using multi-joint three-coordinate systems are inefficient and prone to error. Laser trackers, however, offer a wide **measuring** range, high precision, and ease of use. They allow full fixture adjustment within the same coordinate system, improving both accuracy and work efficiency.
**Key Features of the Laser Tracker:**
1. **Wide Measuring Range and Ease of Use:** With a measuring range of up to 160 meters, it can handle both large-scale production lines and small fixtures. It supports three measurement methods—tracking a mirrored ball, using a wireless contact sensor, or scanning with a laser. Real-time feedback helps operators detect deviations instantly.
2. **Stable Performance and High Precision:** Utilizing ADM and IFM technologies, the laser tracker ensures high data redundancy and reliability. Its proven design makes it ideal for precise **measuring** in demanding environments.
3. **Compact and Portable:** Weighing just 22kg and measuring 620mm in length, it can be easily handled and installed by a single person.
In summary, the laser tracker enables fast, accurate, and reliable detection and assembly of automotive production lines. Its field-based, real-time capabilities make it ideal for on-site inspections of tooling, fixtures, and gages, ensuring consistent quality and repeatable results.
**Portable Coordinate Measuring Instrument**
Portable coordinate **measuring** instruments offer high precision, speed, flexibility, and strong adaptability to on-site conditions. They are widely used for detecting fixtures, analyzing component states, and identifying defects. These devices use a probe to collect coordinate values, which are then processed by software to reflect the true shape and dimensions of the tested object.
Body components are often thin and complex, and stress during processing can affect their alignment. During new model introductions, **welding** fixtures must be measured and adjusted to meet tolerances. In harsh **welding** environments, fixtures tend to loosen over time, requiring regular **measuring** and maintenance. Large fixtures typically use laser trackers, while smaller ones may rely on portable multi-joint three-coordinate **measuring** instruments due to cost and frequency considerations.
These tools not only help identify faulty positions and deviation amounts but also analyze parts after assembly. By scanning entire workpieces, they reveal deformation trends before and after assembly, helping trace the root cause of errors. Combining contact **measurement** with laser scanning allows for both qualitative and quantitative analysis, making it easier for manufacturers to detect and resolve issues efficiently.
**Fully Automatic Movable Double-Arm Coordinate Measuring Machine**
Automotive manufacturing involves large-scale processes where environmental and equipment conditions constantly change. To maintain consistent body quality, regular inspections of the body and sub-assemblies are essential.
The fully automatic double-arm coordinate **measuring** machine DEA PRIMA can automatically **measure** key hole positions and shapes according to pre-programmed procedures, significantly increasing **measuring** speed and data reliability. However, this equipment requires a controlled environment—constant temperature, humidity, and minimal vibration—so it must be placed in a dedicated **measuring** room, limiting it to offline **measurement**.
By analyzing test data, the system generates fluctuation trends and maps, allowing real-time monitoring of key quality parameters. This helps detect early signs of deviation and implement corrective actions, preventing non-conforming products from reaching the market.
**Online Testing Equipment Application**
1. **Laser Online Detection System**
In automotive manufacturing, the accuracy of the body-in-white is critical for overall quality. Due to **welding** deformation and fixture positioning errors, controlling **welding** quality is challenging. Traditional **measuring** methods involve periodic sampling away from the production line, which is slow and less effective.
In 2009, the company introduced a laser online detection system that can monitor key points in real time, ensuring timely detection and resolution of issues. This system greatly improves the accuracy of the body-in-white and supports efficient **measurement** of the J6 body-in-white **welding** assembly.
However, challenges remain, such as interference from dust and vibrations on the production line, requiring careful data filtering to extract meaningful results.
2. **Laser Profile Gap and Step Difference Measuring Equipment**
To enhance body precision, the company introduced Axalt’s laser profile gap and step difference **measuring** equipment. Using a wireless portable SYMBOL laser scanner and LGWorksRT software, it collects large volumes of data quickly and accurately, identifying the root causes of poor product quality.
This system is user-friendly, reduces human error, and improves matching between parts, enhancing overall product quality. It also provides flexible reporting, supporting better decision-making and quality improvement.
**Conclusion**
Building a high-precision body is a complex, systematic process that spans from equipment foundations to final assembly. Ensuring accuracy at every stage is essential to prevent error accumulation. In China’s automotive industry, where the overall level is still developing, achieving such precision is no small feat.
By leveraging advanced **measuring** technologies and applying them effectively, manufacturers can overcome challenges and produce high-quality vehicles. Selecting and combining **measuring** equipment based on production needs is key to improving both the accuracy and aesthetics of domestic automobiles.