Issuu

COMPANY REPORT

ZEISS INDUSTRIAL QUALITY SOLUTIONS

From energy to eMotion

ZEISS eMobility Solutions

X-ray Technology to Play Major Role in Vehicle Electrification

Nicolai Müller

Sales Manager X-ray/ CT Latin America | ZEISS Industrial Metrology

Working for a global supplier of metrology and inspection solutions in the quality lab and production environment, the last few years have been more than exciting. As a recognized partner of the automotive industry, we have served the largest OEMs and its suppliers with quality solutions for automotive components for decades.

Today, we are experiencing first-hand the major changes that this industry is undergoing as it faces the 21st century challenges of climate change, limitation of natural resources such as oil and gas as well as the increase in regulatory requirements.

For many years, structural parts and chassis, especially,were made of individual stamping components being welded or riveted together. This resulted not only in a very time- and cost-intensive process but also in a heavy end-product, since the material of choice was sheet metal. One of the targets for the auto industry is weight reduction, which is the most basic way to increase fuel efficiency and decrease CO2 emissions. On top of that, for the rapidly increasing electrification of vehicles, weight reduction is a driving factor to optimizing the range of hybrid and full electric vehicles. Consequently, many stamping components are being replaced now by parts made of alternative materials and with different production processes, including aluminum casting. The increasing use of aluminum in vehicles because of its lightweight and high strength will drive this market in the upcoming years. Using advanced casting procedures such as high-pressure die casting (HPDC), more and more complex and larger components can be produced. Nowadays we can see cross beams, side members, front carriers, shock towers or battery trays made of aluminum.

However, alternative materials and processes come with new challenges. One of those challenges is material imperfections, such as pores, cracks or inclusions as a result of the casting process. Every part must meet specific quality criteria to fulfill its main functionality. To ensure those quality criteria, X-ray technology can be used to detect those imperfections, classify and evaluate them in order to either accept or reject the produced part. Of course, this technology is not new to the automotive industry since the benefits have been well known for many years and OEMs as well as suppliers are using X-ray systems in their laboratories for analysis or parallel process inspection. But, especially in the last few years, X-ray systems have been gaining more and more importance. They offer the possibility to verify internal characteristics in a nondestructive way and have proven to be a valuable and reliable quality tool in the aluminum casting process.

In particular, structural and chassis parts are of high importance because of their relevance in terms of security in the event of a crash. Also, during use these parts must carry a certain load and are not allowed to fail. Consequently, each individual part must undergo X-ray inspection to verify the internal characteristics. This is becoming a challenge for systems in a laboratory setting, raising the demand for X-ray technology within the production process. These are systems that are capable of 100 percent inspection, meeting cycle

time requirements below the 60s in the rough production environment.

Coming back to my original statement why the last few years have been so exciting for me, representing our X-ray portfolio means working with different customers on individual solutions to tackle new challenges. There is no one-fits-all solution, especially because OEMs have different philosophies and approaches regarding the electrification of vehicles and the components and processes being used. In addition, new automotive companies focusing on fully electric vehicles are establishing themselves in the market, competing with the traditional brands and coming up with new ideas.

One of those players is looking to replace individual structural parts used for the rear underbody with one singlepiece casting, especially to reduce cost and complexity. This process is known now as mega- or giga-casting and introduces new challenges for x-ray technology providers and their employees. What system dimensions will be needed in the future? What will automation concepts look like to meet loading demands? Which cycle times for the inspection process must be met? Some players will join this trend of mega- giga-casting while others will go in a different direction.

For me personally one thing is clear. With the continuous progress of electric vehicles, the demand for x-ray technology for quality processes will drastically increase. But at the same time, customer expectations and demands will increase as well. Therefore, we will see new X-ray systems, solutions and developments coming soon. Fortunately, we are not at the end of these exciting times; this is just the beginning.

Miguel González

Director General | ZEISS México

High-Precision Metrology Solutions for a Growing Industry

Q: How does ZEISS leverage its experience in metrology to provide highly accurate measurement systems to the Mexican automotive industry?

A: ZEISS was founded over 175 years ago and has about 80 years of experience in the automotive industry. Throughout these years, ZEISS has innovated within high-precision measurements. Lately, we have incorporated new technologies, such as scanning and inspection optics, reverse engineering lasers and 3D construction. ZEISS has also developed X-ray testing to verify that a piece follows industry standards and that the material it is made of does not have any impurity or weakness that could lead to material fatigue.

