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TubeInspect

TubeInspect – Efficient quality assurance for tube and wire manufacturing

About AICON

• Founded in 1990 as a spin-off from Volkswagen

R&D and the Technical University Braunschweig by Carl-Thomas Schneider and Werner Bösemann

• Sites:
• Braunschweig, Germany (Headquarters)
• Meersburg, Germany (Scanner Innovation Center)
• More than 120 employees
• As of April 1st, 2016, part of Hexagon Manufacturing

Intelligence with more than 5,500 employees

Product Lines for Inspection, Testing, and Reverse Engineering

TubeInspect

Tube and wire measurement with optical gauge

MoveInspect Technology

Modular portable coordinate measurement technique

AICON Scanner

Surface scanning of complex geometries

Do you want …

INTRODUCTION

• ... to speed up tube and wire inspection?
• ... to avoid the multitude of mechanical gauges?
• ... a true 3D CAD comparison?
• ... to increase the efficiency of your bending machines?
• ... to create data from samples with the help of an easily operated

system?

Then use TubeInspect for your production

INTRODUCTION

• As an optical gauge
• Avoids mechanical gauge investments
• As tube and wire measurement system
• Profit from the measurement in a split second with nominal-actual comparison
• For reverse engineering and prototype manufacturing
• Ascertain the 3D-geometries of model parts for the construction or immediately generate

a bending program.

• For setup and correction of bending machines
• Significantly reduce your set-up time and turn downtime into productive time

TubeInspect measures your tubes and wires!

INTRODUCTION

thin flexible brake lines cooling tubes freeform tubes plastic tubes wires brackets and fittings exhaust pipes engine tubes

TubeInspect

System components

• High-resolution digital cameras

acquire the tube details

TubeInspect exposure technique

SYSTEM COMPONENTS

• The transmitted light assures

equal conditions of brightness

TubeInspect exposure technique

SYSTEM COMPONENTS

• Very precise reference points

guarantee reliable measuring results even in a rough production environment

TubeInspect exposure technique

SYSTEM COMPONENTS

Central data administration around bending process

• Nominal data administration
• Supervising of bending process
• Storing of measurement results
• Network with benders
• Possibility to connect with SPC

software

BendingStudio – Solutions for better bending

SYSTEM COMPONENTS

TubeInspect

Measurement principle

• The tube is captured in high

definition by multiple cameras

Automatic extraction of the tube/wire shape

MEASUREMENT PRINCIPLE

• Detection of 3D cylindrical module
• Automatic detection of the

bending points and bending elements

• Automatic comparison between

nominal and actual module for calculating the gauge fitting

Automatic extraction of the tube/wire shape

MEASUREMENT PRINCIPLE

• Measurement results
• Bending coordinates
• Bending elements
• Optical gauge inspection as sheath

deviation

• Correction data for the bending

machines

• Reports
• Stored in internal database
• Can be exported into different formats
• Interface to SPC software available

Automatic extraction of the tube/wire shape

MEASUREMENT PRINCIPLE

TubeInspect

How can TubeInspect be applied in production?

How can TubeInspect be applied in production?

Application as optical gauge

• A mechanical gauge checks the

installation capability

• Disadvantages:
• Inflexible because it is

part-specific

• User-dependent measurement

results

• Regular review, purchasing,

storage and handling causes high costs

TubeInspect replaces mechanical gauges

TUBEINSPECT AS OPTICAL GAUGE Mechanical gauge An OK part fits into the gauge

• Sheath deviation:

Result documents the accuracy of gauge fit

• Comprehensive measurement

protocol documents the dimensional accuracy

• Graphical nominal to actual

comparison facilitates the fault analysis

TubeInspect replaces mechanical gauges

TUBEINSPECT AS OPTICAL GAUGE Optical gauge testing – Sheath deviation Optical gauge: Air of the gauge is displayed as sheath deviation in a bar shard.

What is the sheath deviation?

TUBEINSPECT AS OPTICAL GAUGE

Inspection criteria – part-specific sheath deviation

TUBEINSPECT AS OPTICAL GAUGE 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

Inspection criteria – functional dimensions

TUBEINSPECT AS OPTICAL GAUGE Parallelism Distance to plane

Integration into a robot-assisted production center

TUBEINSPECT AS OPTICAL GAUGE

How can TubeInspect be applied in production?

