“Industry 4.0” refers to the digitalisation and networking of production processes and environments. In large companies within the automotive industry, these processes are already offering enormous efficiency and diversity. Although we may always refer to an “industrial revolution”, Industry 4.0 is far more about an industrial “evolution” that demands tailor-made solutions.
On the path towards Industry 4.0, experts in measuring and imaging technology can offer solid support. When it comes to entirely individual and bespoke solutions in quality assurance and automation, FARO, the specialist in measuring technology and imaging processes, can offer a comprehensive portfolio and a wealth of experience. FARO deploys high-precision instruments both for tactile and for non-contact recording of objects, whether by means of visual imaging procedures, tactile measuring arms or laser scan technology.
FARO uses these competence building blocks to develop individual solutions directly tailored to the requirements of its customers, from individual building blocks through to complete solutions. The newly launched business area; 3D Solutions & Services, specialises in working together with the client to find freely configurable, rapid and cost-effective measuring and automation solutions in order to support companies on the path towards Industry 4.0.
“We offer a strong knowledge and exchange platform, both for big and small or medium-sized firms”, stresses Markus Grau, Director of Product Management 3D Solutions & Services. “Our goal is to bundle the whole range of competences and thus create the best possible individual measuring and automation solutions for our partners that are more than just ‘state-of-the-art’”. The systematic further development of application solutions within FARO, for example, as well as the interdisciplinary cooperation in a network of research institutions and businesses thus ensure intelligent innovations suitable for practical use.
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.
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.
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 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.
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.
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.
FARO are delighted to announce the launch of the new Vantage Laser Tracker product line. The new FARO® Laser Tracker Vantage product family sets a new price/performance standard for addressing challenges in large-scale metrology including, but not limited to, assembly alignment, part and assembly inspection, machine installation and alignment, and reverse engineering.
The FARO Vantage product family consists of two high performance models, the VantageE with an operating range of 25 meters and the VantageS with an operating range of 80 meters. Both compact models offer industry leading portability with an integrated master control unit (MCU), hot swappable batteries that eliminate the need for AC power and cabling, and industrial grade Wi-Fi for reliable, wireless communications. This set of advanced features, along with a single carrying case, enables easy transport between job sites and/or locations within the factory by a single user.
The FARO VantageS and VantageE Laser Trackers are extremely accurate, portable coordinate measuring machines that enable you to build products, optimize processes, and deliver solutions by measuring quickly, simply and precisely. These Laser Trackers optimize workflow productivity management for large-scale metrology applications including, but not limited to, assembly alignment, part and assembly inspection, machine installation and alignment, and reverse engineering.
You can also view the full Press Release Here.
Invisible Italy, a new TV series launched by BBC ONE takes viewers on a stunning historical journey through three of Italy’s most prominent cities. As part of this programme, ScanLAB projects used FARO scanners to provide viewers with a first hand perspective of Italy’s past.
FARO scanners played a significant role in offering new and previoulsy impossible insights into these cities. Sub-sea LIDAR scans were used in the Bay of Naples to scan underwater and take viewers back in time to explore the Bourbon Tunnels as well as the ruins od Herculaneum, Neapolitan catacombs and Roman Quarries. The whole lenght of the Grand Canal in Venice was also scanned from a moving boat. Other historical sites that the show unvieled was the original ghetto, the secret synagogues and the Jewish quarters. In addition, FARO scanners mapped the enter Vasari corridor including scans of the Uffizi Galley in under an hour.
Each programme is accompanied by 360 Youtube videos which allow viewers to navigate the exact same set of data that was captured by FARO scanners and used by the BBC to create the show. These can be viewed by clicking on the folllowing links. To explore the ruins of the Roman Seaside resort in Naples with a reputation for vice and debauchery please click here. Explore the secret corridor that allowed Florence’s ruthless rulers to travel through their city unseen by clicking here. Discover the secret torture chamber in the heart of the republic’s power structure by clicking here.
The three episodes are initially being aired in the UK but will also air internationally through BBC worldwide and its overseas partners.
To watch Invisible Italy please click here.
After 112 years, the Natural History Museum, London have decided to remove the iconic Dippy the Diplodocus. The specimen will be replaced with the real skeleton of a blue whale that was found on an Irish beach in 1891. Dippy will now embark on a UK tour around 8 venues.
The FARO Focus was used by the team to capture the surface detail of the whole specimen while it was in a mounted position. The task was particularly difficult as the specimen was made up of many different components therefore multiple scans had to be taken from different angles. It took approximately two hours to scan the whole skeleton. The scan data will give scientists the opportunity to learn more about the skeleton and help conservators to move the dinosaur safely around the country.
In addition to this, the FARO ScanArm HD was used to scan the real bones belonging to the blue whale. The reason behind scanning the blue whale was that the Natural History Museum needs to have a digital representation of it should anything unanticipated happen to the real skeleton. The skeleton of the blue whale is one of a kind and almost invaluable. Consequently, the Natural History Museum needs to have as much information about it as possible as this would help them to repair or reconstruct it if it was ever damaged. This project is the first of a huge project that is planned between FARO and the Natural History Museum.
Rugby UK, 21st November 2016 – FARO Technologies, Inc. (NASDAQ: FARO): FARO UK are celebrating the successful debuts of two advanced new products at the FARO UK Laser Technology Event
FARO UK recently hosted a successful Laser Technology Event at the company’s impressive new, Rugby based headquarters. Visitors to the well-attended event were able to witness impressive demonstrations of the latest FARO technologies that are intended for large-volume surface inspection and large scale laser-guided assembly and production.
