Tube Inspect
TubeInspect – Efficient quality assurance for tube and wire manufacturing
About AICON • Founded in 1990 as a spin-off from Volkswagen R&D and the Technical University Braunschweig by Carl-Thomas Schneider and Werner Bösemann • Sites: • Braunschweig, Germany (Headquarters) • Meersburg, Germany (Scanner Innovation Center) • More than 120 employees • As of April 1 st , 2016, part of Hexagon Manufacturing Intelligence with more than 5,500 employees
Product Lines for Inspection, Testing, and Reverse Engineering Tube Inspect Move Inspect Technology AICON Scanner Tube and wire measurement Modular portable coordinate Surface scanning of complex with optical gauge measurement technique geometries
INTRODUCTION Do you want … • ... to speed up tube and wire inspection? • ... to avoid the multitude of mechanical gauges? • ... a true 3D CAD comparison? • ... to increase the efficiency of your bending machines? • ... to create data from samples with the help of an easily operated system?
INTRODUCTION Then use Tube Inspect for your production • As an optical gauge • Avoids mechanical gauge investments • As tube and wire measurement system • Profit from the measurement in a split second with nominal-actual comparison • For reverse engineering and prototype manufacturing • Ascertain the 3D-geometries of model parts for the construction or immediately generate a bending program. • For setup and correction of bending machines • Significantly reduce your set-up time and turn downtime into productive time
INTRODUCTION Tube Inspect measures your tubes and wires! cooling tubes plastic tubes thin flexible brake lines freeform tubes engine tubes wires exhaust pipes brackets and fittings
Tube Inspect System components
SYSTEM COMPONENTS Tube Inspect exposure technique • High-resolution digital cameras acquire the tube details
SYSTEM COMPONENTS Tube Inspect exposure technique • The transmitted light assures equal conditions of brightness
SYSTEM COMPONENTS Tube Inspect exposure technique • Very precise reference points guarantee reliable measuring results even in a rough production environment
SYSTEM COMPONENTS BendingStudio – Solutions for better bending Central data administration around bending process • Nominal data administration • Supervising of bending process • Storing of measurement results • Network with benders • Possibility to connect with SPC software
Tube Inspect Measurement principle
MEASUREMENT PRINCIPLE Automatic extraction of the tube/wire shape • The tube is captured in high definition by multiple cameras
MEASUREMENT PRINCIPLE Automatic extraction of the tube/wire shape • Detection of 3D cylindrical module • Automatic detection of the bending points and bending elements • Automatic comparison between nominal and actual module for calculating the gauge fitting
MEASUREMENT PRINCIPLE Automatic extraction of the tube/wire shape • Measurement results • Bending coordinates • Bending elements • Optical gauge inspection as sheath deviation • Correction data for the bending machines • Reports • Stored in internal database • Can be exported into different formats • Interface to SPC software available
Tube Inspect How can TubeInspect be applied in production?
How can Tube Inspect be applied in production? Application as optical gauge
TUBEINSPECT AS OPTICAL GAUGE Tube Inspect replaces mechanical gauges Mechanical gauge An OK part fits into the • A mechanical gauge checks the gauge installation capability • Disadvantages: • Inflexible because it is part-specific • User-dependent measurement results • Regular review, purchasing, storage and handling causes high costs
TUBEINSPECT AS OPTICAL GAUGE Tube Inspect replaces mechanical gauges • Sheath deviation: Optical gauge: Result documents the accuracy of Air of the gauge is displayed as gauge fit sheath deviation in a bar shard. • Comprehensive measurement protocol documents the dimensional accuracy • Graphical nominal to actual comparison facilitates the fault analysis Optical gauge testing – Sheath deviation
TUBEINSPECT AS OPTICAL GAUGE What is the sheath deviation?
