Eisenmann
An intelligent inspection technique for car body surface can assist customer to realize customized production of vehicles with high quality, and improve production efficiency.
The smallest irregularities in the coated surface are deemed to be faults and are unacceptable, both for customers and automobile manufacturers. For this reason, quality control in the paint shop is a high priority. While automation is continuing to progress, the human eye cannot be replaced in matters of quality assurance. For this, ergonomically well-equipped workstations are needed, such as Eisenmann VarioInspect LED light tunnel. VarioInspect is designed to facilitate and improve the final inspection process for body paintwork, and it also lowers total operating costs.
VarioInspect is a tunnel comprising vertically arranged lights. In the freestanding aluminum portals, workers are provided with all key utilities, such as water and compressed air, via supply lines in the floor. In conjunction with stationary or mobile tool trolleys, this allows them to immediately tackle any faults in the finish. VarioInspects open design conveys a pleasant sense of space, while reducing noise and echoes. Moreover, LED technology means only minimal heat generation, further contributing to a positive working environment. The continuous light strips, purpose-developed by Eisenmann in cooperation with external research organizations, create the ideal lighting conditions for checking the quality of paintwork.
The special Eisenmann LEDs (E-LEDs) are fully adjustable from warm white to cool white, and can therefore be tailored to specific process parameters, such as the color of the paint or the gloss level. Moreover, it is possible to control each light strip individually to achieve exactly the right illumination.
Defects in the paint, such as trapped dust particles, are identified by means of the reflected image created by the light tunnel: the vehicle body passes slowly through the tunnel, and the LED strip lights are reflected by the paint surface. The more clearly the light is reflected, the easier it is to detect faults where there is a transition from light to dark. With VarioInspect, the vertical arrangement of the lights means the reflected image comprises three bands, and it is possible to generate a variety of light colors.
Lower costs for reworking the paint finish of light-colored bodies
VarioInspect can cut the costs associated with reworking the paint finish of vehicles in final assembly by up to twelve percent. This is because the system's diverse control features allow the creation of working conditions tailored to the needs of individual inspectors and to the specific process. As a result, they can find and correct more faults while the body is still in the paint shop.
Lower maintenance effort and electricity consumption
VarioInspect can deliver maintenance cost savings of up to 57 percent compared with conventional light tunnels. The lower expenditure is a result of the extended life of the LED lights and the easy-to-replace external mains adapters. The LEDs deployed on VarioInspect last twice as long as the fluorescent tube lights previously employed. Moreover, they weigh a maximum of ten kilos, and are therefore relatively light and easy to handle, reducing the manual effort associated with maintenance tasks.
VarioInspect also reduces electricity consumption by up to 35 percent - LEDs are inherently energy-efficient, and can be dimmed, i.e. when there is no vehicle body in the tunnel.
Varioinspect – for the smart factory
Based on the rising demand on individuation and customization, smart factory can produce not only multi-vehicle models and vehicle models of multi-platforms, can also improve quality of automobile, and reduce manufacturing costs. VarioInspect can be used to improve production efficiency as it facilitates and improves body paint inspection.