Automation - LMI Corporation

Automation
LASER-PRECISE MEASUREMENTS
for Gap/Flush
Overview
LaserGauge® Automation is a robotic system for measuring
vehicle gap/flush on a moving assembly line. It is costeffective, fast, flexible, and delivers LaserGauge® accurate
measurements.
Utilizing Cross-Vector scanning technology, the
LaserGauge® Automation System provides more surface
information around the edges of assembled panels than any
other robotic laser profiler. This is particularly important for
accurate gap and flush measurements.
The system is flexible. Measurement routines are
developed using the LGWorks software, then measurement
locations for each vehicle are taught to the robot.
Implementation is completed in a matter of days, not weeks.
The Automation software can be used with any brand of robot
and can support 2, 4, or more robots at the same time. It can
be installed by an outside integrator or the plant’s personnel.
Operating Features
Advanced Cross-Vector Measurement Sensor
The most innovative feature of the Automation system is the advanced Cross-Vector scanning sensor.
Traditional laser profilers utilize a single laser stripe coupled with a single imager to capture surface
scans, but a single view does not reveal surface points around the radius on the edge of the gap.
The Cross-Vector sensor utilizes
multiple lasers and multiple views at
crossing angles. This allows the sensor
to see around edges of the radius to
the vertical tangent and beyond. The
result is a complete surface profile and
the most accurate gap measurements.
This provides a higher density of points
around the edges for increased
accuracy and repeatability. No sensor
movement or rolling of the sensor is
required. The sensor is automatically
positioned into non-contact alignment
for each scanning location based on
real-time feedback from the vehicle
position and orientation detection
systems.
Proven LaserGauge Capabilities
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The LaserGauge® line of handheld inspection sensors has been serving automobile manufacturers for 15
years. The LaserGauge® Automation continues that functionality with
an automated gap/flush inspection system that is 100% compatible
with the measurement methodologies (Virtual Gauges) of other
LaserGauge® products.
Inspection routines are created and edited using the LGWorks
software. Virtual Gauges are configured specifically for each
measurement point and specification limits are
defined for each returned value. Detailed
graphics and on-screen messages indicate the
location and progress of the robotic sensor from
one measurement to the next. Complex
calculations referencing measurement data can
be processed in the routine and included in the
data file. All scans and numerical data can also
be saved and output to various formats, pushed
directly into the plant’s data handling system,
and/or passed to a Fitter’s Station for manual
refit of panels.
Flexible Robot Interface
Flexibility and ease of setup has been designed into the system. The Automation software and the robot
controller use two-way communications to control sequencing and operation. Use of an “AnyBus
Communicator” allows easy integration with any robot (ABB, Fanuc, Yaskawa, Kuka, etc.) and a special
TEACH MODE allows quick and easy sensor location on any vehicle. Development tools are available
from Origin Technologies Corporation for third-party integrators or for the plant’s robot programmers to
implement and support the system internally. Virtualization tools allow for the testing of the system before
installation is complete.
Real-Time Vehicle Position/Orientation Tracking and Path Correction
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As the vehicle moves into the
LaserGauge® Automation station, the
system receives the VIN and that is
used to identify the model of vehicle.
Data from the vehicle detection and
positioning/orientation systems along
with specific design information for
that model are fed into the
Automation software. The robot path
is corrected based on this vehiclespecific data. Real-time robot path changes allow the robot to
accurately position the LaserGauge® sensor at the correct location
even though the vehicle is moving or is in a different
orientation/position than when the measurement point was first
taught to the robot. Multiple safeguards are embedded into the
system to prevent the robot from colliding with the vehicle:
 Robot limits – configured by the integrator to limit the robot
to a specified operating envelope
 Software limits – can verify that the car moving into the
inspection station correlates with the VIN received.
 Physical collision detection/prevention – the LaserGauge®
measurement sensor is surrounded by a foam-covered protective cage that will detect when the
robot positions the sensor too close to the vehicle. If a collision is detected, the robot will
immediately E-Stop and halt the conveyor to prevent any damage to the vehicle.
Fitters Module
The Fitter’s Module accumulates and filters the measurement results from a LaserGauge® Automation
station and then displays the results on a separate monitor for the manual refitting of out-of-spec parts.
The fitter can use a handheld LaserGauge® inspection system for a secondary inspection or for
confirmation. Rescanned data can be logged and passed to the factory’s data handling system or it can
be archived. The Fitter’s module software runs on a separate PC from the LaserGauge® Automation
station.
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Advantages
Complete Surface Profile – The Cross-Vector approach
captures surface profiles around edges and down into the
gap. This results in the most complete surface profile and
most accurate measurements from a single scan. No need
for multiple measurement sensors or rotational scanning
motion to acquire a complete scan.
Speed – The scanning process is completed,
measurements calculated, results displayed in the data
table, and the scan plotted on the graph all in less than
one second. The non-contact sensor is able to move from
point to point while the assembly line is in motion.
Cost – The LaserGauge® Automation system is more cost effective than other robotic systems. Use of
plant preferred integrators or internal resources to install the system, the flexibility of the Automation
software, and the ease of setup/implementation all help to reduce the overall cost of the system.
Flexibility – Points can be added and deleted from existing routines, and new routines can be added using
the TEACH MODE, without having to involve the robot programmers. The LaserGauge® Automation
system supports one, two, or more robots.
Compatibility – All routines, virtual gauge definitions and, data output capability are 100% compatible with
all other LaserGauge® products.
Specifications
System Specifications
Measurement Speed
Robot Interface
1 second
Anybus Communicator module
Sensor Specifications
Accuracy
Communication Interface
Size/Weight
Power
Shock Protection
Environment
± 0.001” (±25m)
Ethernet
6.2lbs; 5.5” (w) x 6.75” (h) x 9.5” (l)
24V @ 1 amp
Cast urethane housing
0 – 70 C
101 N. Alloy Drive | Fenton, MI 48430
Phone 810.714.5811 | Fax 810.714.5711
sales@lmicorporation.com | www.lmicorporation.com
Our continuing commitment to quality products may mean a change in specifications without notice.
 LMI Corporation | Distributed by LMI Corporation | This system complies with 21 CFR Chapter I,
Subchapter J.

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