Q: What role do robots play within inline inspection?

A: ZEISS is deeply involved in Industry 4.0 and aims to help clients minimize costs by reducing errors. The company collaborates with the robotics industry to get parts from the production line to measurement points, which are highly precise. Robotization helps to automate processes and minimize errors. Furthermore, robots enable factories to operate 24/7.

Q: How does ZEISS combine its product offering to provide comprehensive metrology solutions?

A: ZEISS provides a comprehensive solution that incorporates hardware and software to check that measurements are correct. We offer measurement and integration software, in addition to a wide range of accessories that can be used as independent solutions or that can be integrated into the production equipment. We have a wide range of software at different levels. During production, information emitted by a machine travels to a control point where quality management can check exact measurements. This technology must work 24 hours a day, every day. Our comprehensive solutions ensure continuous production while avoiding bottlenecks.

Q: How does ZEISS work with clients to help them implement its solutions smoothly?

A: Software programming takes time. Our software engineers work closely with the client to reduce the installation time without compromising the measures that must be taken. All time reductions increase the productivity of the production chain. We have applications that constantly study customer requirements, service engineers who prevent any pause in production and a wide range of services and experts to offer the best solutions to the customer.

Q: How is metrology changing to meet the new precision demands of EV manufacturing?

A: EVs have different mechanical parts and require different manufacturing processes. These vehicles have considerably fewer components than combustion engine vehicles. Electric motors, batteries and transmissions imply a paradigm shift on what we should measure. While this environment involves challenges, ZEISS is working closely with customers to define standards. We have diversified measurement sources to adapt to new technologies and measurement demands.

Q: How does ZEISS adapt to Mexico’s growing manufacturing capacity?

A: Mexico’s manufacturing capacity continues to grow. Under USMCA, several megatrends are coming to the country. The COVID-19 pandemic changed how corporations plan production, leading them to bet more on nearshoring than on offshoring, while technology continues to improve. New production processes involving lower costs create new challenges and opportunities within the metrology business. Both in software and hardware, ZEISS adapts to the highest demands and modern trends.

Q: How has ZEISS México grown its presence in the plastic medical devices segment?

A: The medical devices industry is an important sector in Mexico, with annual production valued at US$20 billion and growing. This industry is concentrated in specific regions, such as Baja California. Medical devices are subject to highly demanding regulations, such as those from the US Food and Drug Administration (FDA). We provide customers with measurement technologies and processes that follow the standards of the FDA and other global agencies. ZEISS continues to grow, learn and improve. By the end of 2022, we will open a quality center in Tijuana, Baja California, which hosts one of the most important medical device clusters in the country.

Q: How does ZEISS México’s portfolio work to meet the demands of the country’s growing aerospace sector?

A: The aerospace industry is demanding and rigorous. ZEISS has a history in this sector, good clients and an understanding of the industry’s measurement and high-precision metrology demands. As Mexico’s aerospace clusters continue to grow, ZEISS has a strategic presence with locations in Silao and Queretaro. We have accreditations from the highest standardization boards and we provide tailor-made measurement solutions for specific aviation parts to ensure they meet clients’ requirements.

Q: What role does ZEISS Metrology Academy play in the training of metrology technicians?

A: Measurement and metrology standards are constantly evolving. While there is good training in Mexico, industry demand is expanding and training must be continuous due to the nature of the industry. New hardware and software equipment require new training.

One of ZEISS’s main goals is to help clients grow their skills and knowledge that the new software demands. Therefore, we have developed a portfolio of ZEISS Academy products so our clients’ personnel can become accredited through different types of training, both virtually and in-person in our quality centers. These certifications complement the training of these technicians.

Q: What are ZEISS México’s main plans and strategies for 2023?

A: ZEISS continues to strengthen its presence in Mexico’s different industries. In addition to the new quality center in Tijuana, ZEISS México will reinforce its position as the most important player for measurement and quality systems in the country.

ZEISS is investing in talent to cover the potential demand. Our plans continue to focus on growing the team, looking for new clients and deepening our relationship with those we already have. We must grow in personnel but also in skills to adapt our technologies to our customers’ operations. The success of our customers is the success of ZEISS.

