Ensuring Precision in Automotive Assembly Lines with Laser Scanners

Laser scanners are used to inspect automotive components such as engine parts, interiors, and body panels. Laser technologies can be used to get accurate measurements and high-resolution images, which manufacturers can then compare to the original design to see if there are any defects or deviations from specifications.

One example of a laser scanner for automotive applications is the laser profiler. This 2D laser is used in quality control to verify dimensional accuracy and surface quality. For instance, it can be used to check the accuracy of the height, length, and width of car doors, hoods, and trunk lid. Inconsistencies in dimensions can lead to issues affecting the appearance and functions of a vehicle or component.

The KEYENCE’s LJ-X8000 Series is a laser profiler that can perform both 2D and 3D measurements and inspections. It can accurately measure the target's shape and create high-quality images, with its maximum laser linewidth reaching over 720 mm. It's also designed to measure both reflective and absorptive surfaces, making it easy to inspect just about any part.

This precision measurement offered by laser scanners and sensors helps automotive manufacturers to maintain quality standards.

Production errors can lead to inefficiency, waste of resources, and many more problems in an assembly line. With laser scanners, engineers can quickly detect imperfections and deviations from original models.

They can then go back to the drawing board and use the new information provided by the scanner to make needed corrections. Such insights can help eliminate production errors before parts and vehicle assembly.

With new information comes new understanding. Engineers may have to analyze existing designs to see if certain parts need to be modified. Instead of starting from scratch, manufacturers use 3D laser scanners to recreate the design. They can then make the necessary improvements, modifications, or reproductions.

The first step is to identify and group parts or assemblies requiring inspection. Next, you need to identify scanning technology that can give the desired level of accuracy.

For example, when planning to inspect chassis components (such as axles and suspension parts), or engine parts (such as cylinder heads and cylinder blocks), laser displacement sensors might be sufficient. These 1D laser sensors can measure a part’s shape, flatness, position, and surface finish.

While this requirement seems to overlap with the previous point, there’s a nuanced difference. There are instances where both 2D and 3D laser scanners would work fine for the same inspection task. In cases where functionality is not a concern, the choice between 3D laser scanners vs. 2D laser scanners can be based on side attractions, such as which one would save the most time and resources, etc.

Laser scanner technology should smoothly integrate with existing systems or other inspection software. The ability to connect a laser scanner with existing inspection setups makes for automated data processing, and helps reduce or eliminate human errors.

High precision can be achieved in automotive assembly inspection when the necessary factors have been thoroughly considered.