STEINBICHLER

ABISOPTICALSURFACEINSPECTION

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25 YEARSOF INSPIRING INNOVATION

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EXPERTISE AND EXPERIENCE IN OPTICAL 3D MEASUREMENTTECHNOLOGY

25 years of experience and expertise in

the field of optical measurement and sen-

sor technology have shaped the success

story of Steinbichler Optotechnik GmbH.

We develop and manufacture all Stein-

bichler products at our central location

in Neubeuern. Thus, our customers ben-

efit from the quality “made in Germany”.

No less than 170 patents prove the in-

novative strength of our company.

In close cooperation with renowned

partners from science and indus-

try, our highly qualified employees

develop practical and user-oriented

solutions for various applications and

sectors.

We set standards in optical 3D

measurement technology, focusing on

innovation and precision as well as

flexibility and openness toward new

approaches.

The technical advantages of our systems

also provide economic and ecological

added value. For example, with our

ABIS sensors for surface inspection, we

offer outstanding quality assurance tools

that help to use costly resources and raw

materials in a highly efficient way.

Using state-of-the-art technologies from

Steinbichler, our customers ensure their

product quality at the highest level.

Our ABIS systems contribute to improv-

ing and maintaining a high level of product

quality in various fields of application,

particularly in safety-critical sectors such

as the automotive industry.

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The surface quality of a product - particularly in the automotive industry - consti-

tutes an important criterion for the customer and is generally seen in close relation

to the quality of the overall vehicle.

Even minimal inevitable disturbances in the early production stages prior to

applying the paint work (e.g. in the press shop or body shop) may cause defects

such as dents, bumps, sink marks, etc. that are invisible to the eye while the

surface is still unpainted. On a high-gloss paint surface, however, even the slight-

est irregularities are clear to see with incident light from the proper angle, and

constitute a reduction in quality that can only be remedied using costly correc-

tive measures.

The early, continuous and complete detection of surface defects with the objective,

high-precision ABIS surface inspection system opens up new perspectives in quality

assurance.

Available in different versions and system concepts, the ABIS systems allow the fast,

reliable and ultra-accurate detection of defects on sheetmetal parts or bodies-in-

white. Time-consuming and thus expensive rework in subsequent process steps,

e.g. at the finish belt, can be efficiently reduced.

Numerous renowned automobile manufacturers have implemented the ABIS

surface inspection system with great success in a wide variety of custom con-

cepts tailored to their press shop environments. These offline systems are ideal

not only for ongoing auditing at regular intervals during the manufacture of a

press lot, but also for checking the first sheet metal parts after a tool change.

ABIS - OPTICAL SURFACE INSPECTIONOBJECTIVE AND EFFICIENT QUALITY CONTROL

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EARLY DEFECT RECOGNITION FOR COST-SAVING AND RESSOURCE-EFFICIENT PRODUCTION

The majority of defects that can occur during the production process are “invisible”

at the early stages of manufacture. These minute surface defects become visually

perceptible later on, however, when subsequent work steps such as paint work

have been completed. At that time, they can only be remedied using expensive

corrective measures.

The costs of removing these defects increase drastically with the progress of work

within the production cycle (press shop, body shop, paint shop, final assembly). Conse-

quently, particularly the rework of defects that have been propagated throughout the

production process constitutes a substantial factor with regard to manpower and time.

Quality control with ABIS substantially optimizes the sustainability of the produc-

tion processes by significant savings of work ressources and raw materials such

as sheet metal and coatings - environmentally friendly and economically efficient

high-end technology.

LATE DETECTION AND CORRECTION OF SURFACE DEFECTS CAUSE HIGH COSTS

PROCESS CHAIN

PRESS SHOP

BODY SHOP

PAINT SHOP

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fact

or 1

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Hubert LechnerSales Surface Inspection

„The ABIS surface inspection system has been

approved and fully accepted by our customers as

an efficient measurement tool in press shops and

body shell work.

