gom automotive testing

GOM mbH

Optical Metrology in Automotive Testing

June 2014

2-Frame Setup / Frame 2 2-Frame Setup / Frame 1

3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3

Optical Metrology in Automotive Testing GOM

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Optical Metrology in Automotive Testing Agenda

GOM: Optical Measuring Techniques

Dynamic 3D-Deformation/Motion Analysis

Static 3D-Deformation Analysis

Full-field 3D Coordinate Measurement




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GOM – Optical Measuring Techniques Company structure

· Development, manufacturing and sales

· Over 300 employees

· 7 GOM branch offices in Europe

· 45 dedicated partner offices worldwide

· More than 7,000 installations

· Measurement technology for companies from the automotive and aerospace industries as well as from the consumer goods sector

GOM is a global partner for optical 3D metrology with over 20 years' experience




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GOM – Industrial 3D Metrology Measurement systems

Full-field

3D Digitizing

ATOS

3D Shape and Dimension Inspection

Material Testing

Dynamic Component Testing

Full-field

3D Strain Measurement

ARAMIS

Deformation Analysis in Sheet Metal Forming

ARGUS

Mobile

Optical CMM

TRITOP

Dynamic

3D Analysis

PONTOS




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GOM – Industrial 3D Metrology All under one roof

Support Training Sales Production Development

Inhouse development,

production, sales,

training concept & support




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GOM – Industrial 3D Metrology Solutions from a single source

ATOS Professional

ATOS 3D measurement system

Free software

Tool & mold making

Injection molding

Sheet metal forming

Parametric software

Integrated processes from data acquisition to evaluation and application

3DMesssysteme 3D software Industrial know-how 3D measurement systems

Optical Metrology Systems Overview




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Optical Metrology in Automotive Testing Application areas and results

3D geometry measurement Shape and dimension inspection

Material testing Material parameters

Component testing Simulation comparison




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Optical Metrology in Automotive Testing GOM measuring systems

Component testing

ATOS

ATOS ScanBox

TRITOP

ARAMIS

PONTOS

PONTOS

ARAMIS

TRITOP ARGUS

3D geometry measurement Material testing




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Optical Metrology in Automotive Testing GOM measuring systems and evaluation software

Viewer and evaluation software

ATOS

ATOS ScanBox

TRITOP

ARAMIS

PONTOS

PONTOS

ARAMIS

TRITOP ARGUS

Component testing

3D geometry measurement Material testing

ATOS 3D Scanner Full-field 3D Coordinate Measurement




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Full-field 3D Coordinate Measurement Fringe projection technique: ATOS 3D digitizer

· Optical 3D scanner for three-dimensional component measurement and inspection

· Non-contact and independent from object size, surface characteristics and component complexity

· Full-field, precise 3D coordinates

· Injection molding and plastics industries

· Sheet metal forming industries

· Casting industry

· Tool and mold making




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Full-field 3D Coordinate Measurement ATOS: Measurement process in three simple steps

Step 1 Measurement

Step 2

Alignment

Step 3

Evaluation

All 3D measurement data and

inspection results in compact

format for exchange and further

analysis

Colleagues and customers Free GOM Inspect software




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ATOS 3D Digitizer 3D measurement data for follow-on processes

3D Mesh (STL)

High resolution for finest details

Measurement of small radii CNC Machining

Data for follow-on processes

Quality Control

Additive Manufacturing

Reverse Engineering

TRITOP Static 3D Coordinate Measurement




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TRITOP 3D Measuring system for static deformation analysis (point-based)

TRITOP

Static deformation analysis

· Measurement of individual points

Measurement and evaluation of

· 3D coordinates

· 3D displacements

· Vector fields

· Visualization of results on CAD data and camera images

Replacing

· Conventional distance sensors

Movement and deformation analysis




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TRITOP 3D Measuring system for static deformation analysis (point-based)

Load tests

· Thermal = climate chamber

· Mechanical = rigidity analysis

Deformation analysis

· Before/after assembly

· Impact of joining process

Inspection and optimization of

· Material/material combinations

· Design and structural analysis (construction)

· Mounting concepts

TRITOP

Assembly: joining process and distortion

Component tests: distortion/failure, static loads

Load tests Design CAD

Mold & tool making

Simulation Injection-molded parts

Assembly




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TRITOP – Static 3D Deformation Measurement Environmental Testing of Components

· System: TRITOP High Resolution

· Environmental-testing of the Front End in a climate chamber.