National Sales Manager | ZEISS México

Mexico to Benefit from Global Supply Chain Reorganization

Q: What are the main priorities for ZEISS México regarding sales?

A: ZEISS México aims to be as close to customers as possible. Presence is key for us as well as having deep knowledge and understanding of our customers’ applications and needs. We are about to open a new quality center in Tijuana that will increase our presence in Baja California and provide a space for our clients to learn more about ZEISS’ technology.

We will continue taking advantage of ZEISS’ solutions portfolio, which is expanding on a daily basis and allows us to offer complete solutions to our customers. For example, the combination of X-ray and tomography equipment with microscopy and coordinatemeasuring machines (CMM) adds great value during the manufacturing of aluminum structures and batteries for EVs.

Q: How does ZEISS decide in which industries and states it should invest?

A: ZEISS México leverages its well-connected global network to learn and turn global opportunities into local opportunities. We work closely with partners in market intelligence, identifying new trends and opportunities. In addition, we build alliances with organizations, institutions and clusters within the medical devices, plastics and automotive industries, which enable us to access new clients.

Q: What strategies does ZEISS México implement to retain clients?

A: We work on two fronts, both related to customer experience. ZEISS México is obsessed with improving customer experience for new and recurring customers, providing them with diverse channels of contact with ZEISS.

ZEISS México also invests in customer service every year. In addition to the technology and quality, the support and attention the brand provides to clients has been a leading differentiator for ZEISS México.

Q: How does ZEISS provide unique added value through its complimentary Smart Services tool?

A: ZEISS México always seeks to offer greater value. Our Smart Services tool allows customers to receive relevant information about their equipment in real time, including detailed information on general operations, alerts, changes in temperature, wear of parts and other variables. The client can integrate this data into their processes and make appropriate decisions to optimize the use of the equipment. We are offering this solution free of charge to our customers.

Q: In the current digital sales environment, how does ZEISS take advantage of its online tools?

A: ZEISS México has multiple digital touch points for customers and we are working to implement more. We have an online store that allows customers to access information. Online purchases are not available yet but the platform provides the customer with product information.

We also take advantage of our online platform to provide webinars, online promotional activities, courses and training, both recorded and live. This allows ZEISS to be close to the customer 24/7. In the

Arturo Zavala

near future, it will be possible to make purchases online according to the current demands that online purchases require, from agility to security and transparency.

Q: How did ZEISS México perform in 2022?

A: It has been a year of double-digit growth in terms of sales and we reached several milestones and objectives. The market has recovered rapidly from the pandemic and ZEISS has been able to take advantage of this development. This growth allows us to continue investing, especially in personnel for our customer support area, which is so important to us. Customers in Mexico expect a great deal of support from a technology company. We have the best trained staff in Mexico.

Q: How is ZEISS México working to take advantage of the nearshoring boom?

A: For ZEISS México, our global network is essential to identifying and targeting new investment opportunities. Several companies are looking to establish themselves in the country and it is likely that ZEISS worked with them somewhere else in the world or that we are currently involved with them. This allows information to flow, allowing us to identify opportunities and build multiregional teams, which come together to offer comprehensive, joint solutions to clients.

Q: You have worked at ZEISS México for over 15 years. What is the main strength of the company?

A: ZEISS has worked hard to consolidate its commercial and technical forces, focusing on having highly-trained experts in products and in the needs of our customers. This is one of the main characteristics that has allowed ZEISS to be successful: offering solutions for real needs. The high level of training and expertise of ZEISS Mexico employees and partners network is the key to our success.

Q: What role will ZEISS’s technologies play in the world’s transition to the metaverse?

A: ZEISS plays a major role in the digital world and the metaverse. The first step when converting an object from the real world to the digital world is measuring data. Metrology is essential for the metaverse and ZEISS is an expert in metrology. We are becoming an increasingly crucial player in this digitization process and the metaverse.

Q: What are ZEISS México’s priorities for 2023?

A: In 2023, ZEISS México will focus on continuing to identify and take advantage of the investment opportunities that are taking place in the current environment, such as the reorganization of global supply chains that has benefited Mexico.

On the other hand, in 2023, we seek to approach industries where historically ZEISS has not had as much presence in Mexico, such as healthcare and aerospace. Our global network allows us to apply our expertise to the Mexican market, which is hungry for innovation. These two sectors are complicated and highly regulated but our responsibility is to help them innovate by accompanying them in the switch to new technologies and allowing them to capitalize on our products.