Featuring a high measurement repeatability and

providing objective inspection results (defect

classification), the systems also score high with

the extremely short measuring times compared

to manual audits and offer high performance for

design-oriented, complex surface shapes.“

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DETECTION OF ALL RELEVANT DEFECT TYPES WITH ABIS IIOBJECTIVE AND FAST MEASUREMENT WITH MODULAR SENSORS

With the ABIS II sensors, a wide range of defect types can be detected. Featuring a reliable,

early recognition and classification of dents, bumps, sink marks, waviness, constrictions, cracks,

etc., the systems represent the perfect quality control instruments for the production of

sheet metal parts and bodies-in-white. Users especially benefit from the high precision and

extremely short cycle times.

The modular sensor technology of ABIS II offers an exceptionally high flexibility. With the

optional integration of the contrast sensor, the detection of contrast-sensitive defects such as

adhesive residues, scratches and dirt, is also possible.

BUMPS DENTS SINK MARKS WAVINESS CONSTRICTIONS CRACKS

EXAMPLES FOR CONTRAST-SENSITIVE DEFECTS:

ADHESIVE RESIDUES SCRATCHES DIRT

EXAMPLES FOR 3D DEFECTS:

ABIS II - CONTINUOUS ANALYSISOF THE SURFACE QUALITY THROUGHOUT THE COMPLETE PROCESS CHAIN

Many users in the automotive industry rely on an integrated surface quality analysis

across the entire process chain. After each of the process steps Single Part, Assembly

and Cathodic Dip Painting, the individual parts are examined again by same inspection

application to identify any surface defects that might affect the top coat quality. The

development of a defect is documented after each process step. Practical experience in

production shows that the relevance of a surface defect can increase or decrease after

a process step.

Based on a process-wide quality analysis, the required rework is done precisely at the re-

quired location on the part and at the required process steps. This increases the efficiency in

the finishing area and results in a significant cost saving. Besides the development of a surface

defect across the process chain, the time-related changes within a production period also

give users important information on the quality changes.

For example, when the audit value deteriorates, corrective action (e.g. regarding press

parameters or tool surfaces) can be taken at an early stage before producing parts with

defects that will later require rework.

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SURFACE INSPECTION WITH ABIS II THROUGHOUT THE COMPLETE PROCESS CHAIN

Single Part Assembly Cathodic Dip Painting

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USER-FRIENDLY SENSOR TECHNOLOGY,SOFTWARE AND AUTOMATIONFOR TOOL MAKING, PRESS SHOP, AND COMPLETE BODYSHELL WORK

ABIS II offers the highest standards in terms of suitability for industrial applications as

well as expandability, defect detection and easy use. To inspect a part, all the user has

to do is select the part on the touch screen and start the test sequence. Thanks to

the high-speed inspection and evaluation capacity, a report of the inspection result

will be available in minimum time.

The entire operation of e.g. an offline system is done very simply by selecting the

relevant part inspection processes on the touch screen. When programming ad-

ditional test sequences for new parts, the user is systematically supported by the

easy-to-use ABIS-TeachIn software.

The classification criteria and threshold values for a subsequent automatic evalua-

tion of the defects are always based on the customer‘s specifications. In addition, the

system applies the customer‘s internal audit note standards and defect names. The

specified threshold values can be flexibly adapted to the relevant production stage

at any time (floating audit).

• Efficient, highly precise quality control

• Objective classification and documented

surface quality

• Easy operation & fast evaluation

• Fully automatable process

• Less rejects and complaints

• Reduction of rework costs

• Sustainable optimization of production

processes

Horst WinterbergGroup Leader Development Surface Inspection

„Our long-term experience in optical measure-

ment technology and image processing, paired

with the know-how of our customers, are the

basis for the success of our unique ABIS surface

inspection systems.“

ABIS - SYSTEM VARIANTSFROM PORTABLE SENSOR AND OFFLINE SYSTEM TO FULLY INTEGRATED UNIT

ABIS II is a flexible system concept that comes in three different versions. Users can thus

choose the sensor system that best meets their application requirements.

