This page shows all inspection solutions for the paint shop

Production line of automobile plant, paint shop. Car body after applying the base paint.

Inspection solutions for the paint shop


  • Increased process reliability
  • Maximum product quality
  • Process monitoring: Counteract process weaknesses in time

Paint Shop

Boost customer satisfaction by increasing the degree of automation in your painting processes. You will also benefit from increased process reliability and outstanding quality.

As paint shop automation advances, ISRA's highly flexible robot guidance systems are your key to higher product quality and more efficient use of robots. QUISS products for precise inspection of PVC applications are the perfect complement to your system.

Our vision systems are specifically designed for position and location detection, paint and surface inspection, and process monitoring. They ensure robust, highly automated processes and guarantee maximum product quality.

Our body shop solutions are supported by our brands:

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PVC Seam Inspection

Paintshop PVC Seam inspection

Reliable PVC seams are essential to ensure high-quality results in vehicle production. RTVision is a flexible solution that can be perfectly tailored to different requirements. The system is particularly suitable for paint applications with large coverage areas. In these applications, RTVision reliably detects all PVC seam interruptions and deviations in width and position. The result is 100% quality throughout the production process. It achieves excellent contrast ratios even at long working distances and in stationary solutions.

These solutions are supported by our brand:

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Benefits

Higher production quality

Lower your total cost of ownership: Save costs and adhesive material by reducing rework and scrap parts

High productivity levels

Increased productivity with automated bead repair

Features, Typical defects and technical data

Features
 
  • Inspection of all conventional adhesive and sealant application types and colors 

  • Inspection of the continuity, width, and position of PVC seams

Typical defects

  • Gaps

  • Width deviations

  • Position deviations

Technical data
 
  • Accuracy in gaps: ± 0.5 mm

  • Accuracy in position: ± 0.1 mm

  • Accuracy in width: ± 0.1 mm

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Car Position Measurement

CAPMES UBC UBS

Robots in the production can only complete their task accurately with a reliable detection of the car body position in the cell.

The ISRA VISION Car Position Measurement (CAPMES) System is the industry standard on the market: it is easy to set up and ensures reliable, precise 3D recognition of the body position and orientation in stop & go operation or line tracking in the cell based on a combination of multiple cameras directed at certain features of the car body (e.g. holes, edges, corners) from various directions.

The 3D position of the body detected by the system is used to provide the off-set data to guide robots accurately in a downstream processing step. As a result, car body tolerances and mechanical position deviations can be compensated perfectly and a wide range of car body types can be accommodated on a single line.

Benefits

Fast and precise measurement of car body position for accurate robot guidance

Full flexibility for handling multiple car types in single production line

Reduced cycle time compared to mechanical fitting systems

Reliable function even under harsh conditions with built-in redundancies

Maximum uptime with automatic failed measurement recovery of alternate feature allowance

Features and technical data

Features
 
  • Reliable feature detection with HDR image capturing

  • Automatic calibration check and recalibration

  • Easy-to-use software with graphical user interface

  • Stop & go operation or line tracking 

  • Compatible with all common robot types

Technical data
 
  • Measuring time < 1 s with 4 cameras

  • Typical measuring accuracy of more than +/- 1 mm

  • Protection flaps for camera and lamps

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Cosmetic Sealing & Tool Inspection Box

Cosmetic Sealer

Different car models and complex parts geometries produced on the same line require precise robot guidance for high-quality application of beads. The accuracy of the robot applying the bead significantly increases the quality of the time-consuming sealing process for roofs, doors, hoods and flaps. 

The robot-mounted Q-GAGE3D sensor system determines the position and orientation of part contours for the application of fine and visible seams. The position deviations detected are used to accurately guide robots in the seam application. An additional gap check can be integrated prior to applicating the seam to further ensure the precise process. The Tool Inspection Box (TIB) automatically checks the nozzle for damage after each application to avoid scrap and damage to the car body.

The result is consistent quality, especially for all relevant visible seams. 