ZEISS Launches Next-Generation

3D Handheld Scanner

ZEISS, a high-precision technology company, has launched its T-SCAN hawk 2, a nextgeneration handheld 3D laser scanner that blends remarkable ease of use and metrologygrade data precision that is certified to meet the highest industry standards. The T-SCAN hawk 2 is a portable system that can be used across many industries, allowing users to scan objects up to multiple meters thanks to its new satellite mode.

Designed and produced in Germany, this tool features a simple and intuitive user interface, with easy-to-operate functionalities. The software can be entirely operated with the T-SCAN hawk 2 interface, meaning there is no need for a laptop. The system also adapts easily to hand movements, thanks to its workflow assistant. The ability to start and navigate directly make it especially user-friendly, facilitating its use under any circumstance.

Satellite Mode Ensures Distance Control

The T-SCAN hawk 2 delivers high-precision data. It is ideal for working in confined spaces and hard-to-reach areas as well as reaching larger objects without the need for the classic builtin photogrammetry with coded markers. This is thanks to the innovative new satellite mode that allows users to capture data with accuracy and precision. This is a significant improvement compared to traditional handheld laser scanners that are limited by their range capacity. The device projects a red laser marker to help users maintain an ideal working distance.

Seamless Transition Between Tasks

In addition to its versatility and ease of use, the ZEISS T-SCAN hawk 2 provides high precision and adaptability. The device can be adjusted for resolution and field of view, allowing it to be used in challenging environments, such as confined spaces or hard-to-reach areas. In addition, the laser scanner is designed to work on a wide range of materials and surfaces, including dark or shiny surfaces, while delivering 3D measurement data with the highest accuracy.

Industry Versatility

The ZEISS T-SCAN hawk 2 is a highly portable device that can be used in a variety of industries. It is an ideal solution for the automotive, shipping and railway, aerospace and energy sectors as well as for mold and machine manufacturing. The device comes in a compact case that contains additional tools, such as a hyperscale for fast recalibration and a power delivery hub, resulting in a complete solution for on-the-go measurements.

GOM Inspect, Integral Software Solutions for 3D Inspection

The T-SCAN hawk 2 blends with GOM Inspect, the company’s 3D inspection software that seeks to take user experience to the next level thanks to powerful functions like GD&T calculations, trend analyses and digital assembly. The software also offers specialized packages for various industries and a parametric concept for efficient project templates.

Ready to Work, No Matter the Job

Thanks to its powerful and versatile functionalities, this handheld laser scanner offers a broad range of features that are ideal for industrial work. Whether it is quality control, MRO activities or reverse engineering, the T-SCAN hawk 2 delivers reliable, high-precision data under any circumstance and at any moment thanks to its easy-to-use, satellite mode, intuitive interface and portability. This device aims to be a must-have tool for any user.

The Next Generation: ZEISS PRISMO Family

When it comes to precision, it is imperative to achieve reproducible maximum accuracy at the highest measuring speeds. The ZEISS PRISMO Family of coordinate measuring machines (CMMs) has been leading the way for more than 30 years and ZEISS PRISMO is considered the future of precision.

Precision keeps the production process together, from reliability to quality assurance. It is also constantly evolving by combining speed, flexibility, and productivity at a higher level than ever before.

For any CMM to be successful, it must also combine safety and efficiency, whether in the controlled setting of the quality lab or under tough environmental conditions on the production line itself, according to ZEISS. To create a win-win situation, it is necessary to obtain a high throughput with a minimal rejection rate and to reduce costs by eliminating downtime. This demands the best precision that the market can offer.

In their pursuit of precision, manufacturers produce top product quality that meets the challenging requirements of their consumers. Not only do they need to handle tight tolerances and complex geometries, but they also must maximize output while ensuring the necessary degree of safety. The question many ask is whether there is a way to reduce production rejects and save time while guaranteeing superlative measurement performance?

Manufacturers agree that one way of boosting speed is to fundamentally reimagine how processes are performed, enabling them to be completed in a fraction of the time. Such innovations can deliver significant efficiency gains without sacrificing

accuracy, if they are backed up by automated features that cut speed to safe levels in the event of a hazard.

