Feature Thermal imaging & vision systems Visualising car production
With quality control essential during car manufacturing, both BMW and Fiat are using FLIR Systems thermal imaging cameras for reliable and cost-efficient inspection processes
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t the BMW manufacturing site in Dingolfing, Bavaria, all vehicles are subjected to numerous quality control measures. The goal here is cost- and time-efficient automated testing, so identifying the optimum proce- dure for each inspection task is a priority. Testing exhaust flaps is a prime example, as not all models with dual exhaust systems operate the same. While twin tail pipes are common on BMW’s with V8 engines, with the M5 the exhaust flap on the second tail pipe is only activated at a specified RPM. The inspection method therefore has to be flexible enough to allow the specific characteristics of each model to be checked. As a solution, BMW has been using thermal imaging for many years to visualise the thermal profile of the tailpipes in the dual pipe exhaust system against the specification of each model.
imaging cameras are again being used.
A new imaging solution Historically, each dynamometer test rig was fitted with two thermal imaging cameras, mounted to inspect the left and right tail pipes from above and the side. This, however, was an expensive solution, with costs increasing over time as the models chosen required frequent repair. To overcome this, Robert Halbritter of FLIR Systems’ sales partner and integrator TOPA, suggested a solution that would halve the cost of the new camera hardware while improving reliability. For each dynamometer, he recommended the use of a single, fixed mounted FLIR A-Series thermal imaging camera with a wide angle 45˚ lens to cover the field of view previously provided by two cameras. Positioned centrally on the rig, the camera would be able to image the entire end of the vehicle from a distance of approximately 2m.
BMW was already experienced with FLIR thermal imag- ing cameras, having used them for predictive maintenance of electrical switchgear since 1997, and this new proposal also proved attractive due to the promised cost and perfor- mance gains.
The A-Series camera generates an analogue thermal imaging
video signal with a frame rate of 30Hz, which is ideal for recording exhaust flow. Furthermore, it provides multiple connection options, has a digital output for alarm activa- tion and for controlling external devices, supports both GigE Vision and GeniCam protocols, and data is transmit- ted via TCP IP or Ethernet.
The cameras have been installed on each of the dynamome-
ter rigs, transmitting real-time images of the exhaust systems to a monitor at the front of each vehicle, enabling the inspector to see if the flap is functioning properly from changes in the thermal profile. These are working reliably 24/7, enabling continuous inspection.
Monitoring adhesive curing at Fiat Another manufacturer that has selected thermal imaging solu- tions from FLIR is Fiat. As with many other manufacturers, the company uses bonded composites to achieve both strength and low weight. To achieve the optimal bond between the structural layers, induction heating is used to cure the adhesives at temperatures between 150˚ and 180˚C, and the thermal efficiency of the process has to be carefully monitored. If one, or more, of the adhesion points fails to reach cure temperature, there will be a serious weakness in the panel or component. To help here, FLIR A-Series thermal
Instrumentation NOVEMBER 2013
If the induction heating process fails to reach the correct temperature, an alarm will sound to indicate an unsuccessful bond. The component is then discarded.
The FLIR Software Development Kit allowed an interface to be created for the A-Series camera to acquire thermal data from the induction heating process. This data is needed for accurate process control and traceability.
Fully radiometric video footage from the camera is trans- ferred to the control system via GigE Vision, an interface that allows fast image transfer using standard cable over long distances.
Additional measurement points can be easily added to the Fiat system at any time, allowing the system to be changed in accordance with new car models and future production needs. With new cars containing an increasing number of bonded joints, this is an important facility both in terms of quality control and production efficiency.
FLIR Systems T: 01732 220011
LIR Systems has launched a new series of feature-packed yet cost-effective entry-level thermal imaging cameras, plus a new range of cameras for those who want more than an entry level device, but not all the features that characterise its professional models. The entry-level and cost-effective cameras are lightweight yet easy to use. The Ex-Series devices (models E4, E5, E6 and E8) are described as ‘true thermal imaging’ cameras, and feature the company’s patented MSX-technology for real-time pin-sharp thermal images, quicker target orientation and clean reports. They also include a built-in visual camera, multi spectral image storage and analysis tools. For those who want more than an entry level thermal imaging camera but not the sophisticated
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features that characterise its professional models, the company is also offering the Exx-Series. There are three models available – E40/50/60 – with the top of the range providing a resolution of 320 x 240 pixels. All three feature MSX technology. These advanced cameras are thermally tuneable and manually focusable, and are said to offer exceptional imaging quality and standard features such as continuous zoom, thermal fusion, text/voice annotation, WiFi and Meterlink. These also have an intuitive keypad, touch screen and menu; and the system allows the thermal, visual, MSX and picture-in-picture images to be saved with one click. All thermal data is automatically embedded and the image can also be edited in the camera.
Full information can be found on
www.connectingindustry.com 17 Enter 657
www.flir.com Introducing new feature-packed thermal imagers
Thermal imaging at Fiat shows
induction heating at work. Here, metal parts heat up from room temperature to 180˚C in seconds
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