New FARO laser innovations on display included the FARO VectorRI imaging laser radar, featuring the world’s only LIDAR with High Speed Imaging technology (HSI). The advanced VectorRI is an ultra-high speed, large-volume, non-contact 3D measurement solution with high-resolution 3D imaging and projection guidance for both manual and automated manufacturing processes.
In addition, the new FARO TracerM laser projector, intended for laser-guided assembly and production, was also demonstrated. Eliminating physical templates, the innovative new FARO product allows operators to quickly and accurately position components with absolute confidence.
Attendees from industries such as civil engineering, automotive and both rail and aerospace manufacturing were extremely impressed by the precise, large-volume capabilities of FARO’s advanced new technologies. FARO staff are now busy following-up the many leads generated at the event and performing on-site demonstration of the company’s new products.
At this year’s Intergeo in Hamburg, FARO® presented numerous new and enhanced products to its architecture, engineering and construction customers. Intergeo attendees were able to see first-hand the Laser Scanner FocusS Laser Scanner, the Freestyle3D Objects Handheld Scanner, SCENE, PointSense Software and the newly announced Mobil Mapping Solution, the Road Scanner C.
Generating the most interest and enthusiasm was the new Laser Scanner FocusS which was the highlight at the FARO booth and was visualized on a big screen multiple times. The FocusS is the most recent member of FARO’s popular laser scanner product line, which compliments the functionality of its latest Focus3D predecessors, adding several customer-centric features. An extended scanning range (150 m and 300 m), an extended operating temperature (-20° C to +55° C), the industry standard Ingress Protection (IP) rating classification IP54, an innovative accessory bay and a built-in compensation routine all provide AEC professionals with enhanced versatility and efficiency in the field. With a larger and luminous touch-screen the FocusS offers easy operation and its weight is more than 20% lighter in comparison to the previous generation models.
For precise scanning of mid-range measurement volume, FARO presented the new powerful Freestyle3D Objects Handheld Scanner as an Early Adopter Product to trade show visitors. Primarily designed for the Product Design market, the device also provides AEC professionals with a solution for 3D capturing medium-size MEP components and historical artifacts such as relics and sculptures. With a scanning range of 0.3 to 0.8 meter, the FARO Freestyle3D Objects captures scan data quickly in detailed colour and is suitable for different ambitious measurement tasks.
With the releases of FARO SCENE 6.2, customers could gain an insight into how the new on-site compensation tool is supported software based. Next to gaining information on the workflow of verifying and adjusting the scanner’s compensation parameters, customers learned how to generate a comprehensive compensation document automatically.
Trade show visitors that have been searching for solutions to efficiently process their laser scanning data, were able to see the introduction of the new PointSense Software programs. FARO has introduced new powerful tools for the modeling and alignment of building and plant components based on point cloud data, such as the new SmartSnap command in PointSense for AutoCAD and the extraction of MEP pipes in PointSense for Revit®.
Finally, attendees were amazed with the introduction of the new Road Scanner C, FARO’s first mobile mapping application, addressing customers in the infrastructure field with a state-of-the-art documentation solution. Realized as a joint project with the partner SITECO, FARO® will concentrate on the hardware sale.
Intergeo proved to be an extremely successful event for FARO which included three days on the trade show floor filled with positive customer feedback, numerous new contacts and insightful ideas for future product developments.
It is with great pleasure that we can announce that the FARO Focus X330 won the award for the best hardware product of the year at the Construction Computing Awards 2016.
David Southam, Regional manager for Europe North collected the award on behalf of Faro Technologies and had the following to say, “It was a great pleasure to be nominated for this year’s best hardware category at the Hammers 2016, it was a fabulous evening with many of the key construction players represented at the awards. The team and I had a really good night with superb entertainment and great networking opportunities.”
The winners of the 2016 Construction Computing Awards were announced at a gala event at BMA House in London. Over 180 supporting guests gathered to see the outcome of the readers’ online voting and judging panel’s deliberations.
FARO won the best hardware product of 2016 with the Faro Focus X330, a terrestrial 3D laser scanner specially designed for outdoor applications due its small size, light weight, extra long range, extended scanning possibilities even in direct sunlight and easy positioning with to the integrated GPS receiver.
To learn more about the FARO Focus laser scanner please click here.
On the 8th – 9th November 2016, FARO will be hosting an exclusive two-day laser technology event at our FARO UK Office in Rugby.
During this event we will present the FARO VectorRI Imaging Laser Radar, an ultra-high speed, large-volume, non-contact 3D measurement solution with high-resolution 3D imaging and projection guidance for manual and automated manufacturing processes.
Visitors will also be given the opportunity to see a live-demo of the new FARO TracerM Laser Projector for laser-guided assembly and production.
We will also offer a guided tour of our UK Service/Calibration Centre.
For more information about this event please click here.
FARO’s Super 6DoF package combines all the capabilities of 3D Measurement Arm and Laser Tracker technology to create an integrated 3D measurement system that is the industry’s only 6-degrees-of-freedom (6DoF)* solution that completely eliminates line-of-sight challenges and significantly expands measurement range while maintaining superior accuracy.
Benefits to Existing Users:
If you already use a Laser Tracker, adding the FaroArm will eliminate line-of-sight restrictions and will provide fast, high-resolution 3D scanning to easily measure difficult to reach features and surfaces.
If you already use a FaroArm, adding the Laser Tracker will expand the Arm’s working volume so it can be quickly positioned with greater accuracy.
The Super 6DoF package provides greater capability and value with a turnkey bundle that includes two separate portable coordinate measurement machines (PCMM) and leading 6DoF capabilities.
*6-degrees-of-freedom (6DoF): A specific parameter count for the number of degrees of freedom an object has in three-dimensional space.