It is important that all efforts to increase productivity promote longterm feasibility. Sustainability, energy efficiency, noise reduction, and ergonomic handling: These are just some of the areas in which CMMs must deliver. To be a sound investment, they must be truly ready for the future.

Among the most accurate CMMs on the market are the ZEISS PRISMO. This machine is fully compliant with requirements and has been awarded DGUV certification due to its high standards. The new generation of the ZEISS PRISMO Family boasts the following features:

+ The ZEISS PowerSaver feature automatically disconnects ZEISS PRISMO from the power supply after a preconfigured period, reducing power consumption to zero during downtime.

+ The ZEISS AirSaver feature automatically switches off the compressed air after a preconfigured period, cutting air consumption by up to 60%.

+ The new C99m controller from ZEISS cuts power consumption by 68% for a standardized test cycle.

+ The new control panel holder ensures improved storage.

+ The new design of the front cover reduces the distance between the user and the measuring area. This ensures easier manual loading of heavy parts.

+ Safety laser scanners offer total coverage around the machine and trigger an automatic speed reduction upon detection of a hazard.

+ ZEISS PRISMO fortis is suitable for quality labs and inline settings up to 40°C.

All four models in the ZEISS PRISMO Family help operators meet their individual measurement requirements with confidence and speed. All models are also compatible with the new ZEISS VAST Rotary Table Axis (ZVRA) option, which defines the axis of the rotary table nearly 75% faster than before – and provides the ideal foundation for ensuring the highest possible accuracy during measurement.

The new performance package ZEISS CMM Acceleration Mode for Aerospace Applications cuts blade and blisk measurement times by as much as 70%. It is exclusive to ZEISS PRISMO 7/12/7 fortis, which is equipped with the ZEISS VAST Rotary Table (ZVR) and ZVRA processes. Working in tandem with the safety laser scanners, ZVR significantly increases the rotary table movement speed as well as the measurement speed. The dedicated application support also adds a number of performance adjustments and enhancements for even greater customization and productivity.

This package is crafted for a range of components in a variety of sectors. For instance, ZEISS CMM Acceleration Mode for Aerospace Applications handles the measurement of blades and blisks. ZVRA performs a single smooth measurement to quickly and accurately define the rotary table axis, after which ZVR measures the blade or blisk on different levels. ZVRA and ZVR ensure repeatable measurements with a reproducibility below 10% of the specified tolerances, as required by the industry to ensure measuring equipment capability.

There is no middle-ground when it comes to precision. With the new generation of the renowned ZEISS PRISMO Family, the future of precision is here. According to the company, sales in Mexico during its first year after ZEISS PRISMO launching is to close at US$1.2 million.

Tijuana Quality Center Delivers Continuity, Precision, Accuracy

Mexico’s medical device industry represents significant opportunities for manufacturers looking to expand their production and bring innovative medical devices to market. To address this potential, ZEISS Industrial Quality Solutions, a leading manufacturer of multidimensional metrology solutions, has opened its latest Quality Excellence Center, located in Tijuana, Baja California.

The Tijuana center is expected to continue providing high levels of precision, accuracy and safety to ensure compliance with regulatory standards as well as protecting the health and well-being of patients. Tijuana had one of the highest industrial growth rates in the medical device sector last year.

“Tijuana is among the most important markets with the greatest growth potential for the manufacturing sector, especially in industries like medical devices and aerospace. By combining its strategic location, highly trained personnel and high-quality products that meet international standards, success is guaranteed. ZEISS seeks to promote Mexico’s leading role as a reliable partner for world-class production,” said Arturo Zavala, National Sales Manager for ZEISS Mexico.

Mexico has the largest medical device industry in Latin America, with a market value of US$8.7 billion in 202. The market is forecast to grow at a compound annual rate of 6.3% between 2021 and 2028.

The Tijuana Quality Excellence Center is designed to provide support and solutions to industries that must adhere to stringent measurement and inspection requirements for their components. These range from metallic and plastic medical devices, such as dental implants or prosthetics, to sheet metal for aircraft turbines for the aerospace industry. In addition, it will provide a range of industrial-grade solutions designed to help manufacturers produce high-quality medical devices that protect the health and well-being of patients.

