Feb
01
2017

FARO solutions for inspection in R&D applications inside the automotive industry

FARO measurement technologies have been selected by leading automotive companies to support their production processes in different areas such as research and development, pre-production, production and digital factory & facility management.

In this brief blog post we will give you an overview of the research and development applications, the core of innovation processes and the backbone on which the success of a company in today’s hyper-competitive market depends on.

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Clay Studios – CNC Cutter Paths

If the creative act of determining and defining a car‘s form takes place prior to the physical production, clay studios must be used to generate data for CAD and CAM software, and CNC cutter paths for model machining.

Clay studios were one of the first in the automotive industry to implement scanning technology into their day-to-day processes to convert the physical model into CAD, which can then be used as a reference for all further developments.

The configurable FARO optical scanning solutions can easily be moved around the workshop and used to scan the entire surface of the model, quickly collecting all the necessary data for successive processing. Scanned data are also used to generate CNC cutter paths to allow subsequent machining or for reverse engineering.

 

Modelling

Using virtual models, designers and bodywork specialists can analyse and compare different design options. Single parts as well as entire sub-assemblies can be assessed in terms of geometry, dimensions and form all in the digital domain.

FARO’s 3D portable measuring systems allow development engineers to move physical samples into the CAD realm to build virtual models for dimensional analysis, computational fluid dynamics (CFD) and finite element analysis (FEA). Virtual design testing can also be completed for failure modes and effects analysis (FMEA) and noise, vibration and harshness (NVH) analysis.

 

Crash Tests

Crash testing is performed to determine the dimensional impact on a vehicle or on some specific components when crashing an object at a given speed. Quality can be a matter of life or death and minimizing the impact of accidents e.g. with the aid of improved safety systems can be decisive for passenger survival.

FARO systems allow users to measure the entire vehicle before and after the crash. A comparison of the two sets of scanned data can then be performed by engineers to analyse and evaluate the dimensional impact of the crash.

Tests may be part of a R&D development cycle as the manufacturers look for ways to improve the quality of passive safety systems such as crumple zones, roll pillars and seat belts. But tests can also be carried out by test centres with the aim of providing objective assessments of component and car safety for OEMs or verifying and certifying that vehicles and parts meet regulatory requirements.

The FARO hardware and software are part of an efficient workflow in order to produce deformation reports or safety certificates with minimal effort.

 

Benchmarking – Analysis of Competitive Vehicles

The term “benchmarking” has been used to describe the process where one OEM evaluates the products of competitors such as entire vehicles, parts and assemblies. Automakers continue to look for any advantage they can find to stay ahead of their competition.

Rather than taking a select number of measurements on a given part, FARO solutions ensure complete part coverage with the possibility to digitize the entire object surface and generate a 3D CAD model.

FARO’s optical measurement systems allow users to seamlessly scan across diverse surface materials regardless of contrast, reflectivity or part complexity, and to capture intricate components in fine detail. The scan data enables an optimal understanding of the dimensional characteristics of the competitor’s products to be obtained. No time intensive pre-programming for single part capturing is needed.

 

Cubing inspection

Despite the availability of design data, companies are still using solid models in original size to analyse the characteristics of vehicles and individual components. The aim of Cubing is to bring parts and components together and evaluate how they fit each other. Once parts are mounted on a structure that replicate and simulate a real configuration, they can be measured and their reciprocal alignment checked and documented.

The solid model is based on a flexible frame with adjustable fixings, allowing a quick configuration of the car parts and components. Cubing inspection with the FARO solutions enables users to detect production issues early on in the development process of a vehicle so that problematic parts can be easily identified. This procedure is also particularly helpful for supplier support.

 

Reverse Engineering

The process of manufacturing special aftermarket accessories or customized components can benefit by using the FARO measurement systems as an ideal solution for reverse engineering the source vehicles. Design elements to be modified can be scanned using the FARO optical solutions in order to generate the CAD models that will then form the basis of the design activity.

Prototypes can be created, via traditional methods or 3D Printing and then attached to the source item and further checked by using the FARO solution to ensure that they match the CAD design drawings. Further modifications can be made to the physical prototype directly to improve the fit or enhance the design and then measured again to incorporate any changes into the CAD drawing.

Using the FARO augmented reality technology, digitally designed components can be easily compared, in the virtual domain, to real parts or physical mockups for the first design review and to check the fit.

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