TUBEINSPECT AS OPTICAL GAUGE Inspection criteria – part-specific sheath deviation 8 4 5 3 6 1 2 7 1 2 3 4 5 6 7 8
TUBEINSPECT AS OPTICAL GAUGE Inspection criteria – functional dimensions Parallelism Distance to plane
TUBEINSPECT AS OPTICAL GAUGE Integration into a robot-assisted production center
How can Tube Inspect be applied in production? Application as tube and wire measurement system
APPLICATION AS MEASUREMENT SYSTEM Functions and features • User independent measurement results • Measurement accuracy: to ± 0.035mm • Part specific alignment • Interface to SPC software Result: Extensive measurement reports
How can Tube Inspect be applied in production? Application for Reverse Engineering
APPLICATION AS REVERSE ENGINEERING Tube Inspect generates 3D-Geomtries easy and fast Sample Reverse Engineering Manufacturing Serial monitoring
APPLICATION FOR REVERSE ENGINEERING Your benefits at a glance! • Contour capture of samples within seconds • Automatic generation of bending data • Monitoring of the prototype manufacturing TubeInspect offers flexibility even at the smallest batch sizes!
How can Tube Inspect be applied in production? Set-up of bending machines
SET-UP OF BENDING MACHINES Step 1: Analysis of the first part Part out of tolerance!
SET-UP OF BENDING MACHINES Step 2: Transfer of Tube Inspect correction data Data transfer via TCP/IP- network
SET-UP OF BENDING MACHINES Step 3: Control for production release Part within tolerance!
SET-UP OF BENDING MACHINES Your benefits at a glance! • Automatic calculation of the correction data • Fast correction even on long tubes up to a length of 7m • Simulation module with virtual gauge inspection reduces bending trials to a minimum Noticeable cost savings by the shortened set-up time and reduction of reject
Tube Inspect BendingStudio – Solutions for better bending
BENDINGSTUDIO – SOLUTIONS FOR BETTER BENDING CAD-WIZARD – extracting bending data of CAD model • Importing of IGES or STEP files • Wizard for selecting tube ´ s geometry semi-automatically • Calculating the bending data (P/B/R) respectively x, y, z of bending points
BENDINGSTUDIO – SOLUTIONS FOR BETTER BENDING Measurement of long parts by pursuing Step 1: measuring section 1 Step 2: measuring section 2 Overlapping area enable step 3: • Automatic combination of measurement section 1 & 2 • Calculating and output of the result of the complete measurement
BENDINGSTUDIO – SOLUTIONS FOR BETTER BENDING BRANCH – measurement of branched tubes and wires Step 1: controlling intermediate steps • Proving of separate parts Step 2: end controlling • Proving of the correct assembled branched part • Gauge controlling of end products
BENDINGSTUDIO – SOLUTIONS FOR BETTER BENDING ASSEMBLY – parts with brackets and fittings TubeInspect Adapter • Control the position and direction of holders and fittings • Controlling of distances and angles of assembled parts
BENDINGSTUDIO – SOLUTIONS FOR BETTER BENDING Network of BendingStudio connects your plants! Head quarter - Management Plant I – Plant II – Production planning Quality department Plant I - Production Plant II - Production Company´s central server Company´s central back-up
Tube Inspect Reference customers - More than 320 installations! -
REFERENCE CUSTOMERS Small and medium-sized tube manufacturers • Very fast and effective process control thanks to extremely short measuring time • Significant decrease of costs due to reduced number of deficient parts • Dramatically reduced set-up time of the bending machines - additional free machine capacities mean hard cash to the companies
REFERENCE CUSTOMERS Aerospace industry • Accuracy advantage typically 5 times better repeatability compared to an articulated arm • TubeInspect reduces the reject considerably • TubeInspect assures an efficient production also in case of small batches
REFERENCE CUSTOMERS Automotive industry • Wide measurement range assures flexible application • Only one measuring system for several bending machines • Fast “ return on investment ” due to reduction of material consumption, faster set-up and waiving of gauges
Tube Inspect Products
PRODUCTS Tube Inspect - and which system do you need? TubeInspect P8 TubeInspect P16
PRODUCTS Tube Inspect - and which system do you need? Maximum Measuring volume Measurable tube Accuracy Model measurable tube [mm] diameters lengths TubeInspect 3.0 – 200mm 2,600 x 1,250 x 700 7m ± 0.085mm P16 TubeInspect 1 – 125mm 1,000 x 580 x 400 2m ± 0.035mm P8
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