In the past decade, automotive manufacturers have been exploring various measurement techniques to enhance product quality, shorten time-to-market for new models, and streamline production processes. On one hand, reliable metrology methods are used to detect, analyze, and sample issues during measurements or in real-time on the production line. On the other hand, when a quality issue arises, online control systems can respond quickly, but they often provide only limited accuracy and size data.
Most manufacturers and suppliers currently rely on a mix of on-site and traditional measurement approaches. However, this combination often leads to overlapping efforts and challenges in efficiency and consistency. The emergence of new technologies, such as non-contact optical scanning heads, has expanded the capabilities of traditional measuring machines. These advanced scanning heads, initially used manually, have evolved into semi-automatic units and are now widely applied in the automotive industry for tasks like prototype testing, sheet metal stamping, and body-in-white measurements. Over time, the shift toward fully automated and online measurement systems is reshaping traditional metrology practices.
Hexagon Metrology’s newly launched 360° Smart Inline Measurement Solutions (360° SIMS) is designed to seamlessly integrate into automotive production lines—whether during trial runs, mass production, or development phases. This solution supports 100% full-surface and key feature inspection of bodies, components, and sub-assemblies, helping automakers achieve superior online measurement performance and ensure high-quality output throughout the production process.
**Bridging the Gap Between Measurement and Process Control**
The 360° SIMS solution addresses numerous challenges, including 100% component and sub-assembly measurement within the production cycle, 24/7 operation in harsh environments, and full integration with automated production lines. It enables real-time process control, offering a powerful method for monitoring and managing quality. By combining advanced 3D metrology with process control techniques, Hexagon provides a comprehensive system that integrates measurement and control functions, allowing both online and offline measurement and adjustment.
The 360° SIMS relies on several key technologies:
- Industrial-grade robots for flexible sensor positioning
- Photometric measurement systems for surface analysis
- A specialized software package for enterprise-wide measurement operations
- Integration with automation and plant control systems
- Proprietary software for visualizing and reporting color difference data
The system is highly adaptable, with configurations tailored for different environments and applications. It includes robotic systems equipped with white light photometric sensors, powerful point cloud processing software, and all necessary automation tools for efficient measurement. Available options include online, in-line, and off-line setups, supporting applications across press shops, body shops, and final assembly plants.
**Online Measurement Enhances Efficiency**
The 360° SIMS system introduces several patented innovations, such as alignment tools for large components and advanced software for analyzing massive datasets. Fixed optical sensors are used to measure hidden features or critical points on the vehicle body, enhancing the accuracy of the measurement process.
The system is largely automated, requiring minimal training for operators to monitor the entire process. Simple visualization tools allow quick identification of quality issues, enabling faster problem resolution at the production site. This makes it easier to track quality from the start of a new product launch through pilot production and into full-scale manufacturing.
**The Future of Manufacturing**
Based on customer feedback, the implementation of 360° SIMS has led to significant improvements in efficiency, speed, and the ability to resolve issues quickly. It also offers cost savings, operational flexibility, and the capability to measure multiple models, supporting product upgrades and reducing time-to-market for new vehicles.
"Hexagon's 360° Smart Inline Measurement Solutions represent a new era in automotive metrology, providing manufacturers with deeper insights and actionable data to accelerate production and improve quality monitoring," said Giacomo Barilà , Director of Operations at Hexagon Metrology Automation Solutions. "This marks a major step toward the digital factory of the future, delivering a fully automated, high-speed measurement system that brings new levels of quality insight to OEMs and Tier 1 suppliers."
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