The flexible, compact and highly precise ABISoptimizer sensor system has been developed

especially for applications at an early stage of the manufacturing process. Due to its high

mobility, the system allows for an easy change of the location for concurrent and focused,

punctual inspection measurements in production.

ABIS II Offline allows data acquisition and evaluation at an automatic test stand and is excel-

lently suited for accompanying production monitoring. Defect catalogs and classification

criteria that have been compiled during the planning stage can be extended and modified.

The ABIS II Offline cell can be configured for both mobile use and stationary installation at a

fixed position in the press shop. The mobile Offline version features one or more portable

platforms, on which the system components are mounted.

With ABIS II Inline, a fully automatic inspection and assessment can be performed by

direct integration of the system concept into the manufacturing environment of the

body shop or press shop.

According to the customer‘s specifications, the ABIS II Inline system can be configured

for either 100 % inspection of all parts or for the inspection of certain object areas and

defined zones on the test part.

The achieved complete or partial inspection of bodyshells and sheet metal parts sets

highest standards in quality assurance and auditing.

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VIRTUAL DESIGNINDIVIDUAL SYSTEM CONFIGURATION PERFECT FOR INTEGRATION INTO PRODUCTION PROCESSES

Before an ABIS II surface inspection system is installed, a virtual system concept is always

created first. Simulation programs help to select the specific robot and its position with

reference to the part under test. This ensures that the sensor will be able to reach all the

positions required for inspection.

How many sensors and data analyzers the final system concept provides depends on the

part size(s) (from small bodyshell parts to the complete car body / body-in-white) and on

the specified maximum inspection time per part (cycle time).

Corresponding accessibility studies and cycle time simulations build the basis for optimal

customer-specific system configurations.

The safety concept and the construction of the system are designed and implemented in

accordance with user guidelines. Customers can choose to do this themselves or order a

complete, end-to-end surface inspection solution.

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TESTIMONIALS / REFERENCES

“The ABIS system enables us to

objectively analyze the surface quality

in the individual process steps – from

the single part through to assembly

and cathodic dip painting – and take

targeted measures.

For the good business relationship

with our customers for body-

shell panels, the ABIS system is an

excellent inspection system for the

objective documentation of surface

quality.”

Jorge PalenzuelaHead of Quality Assurance RussiaGestamp Automation

“The optical surface inspection sys-

tem must be ready to run day and

night. It now replaces the whetstone

formerly used by the QA staff.

Thus, we can check more parts and

classify them objectively in the same

time period.”

Uwe WalcherSystem Operator Press Shop III Audi AG Ingolstadt

„Quality control and customer satisfac-

tion are top priorities at TOWER

Automotive.

With the Zwickau plant, the first

TOWER Automotive press shop now

utilizes the ABIS II system for objective

surface inspection of body shell parts.

Thus, the surface quality of complex-

shaped body shell parts is now fully

documented for our customers very

quickly and clearly.“

Dietmar LeichsenringMGR Equipment & Facility Realisation EuropeTOWER Automotive

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REF

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REFERENCES

Audi AG

BMW AG

Daimler AG

General Motors

Gestamp

Honda

KIA Slovakia

PSA Peugeot Citroën

Tower Automotive

Toyota

Volkswagen AG

Zwick-Roell

Since our company´s foundation, a central

part of our business philosophy has been

focused on an international orientation of

our sales and support activities.

For more than two decades now, custom-

ers from all over the world benefit from

our innovative metrology solutions and

corresponding technical support services.

For the complex automated surface

inspection units, professional local support

is guaranteed by highly qualified service

technicians.

Having established numerous international

subsidiaries and a worldwide distribution

network, we offer our high-end products

and services across all continents.

International Subsidiaries:USA • BRAZIL • P.R. CHINA • INDIAFRANCE • PORTUGAL • UK • AUSTRIA • RUS

STEINBICHLER OPTOTECHNIK GmbHGeorg-Wiesböck-Ring 12 • 83115 Neubeuern • GermanyTel.: +49-8035-8704-0 • Fax: +49-8035-1010 sales@steinbichler.dewww.steinbichler.de

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