· Temperature range: 20°C – 85°C

· Reference temperature at 20°C

· The Front End stays for several days in a climate chamber at a given temperature.

· After that the Frond End is measured again at reference temperature to determine the deformation.




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· Measuring the gap size change an the flush change.




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· Measuring the gap size change an the flush change.

PONTOS Dynamic Deformation Analysis




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PONTOS 3D Measuring system for dynamic deformation analysis (point-based)

PONTOS

Dynamic deformation analysis

· Measurement of individual points


· 3D coordinates

· 3D displacements and deformation

· Speed, acceleration

Replacing


· Acceleration sensors for low-frequency applications

Dynamic component behavior

· Static to highly dynamic

· 6 DOF analyses

Validation of FE simulations




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PONTOS – Dynamic Deformation Analysis 3D Measuring system for dynamic deformation analysis (point-based)

Typical Appilications:

· Door, hood and closures tests on vehicles

· Measurement of the dynamic engine motion and deformation

· Crash applications such as head impact, leg impact and pendulum tests

· Vibration analysis of vehicle components

· Measurements of movements of vehicle components

· Deformation measurements of suspension components

· Deformation measurements on engine test bench

· Stiffness measurements of components




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PONTOS – Dynamic Deformation Analysis Door Slam Analysis

Application: Door Slam

· Determination of door deformation during the door slam process

· Behavior of the door lock mechanism

· Compression of the seal aproving door seal concept

· Determining the closing speed

· Determination and optimizing steps for reducing the Door closing speed

∙ About 80 3D measurement points ∙ Setup time: about 40 minutes




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· Measuring Frequency 500 Hz

· Evaluation time: about 10 minutes




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· CAD

· Comparison to CAD

· Link CAD meshes to components

· Animation




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PONTOS – Dynamic Deformation Analysis Crash Testing: Sled Crash

· Speed analysis of different components

· 3D movement of components

· Deformation of components

· 6-DoF (Angle) analysis of components

· Trajectories of components




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PONTOS – Dynamic Deformation Analysis Crash Testing: Sled Crash

ARAMIS Full-field Deformation Analysis




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ARAMIS Measuring system for dynamic deformation analysis (full-field)

ARAMIS


· Full-field measurement


· Full-field 3D deformation

· Full-field strain

· Material parameters

Replacing


· Strain gauges

Dynamic component behavior

· Static to highly dynamic

· Bulge tests and failure analysis

Definition of material parameters and validation of FE simulations




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ARAMIS Application: Determination of material parameters

Parameters for virtual development

· Material characteristics (e-module, anisotropy, …)

Local measurement for precise determination of material parameters

· Tensile, pressure, shear, bending tests

High-resolution, non-tactile measurement

· Detailed full-field information

Inspection and optimization of

· Input parameters for simulation

· Simulation results

· Product development

ARAMIS

Determination of material parameters


Mold & tool making


Assembly




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ARAMIS Application: Determination of material parameters


Mold & tool making


Assembly




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ARAMIS Application: Component Testing with static and dynamic loads


· 3D displacement and deformation

· Strain and failure behavior

Optimization of

· Component reliability and construction

· Material/material combinations

· Function inspection

Comparison with FE simulation

Load tests Mold & tool making


Assembly Design CAD




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ARAMIS Airbag Testing

· Measuring the Airbag deployment to evaluate the deformation of the cover from the passengers airbag

· Evaluate the speed and strain of the cover from the passengers airbag



Assembly Design CAD




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ARAMIS Airbag Testing

· Measuring the Airbag deployment to evaluate the deformation of the cover from the passengers airbag

· Evaluate the speed and strain of the cover from the passengers airbag



Assembly Design CAD




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ARAMIS Tire Testing

· Measure the deformation of tire wall

· Determine strain of tire wall

· At speed from 0km/h up to more than 300km/h

· At different wheel loads




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ARAMIS Tire Testing




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ARAMIS Tire Testing

ARAMIS System an Rollenprüfstand

Summary




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Static and Dynamic Load Tests on Plastic Components Summary

Static and dynamic

deformation analysis

· Point-based and full-field

Replacing conventional distance sensors

Comparison with simulation

· Point-based and full-field

Optimization and acceleration of the development process

ARAMIS PONTOS TRITOP ATOS

Component

Thank you for your attention

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