Tuning for your processes in automotive engineering

What makes WERKLICHT better?

Laser projection of bolt positions directly onto the component.

• Flexible with regard to changes.
• Precise display and control.
• Easy to use. Up to 80% faster than previous methods.

In prototype construction, WERKLICHT is used for stud welding, among other things. WERKLICHT projects the exact position of the individual studs onto the body panel. After briefly marking the projected stud position, the stud can be set. WERKLICHT thus eliminates the time-consuming and costly use of coordinate measuring machines and achieves time savings of up to 75%. 

Challenge:
Stud welding
Manual welding of studs (number:100+)

What tools have been used to date?
Templates:

• Expensive and laborious to manufacture
• Inflexible to changes
• Fast

Coordinate measuring machines:

• Expensive and resource intensive (measuring station)
• Slow
• Precise

The use of WERKLICHT also completely eliminates templates and thus their production and storage. Overall, this shortened process allows design changes to be implemented much faster.

What makes WERKLICHT better?
The use of 3D laser projection significantly reduces the inspection effort in quality control and at the same time makes a significant contribution to workplace ergonomics.

Particularly in series production with short cycle times, the manual search and post-processing are very challenging for production employees, especially for very large, three-dimensional and not necessarily planar components. This is because the probability that features or areas that need to be reworked remain undetected is correspondingly high, especially with such workpieces. 

Thanks to the use of dynamic laser projection, all points relevant to post-processing can be optimally visualized. Model-based tracking is used for this purpose. This continuously compares the geometry known from the CAD model with the image of the component in camera images from the different viewing angles of the laser projectors. Once the part has been “snapped in”, it is continuously tracked so that the marked points can always be displayed in the correct position, regardless of the height or position at which it is moved. The production worker can thus reach the points to be machined in an ergonomically optimal way. In addition, no points can be overlooked.

What makes WERKLICHT better?
Direct and immediate projection of defect color representations and measured values.

• Simply read in the measurement report and get started
• Sustained and accurate communication
• Elimination of time-consuming, manual labeling processes
• Discussion of current data status

WERKLICHT Video projects measurement results onto components, either in the form of false colors or deviation maps or individual point measurement values. The projection always remains in the correct position and dynamically adapts to the position of the component. The measurement data from conventional optical and tactile measuring devices are used as the basis for the projection. 

What means have been used so far?
False color representation via PDF and Powerpoint:

• Many discussions
• High effort for professional communication of the result

Drawing of point measurement values on component:

• Very time consuming
• therefore often discussion of “old data statuses
• Inflexible

The aim of this presentation method is to create a common understanding of problems among those involved in the product development process. This makes WERKLICHT Video a communication tool that avoids serious communication and interpretation gaps between departments and management levels.