3D Gap and Flush Inspection
Improve panel alignment, boost operational performance, and increase safety
A common application in the automotive industry is flush and gap inspection to ensure that vehicle panels are aligned properly. Although this application appears relatively simple, the value of the flush and gap inspection system lies in the details. For example, a 2D system may determine if a gap is consistent between a door and a body panel. However, determining if two panels are flush or on the same plane is more complicated. Compact 3D systems such as the In-Sight 3D-L4000 can easily and quickly detect whether panels are on the same plane through an industry-proven In-Sight software program designed in an intuitive spreadsheet format.
Recently, using a In-Sight 3D-L4000 smart camera from Cognex, an automotive OEM was able to generate high-quality, 2K-resolution images at up to 4 kHz, with significantly easier integration, and measurement accuracy. These results were made possible through Cognex’s patented speckle-free blue laser optics and compact design. This optical design has several benefits, including eye safe operation while delivering more light to the surface any competing solutions, more accurate 3D point clouds for measurements, and the ability to measure 100% of the In-Sight 3D-L4000’s field of view even if up to 50% of the laser is blocked by debris. This final benefit is an unprecedented achievement in 3D laser scanning, which normally limits the designer’s option to mount the scanner upside down because of concerns about debris blocking the laser light.
Robots assembly benefits from compact design
The compact design of the In-Sight 3D-L4000 is a large deciding factor when solving gap-and-flush applications. When potential solutions, whether 2D or 3D, require external controllers or connections to a PC, system integration is more complicated and consumes more valuable floor space. And since many applications require sensors to be mounted on the end of robotic arms, wires connecting external devices are an important design consideration. The compact In-Sight 3D-L4000 solution requires no external PC or drivers. The lack of additional devices makes integration less disruptive and works well for robotic arm end-effector applications. With its ease of use, ease of integration, and compact design, the In-Sight 3D-L4000 offers the most competitive advantage on car inspection lines.