Mapvision Quality Gate 400 Series is the fastest in-line inspection system for car body and chassis components available today. It can measure complex welded assemblies like cross car beams, subframes and axles within the line cycle time, typically hundreds of 3D features (x,y,z) in less than 30 seconds. Technology highlights Photogrammetric measurement Mapvision RAIC multi-camera system with static cameras and LED illumination system Software-based solution: No robots or other moving parts involved in measurement Technology benefits Fastest in-line measurement with CMM-comparable results Unique Mapvision QI function indicates quality of each measurement Stable calibration Software alignment does not require accurate positioning of the part Unique flexibility: Can inspect different variants in one system Can inspect two completely different parts in parallel using the double shuttle solution en
A typical 400 Series system installed on a welding line with a subframe loaded into the Gate Unit. After the door closes, Quality Gate will take measurement images, the door will open and the robot will remove the part. Cycle time Typically 30 seconds in automatic operation, depending on line automation and part loading Measurement capability Repeatability: ~ ± 0.0 mm with production parts Correlation to CMM: ~ ± 0.1 mm with production parts Verified with MSA Type-1 and Type-/3 studies, using production parts Maximum size of measured part Standard system: 1500 x 900 x 600 mm (length x width x height) Customised solutions allow even larger parts to be inspected Number of inspected features As many as needed, typically 50-00 features Inspections 3D measurement with x,y and z data on each feature Calculation of angles, distances, etc. Visual inspection with presence and orientation of components, like weld nuts, weld studs and clip nuts Parts to be inspected Cross car beams: welded steel, welded aluminium, die cast magnesium Subframes: welded steel or aluminium Twist beam axles with camber and toe measurement Other body and chassis parts with similar characteristics
Quality Gate can inspect every feature of every part that you produce. We call this Mapvision 100% x 100% inspection. This gives you a completely new way to optimize your operation and to reduce quality-related costs. Mapvision 100% x 100% inspection changes the way you think about line adjustment. With Mapvision Quality Gate, you will adjust your process quickly and efficiently Adjusting a complex welding process using traditional measurement systems is timeconsuming and uncertain. When the data for adjustments comes from an in-line system, everything gets quicker and simpler. Adjusting your line to nominal eliminates systematic errors in your process. - Your new line will produce green parts quicker than ever before - You can keep you process in nominal - An efficient process allows more variation and reduces waste - Troubleshooting with 100% x 100% data allows you to solve production issues more effectively An important additional benefit is that 100% measurement eliminates the requirement to maintain a capable production process. No sampling means no process capability analyses are needed. This saves a considerable amount of your time and resources. You will deliver only good parts In reality, random errors still occur, for many reasons. Therefore, the only way to prevent shipping bad parts is to use 100% x 100% inspection data to detect them. This brings you very close to zero-defect deliveries. - No direct external quality-related costs - Happy customers and more good business Well-adjusted process + 100% final inspection = peace of mind 3
Main system components 1) Gate Unit ) Automatic door 3) Electrical cabinet 4) Control Unit The electrical cabinet and Control Unit can be adjacent to or freestanding near the system. The picture shows the top view of a Quality Gate unit with two automatic doors for loading and unloading from either long side of the system. 1 3 4 System Configurations D1 4 A One door, automation interface One robot loads the part from one side. AD 4 Two automatic doors, automation interface One robot loads the part from one side and a second robot unloads the part from the other side. This speeds up the operation cycle. S1 4 DS A Single shuttle, drive system, automation interface One robot loads the part onto a fixture on a shuttle. This is for when the robot cannot access the system to place the part inside the Gate Unit. S1 4 DS HMI Single shuttle, drive system, manual operation with HMI kit A human operator loads the part manually and runs the shuttle with command buttons. S1 4 M Single shuttle, manual operation A human operator loads the part manually and runs the shuttle manually. S 4 DS A Double shuttle, drive system, automation interface Two robots, one on each side, load two different parts. This is to inspect two different parts in parallel. S 4 DS A Double shuttle, drive system, manual operation with HMI kit Human operators load the parts manually and run the shuttles with command buttons. This is to inspect two different parts in parallel. S 4 M Manual double shuttle 4 Human operators load the parts manually and run the shuttles manually. This is to inspect two different parts in parallel.
Mapvision Result Suite software is the key to understanding and using the in-line measurement data provided by your Quality Gate system. It is intuitive and user-friendly, transforming the measurement data into a clear picture of your production process. The information it provides allows you to adjust your process efficiently and verify the results quickly. Our Green Part Program provides training and consultation services to ensure that you get the full benefits of your system. We will be on-site to train and assist you until you can use Quality Gate to adjust your line efficiently and produce consistently good parts. After that, we can visit you whenever needed, and help you online with our remote support services. Our maintenance and support service MAPcare keeps your Quality Gate system in efficient working order over its entire lifetime. The service includes programming adaptations, annual maintenance, software upgrades and remote technical support. Mapvision Ltd. Ruosilantie 10 FI-00390 Helsinki, Finland Tel. +358 08 389 389 sales@mapvision.fi www.mapvision.fi VAT N FI0660331 400 Overview 017-01 en Copyright Mapvision Ltd. 017. All rights reserved. Mapvision, MAPcare, Quality Gate and RAIC are registered trademarks of Mapvision Ltd. Mapvision operates a policy of continuous development. Mapvision reserves the right to make changes and improvements to any of the products described in this document without prior notice.