Revolutionizing In-line Quality Control with Flexible Measurement Systems

Meeting the Demand for Precision in Manufacturing

In the world of manufacturing, consistency and quality are everything. From automotive to aerospace, industries rely on precise measurements to minimize waste and maintain productivity. Traditional metrology tools like Coordinate Measuring Machines (CMMs) and Camera Tunnels have long been a staple in quality control. However, as the demand for faster, more flexible production lines grows, the industry embraces the Flexible Measurement System (FMS). This robot-based inspection solution combines adaptability with precision, allowing in-line, 100% quality inspection while keeping up with fast-paced production.

What is a Flexible Measurement System?

Flexible Measurement Systems (FMS) bring a new level of precision and efficiency to manufacturing. Unlike traditional fixed systems, FMS uses robots equipped with non-contact sensors to inspect workpieces for features like holes, slots, edges, and bolts. Each system includes multiple robots and sensors, creating a large and versatile measurement envelope. This capability enables manufacturers to achieve detailed inspections directly in line, reducing response times for quality issues, minimizing waste, and improving productivity.

Why Absolute Accuracy is Key

Robots used in FMS systems must be both repeatable and accurate. While most robots offer high repeatability, maintaining absolute accuracy over time in real-world production environments is a different challenge. Temperature fluctuations and robot self-heating can distort a robot’s metal structure, causing position drift and reducing accuracy. This is where DynaFlex™ by Dynalog steps in, enabling FMS to function at a “CMM-like” level without needing a reference part, saving time and ensuring that the robot measurements are as close to reality as possible.

The Power of Calibration and Temperature Compensation

The DynaFlex™ system, integrated into FMS, delivers two essential functions:

1. Calibration: DynaFlex™ identifies and adjusts the robot’s parameters, including the robot’s kinematic structure, Tool Center Point (TCP), and fixture alignment. This process ensures that each measurement aligns with the CAD data and provides a baseline for high accuracy.
2. Temperature Compensation: Over time, heat from the robot’s motors and ambient temperature swings cause the structure to expand and contract. DynaFlex™ continuously monitors and compensates for these changes, maintaining accuracy down to the 0.1 mm level even under fluctuating conditions.

Real-World Impact: Case Study with Renault

In 2003, Renault pioneered the integration of an FMS in their Clio body shop in Flins, using four ABB robots equipped with Perceptron FlexiCam sensors. The system measures 20 points on each car body, providing real-time inspection without slowing down production. This setup has allowed Renault to achieve the same level of accuracy as a CMM while benefiting from the speed and flexibility of in-line inspection. With DynaFlex™ in place, the system compensates for any drift over time, so every Clio body leaves the line consistently.

The Future of In-line Inspection with FMS

Flexible Measurement Systems are becoming essential across industries as they push the limits of speed, flexibility, and accuracy. Dynalog’s DynaFlex™ software integrates seamlessly with systems from providers like Perceptron and Edixia, proving itself as a critical asset for maintaining measurement precision. With new advancements, FMS solutions are poised to expand beyond automotive and aerospace, offering unparalleled inspection capabilities in various sectors.

Whether in automotive manufacturing or aerospace inspection, FMS combined with DynaFlex™ provides a dynamic solution for high-precision, real-time quality control. This leap in inspection technology is setting new standards in manufacturing, making it possible to produce high-quality products consistently and efficiently.