Benefits

Highly precise application of beads significantly increases productivity and fulfills the high demands in function, quality, and aesthetic

Reproduceable application of bead material within exact tolerances

Full flexibility for handling multiple car types in single production line

Automated teaching process reduces onsite commissioning and the integration time for new parts

Reduced preventive maintenance requirements

Features and technical data

Features
 
  • High speed image processing on integrated FPGA

  • Path correction software with almost NO Teach-In and Re-Teach Effort

  • Sophisticated Time Synchronization between Robot and Sensor

Technical data
 
  • Scan frequency up to 500Hz for robot speed of approx. 600mm/s possible

  • Measuring Principle​: Laser Line Triangulation​

  • Fast TCP/IP interface to send robot poses in interpolation cycle of robot (~10ms)

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Paint Inspection

Paint Inspection

The CarPaintVision (CPV) surface inspection system detects and classifies all relevant paint defects on car body surfaces in a cycle-time-neutral manner – on-the-fly or stop & go. With modern hybrid-technology, almost all car paint defects are detected at a rate of well over 98.5%. Inspection data is evaluated in the process cycle using proven algorithms and classified according to individual customer specifications. Defect information is immediately available for continuous optimization of the production process. Optionally, the detected defects can be automatically marked for rework in a downstream station.

Benefits

Objective and consistent evaluation of the quality of painted surfaces

Detects and classifies all relevant paint defects in a cycle-time-neutral manner

Fast cycle time: Complete car body inspection (< 60 seconds)

Fully automatable: 24/7 continuous operation

Process optimization thanks to real-time monitoring

Reduced personnel deployment

Features, Typical defects and technical data

Features
 
  • Vibration-resistant inspection technology for cost-efficient installations

  • Most flexible system for all car bodies 

  • Improved process optimization with 100% classification performance

  • On-the-fly and stop & go inspection possible 

  • Fully automatic robot path planning

  • Fully automatic defect marking unit available as an option 

Typical defects

  • Paint runners

  • Inclusions

  • Shallow Crater

  • Pinhole Crater 

  • Dent 

  • Bump 

  • Boilers

  • Scratches 

Technical data
 
  • Defect detection: ≥≥ 0.15 mm 

  • >>98,5% defect detection rate 

  • Topographical and non-topographical defects

  • 100% of relevant surfaces in one cycle

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Foam Insertion

Foam Insertion

Automotive manufacturers use PU foam to dampen the sound inside a vehicle’s cab and prevent road, wind, and engine noise from entering the vehicle interior. These foams are dispensed  into vehicle pillars inside the car body, doors, fenders, and other cavities with special application systems.

Mobile robot guidance systems enable the fast and accurate application of PU foams by detecting cavity openings unique to each car model. The STEREO3D sensor system determines the position and orientation of objects using identifiable features such as holes. The position deviations it detects are used to guide robots accurately in downstream processing steps. As a result, mechanical position deviations can be compensated perfectly. Furthermore, a wide range of product types on a single line can be accommodated. Depending on the application, multiple sensors can be combined as necessary.

Benefits

100% foam insertion on all cars

Full flexibility to handle multiple car types in the same line

Minimal effort for preventive maintenance

Features and technical data

Features
 
  • Automatic adjustment of the robot guidance

  • “Stop-&-Go” or “On-the-Fly” layout possible

  • Stationary sensor mounting

  • Simple and clearly structured GUI

  • All measurements are independent of the color or reflection properties of the components

Technical data
 
  • Stationary or robot-mounted

  • Flexible use for “stop & go”, “moving-line” and “on-the-fly” processing

  • Robot interface for all common robot manufacturers

  • Accuracy of 0.2 mm 

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Production Analytics

IQ-VIS

Ensure that your quality standards are met: With comprehensive visualization, analysis, reporting, and alerting tools, IQ-VIS enables live monitoring of ongoing production. The database system collects, consolidates, aggregates, and analyzes all results from the various measurement systems throughout a production facility.

IQ-VIS is an intelligent toolbox for a wide range of users, such as maintenance, operations, and management. The client-server architecture allows data to be accessed both locally and across plants.

This makes production more transparent and allows emerging trends to be visualized in the shortest possible time. Negative influences on product quality can be addressed immediately before quality problems cause additional costs.

Benefits

Control center function for real-time status visualization in the systems

Analysis function for conducting special comparisons, e.g. correlation analysis

Reporting function for automatically generating customer-specific reports

Customer service & training

Service

For the efficient and future-proof operation of your production systems our highly qualified service teams support you globally in all matters. We provide the implementation, maintenance and servicing as well as the analysis and optimization of your systems - quickly, reliably, 24/7. 

Visit our service center and request your customized service solution. 

Furthermore, learn in the ISRA VISION Academy how our competent trainers always keep your employees up to date with the latest knowledge so that system operators, product engineers and quality managers become real inspection experts.

Visit our ISRA VISION Academy and book your individual and scalable trainings.

Contact us

Iris Eppl

Technical Inside Sales

Frankfurter Straße 112
64293 , Darmstadt
germany