We are describing a fully automatic in-line shape inspection system for controlling the shape of moving objects on a conveyor belt. The shapes of the objects are measured using a full-field optical shape measurement method based on photogrammetry. The photogrammetry system consists of four cameras, a flash, and a triggering device. When an object to be measured arrives at a given position relative to the system, the flash and cameras are synchronously triggered to capture images of the moving object.From the captured images a point-cloud representing the measured shape is created. The point-cloud is then aligned to a CAD-model, which defines the nominal shape of the measured object, using a best-fit method and a feature-based alignment method. Deviations between the point-cloud and the CAD-model are computed giving the output of the inspection process. The computational time to create a point-cloud from the captured images is about 30 seconds and the computational time for the comparison with the CAD-model is about ten milliseconds. We report on recent progress with the shape inspection system.
This paper presents a system for full automation of free-form-fabrication of fully dense metal structures using robotized laser melting of wire. The structure is built of beads of melted wire laid side by side and layer upon layer governed by synchronized robot motion. By full automation is here meant that the process starts with a product specification of a component, and ends in a geometrically validated dense metal component fulfilling industrial material requirements. Due to the complexity of this flexible manufacturing system, a number of different disciplines are involved. This paper discusses mainly the system design, which includes how off-line programming is used for automatic generation of code and how feedback control is used for on-line adjustment of parameters based on desired building properties. To meet industrial needs, the project is carried out in a close cooperation between research and development activities in academy and industry.
In this paper a novel approach towards automation of robotized laser metal-wire deposition (RLMwD) is described. The RLMwD technique is being developed at University West in cooperation with Swedish industry for solid freeform fabrication of fully dense metal structures. The process utilizes robotized fibre laser welding and metal wire filler material, together with a layered manufacturing method, to create metal structures directly from a CAD drawing. The RLMwD process can also be used for repair or modification of existing components. This paper faces the challenge of designing a control system for maintaining stable process variables, such as a constant layer height and a stable component temperature, during the entire manufacturing process. Several problems are identified and discussed in the paper, e.g. the difficulty of obtaining the bead height in the weld pool environment. The case study is a repair application for stamping tools, where worn out trim edges are to be repaired. Issues regarding the control design, system identification, and the practical implementation of this application are discussed.
Support processes in industrial energy systems, such as heating, ventilation and cooling systems, are important processes in industrial premises as they are related to energy cost, product quality as well as the indoor environment.
In the vehicle production process the paint shop is the most energy intensive part, and about 75% of the energy is used in the ovens and spray booths. The spray booth line, which includes paint application and the oven, uses large quantities of air in order to keep the air quality in an optimal range to achieve the desired paint quality. The approach used in paint shops has up to now been to keep as much of steady state conditions as possible to avoid paint defects due to disturbances in the balance. This means that these high air flows are used also at low and non production hours. There is thus a large potential to increase energy efficiency by controlling the air flow and heating without losing the critical balances. This paper will present an initial post-implementation evaluation of the energy efficiency potential and experiences after running this type of system. CFD has been used to investigate the control strategy.