Application as tube and wire measurement system

• User independent measurement

results

• Measurement accuracy:

to ± 0.035mm

• Part specific alignment
• Interface to SPC software

 Result: Extensive measurement reports

Functions and features

APPLICATION AS MEASUREMENT SYSTEM

How can TubeInspect be applied in production?

Application for Reverse Engineering

TubeInspect generates 3D-Geomtries easy and fast

APPLICATION AS REVERSE ENGINEERING

Sample Reverse Engineering Manufacturing Serial monitoring

Your benefits at a glance!

APPLICATION FOR REVERSE ENGINEERING

• Contour capture of samples within seconds
• Automatic generation of bending data
• Monitoring of the prototype manufacturing

 TubeInspect offers flexibility even at the smallest batch sizes!

How can TubeInspect be applied in production?

Set-up of bending machines

Part out of tolerance!

Step 1: Analysis of the first part

SET-UP OF BENDING MACHINES

Data transfer via TCP/IP- network

Step 2: Transfer of TubeInspect correction data

SET-UP OF BENDING MACHINES

Part within tolerance!

Step 3: Control for production release

SET-UP OF BENDING MACHINES

Your benefits at a glance!

SET-UP OF BENDING MACHINES

• Automatic calculation of the correction data
• Fast correction even on long tubes up to a length of 7m
• Simulation module with virtual gauge inspection reduces

bending trials to a minimum  Noticeable cost savings by the shortened set-up time and reduction of reject

TubeInspect

BendingStudio – Solutions for better bending

• Importing of IGES or STEP files
• Wizard for selecting tube´s

geometry semi-automatically

• Calculating the bending data

(P/B/R) respectively x, y, z of bending points

CAD-WIZARD – extracting bending data of CAD model

BENDINGSTUDIO – SOLUTIONS FOR BETTER BENDING

Step 1: measuring section 1 Step 2: measuring section 2 Overlapping area enable step 3:

• Automatic combination of

measurement section 1 & 2

• Calculating and output of the

result of the complete measurement

Measurement of long parts by pursuing

BENDINGSTUDIO – SOLUTIONS FOR BETTER BENDING

Step 1: controlling intermediate steps

• Proving of separate parts

Step 2: end controlling

• Proving of the correct assembled

branched part

• Gauge controlling of end

products

BRANCH – measurement of branched tubes and wires

BENDINGSTUDIO – SOLUTIONS FOR BETTER BENDING

TubeInspect Adapter

• Control the position and direction
• f holders and fittings
• Controlling of distances and

angles of assembled parts

ASSEMBLY – parts with brackets and fittings

BENDINGSTUDIO – SOLUTIONS FOR BETTER BENDING

Network of BendingStudio connects your plants!

BENDINGSTUDIO – SOLUTIONS FOR BETTER BENDING

Plant II – Quality department Plant I – Production planning Plant I - Production Plant II - Production Head quarter - Management Company´s central server Company´s central back-up

TubeInspect

Reference customers

• More than 320 installations! -

• Very fast and effective process

control thanks to extremely short measuring time

• Significant decrease of costs due

to reduced number of deficient parts

• Dramatically reduced set-up time
• f the bending machines -

additional free machine capacities mean hard cash to the companies

Small and medium-sized tube manufacturers

REFERENCE CUSTOMERS

• Accuracy advantage typically 5

times better repeatability compared to an articulated arm

• TubeInspect reduces the reject

considerably

• TubeInspect assures an efficient

production also in case of small batches

Aerospace industry

REFERENCE CUSTOMERS

• Wide measurement range assures

flexible application

• Only one measuring system for

several bending machines

• Fast “return on investment” due

to reduction of material consumption, faster set-up and waiving of gauges

Automotive industry

REFERENCE CUSTOMERS

TubeInspect

Products

TubeInspect - and which system do you need?

PRODUCTS

TubeInspect P8 TubeInspect P16

TubeInspect - and which system do you need?

PRODUCTS

Model Measuring volume [mm] Maximum measurable tube lengths Measurable tube diameters Accuracy

TubeInspect P16 2,600 x 1,250 x 700 7m 3.0 – 200mm ± 0.085mm TubeInspect P8 1,000 x 580 x 400 2m 1 – 125mm ± 0.035mm

Thank you for your attention!