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Automation Technologies 4/2014

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Automation Technologies 4/2014

machine vision Thermal

machine vision Thermal imaging cameras in automotive quality control Chris Brown, Frank Liebelt The BMW 5-Series, 6-Serie, 7-Series and 3-Series Gran Turismo are produced in the Dingolfing plant in Lower Bavaria. Around 18,500 people work at the site. Basic functions from signal horn to engine-specific performance are thoroughly tested. Thermographic cameras are ideally suited for this type of quality control and ensure the proper functioning of automobile production. New vehicles are subjected to a number of individual and automated quality control measures including analysis in one of ten separate roller dynamometers. Basic functions from signal horn to engine-specific performance are thoroughly tested, as is the BMW Night Vision System, based on a Flir detector. The entire process just takes a few minutes, during which each correct function has to be confirmed either automatically or by an inspector who sits in the vehicle monitoring displayed inspection data. The tests vary in both type and duration according to the specification of each model and are programmed to be conducted in an automated sequence. Author: Chris Brown, Business Development Manager EMEA, Flir Systems Limited, UK; Frank Liebelt, journalist, Frankfurt, Germany Simple, fast and reliable testing Whilst cost- and time-efficient testing is the common goal, identifying the optimum procedure for each AUTOMATION TECHNOLOGIES 4/2014

machine vision next page The BMW plant in Dingolfing, Germany, is using thermal imaging cameras for electro-thermography of switch cabinets and rooms and for quality control inspection task needs individual consideration. This is the case, for example, when testing the exhaust flaps on the dual exhaust system. Twin tail pipes are a feature of the high performance BMW vehicles with large, 8-cylinder engines. On the BMW M5 model the requirement is different again, as the exhaust flap on the second tailpipe is only activated at a specified RPM. The reason for this may be at first surprising as it’s all about acoustic design but the sound of a powerful engine should be impressive. Therefore a BMW M5 only opens the second tailpipe exhaust flap when it is really needed. Of course this feature has to be inspected which is more complicated than it appears at first glance. To check the efficiency of this operation thermal imaging cameras – a different brand to FLIR – were initially specified for each dynamometer rig. Their purpose was to visualise the thermal profile of the respective tailpipes in the dual pipe exhaust system. Thermal imaging cameras check exhaust flow Each system comprised two thermal imaging cameras, mounted to inspect the left and right tail pipes from above and the side. The solution was not only expensive to buy but costs also increased with time as the cameras required frequent repair. After eight years the viability of a new system was therefore evaluated. Robert Halbritter of Flir Systems’ sales partner and integrator Topa GmbH, offered a very attractive solution that would halve the cost of new camera hardware. He recommended the use of a single, fix-mounted Flir A310 with a 45º lens for each dynamometer. The advantage: that which was previously inspected using two cameras mounted on the sides could now be visualised using a single centrally positioned Flir camera. This is possible as the field of view AUTOMATION TECHNOLOGIES 4/2014

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