From left to right: Julio César Casanova, quality excellence centers manager; Federico Villegas, general director ZEISS Mexico; Arturo Zavala, national sales manager ZEISS Mexico; Socorro Macías Ahumada, medical products cluster president Baja California and Rafael Lelo de Larrea, industrial quality solutions director ZEISS Mexico.

“This center has a broad portfolio and state-of-the-art measurement equipment that allows us to do initial sampling to large-scale measurements for industry components that must meet the highest standards of precision,” said Zavala.

Whether it is a measurement service for 3D scans, CT scans, or 2D X-ray inspection, the Tijuana center will provide solutions that help drive productivity, quality control, and accuracy assurance, Zavala added.

Read the complete article

ZEISS – Your eMobility Industry Partner

The electric car market has experienced robust sales growth around the world in recent years, contributing to enhanced vehicle performance and a cleaner world. Industry analysts estimate that in 2023, 1 in 5 cars sold will be electric.

Contributing to this greener trend, ZEISS eMobility solutions are integrated, complete and ready to tackle the new sustainability reality. According to the company’s latest report, electric vehicle sales are expected to exceed US$800 billion by 2027. The sharp increase in demand is putting greater pressure on manufacturers and suppliers. Quality assurance, in particular, faces new challenges that slow down processes, especially in rapidly-growing companies. Today, ZEISS eMobility has over 1,000 customers around the world in the Neighborhood Electric Vehicle (NEV) sector, making it one of the industry’s most important partners. According to Autoblog, NEVs were generally built to have a top speed of 25 miles per hour (40 km/h), with a maximum loaded weight of 3,000lb (1,400kg).

“When it comes to quality management, major OEMs and battery and electric motor suppliers rely on ZEISS solutions.” Bob Chen, Global Head of NEV Business at ZEISS, said.

There is no doubt that NEVs are storming the roads, especially in Europe, where it is estimated that by 2030, 185 million electric motors will be needed for NEV production. These are mostly cars, trucks, twowheelers as well as agricultural and construction machinery. ZEISS says that batteries in particular are key in this mobility revolution because they determine output and range and are relevant for the structure and safety of the entire vehicle.

International OEMs and suppliers can attest that ZEISS eMobility Solutions has provided them with more than 50 solutions tailored to quality assurance in e-mobility. In addition, the company continues to add new solutions to its wide range of imaging, analytical and metrological systems in the field of inline inspections and software, says ZEISS.

Despite these technological advancements and business opportunities in recent years, challenges in quality assurance have risen.

ZEISS explains that the industry has to take on changing technologies and their impact on manufacturing processes as a result of the rapid development in the e-mobility industry. The battery is a perfect example: To meet high efficiency, reliability, and safety requirements in large-scale battery production, having the highest precision is required from the very start. In addition, the company says that “quality criteria affect the choice of raw materials, the process of battery engineering as well as quality control of critical steps during electrode production down to the assembly of cells, modules and battery trays while meeting stringent tolerances.”

ZEISS is also actively involved in Hairpins and stators. In recent years, ZEISS developed its ScanBox solution especially for full-field, automated scanning of hairpins and whole stators, thus obtaining a metrology with high efficiency gains.

Today, manufacturers bend wires into the shape of a hairpin during electric vehicle production. For the most part, these hairpins are made of a rectangular copper wire and are coated with an insulating layer. The dimensions and positions of these hairpins need to be inspected during stator assembly since they tend to deform easily and their ends are difficult to weld, says ZEISS.

Optical measuring devices are a beneficial solution for hairpin quality control, since the wires are extremely touch-sensitive. Moreover, the geometry and position of the hairpins can only be verified with fullfield 3D data. Therefore, ZEISS and other electric motors and hairpin stators manufacturers have been working together in this field for a long period of time.

Optical 3D measuring for eMotors

ZEISS developed a packaged device with a powerful inspection software for detailed 3D data evaluations. In addition, it is a compact 3D measuring system that has the capability to perform at rapid speed while accurately scanning the hairpins’ highly reflective insulating layer. ZEISS highlights that the optical 3D measuring machine captures the free-form 3D coordinates of individual hairpins and the entire stator at the click of a button while delivering high-resolution quality information, which is clear and easy to understand within seconds.

Laminated Cores

ZEISS provides quality assurance for laminated cores by introducing a software that performs complete analysis measurements that include the form, angle and position tolerances of hairpins as well as bending points, bending radii and leg lengths, says the company.

Since stator cores are made of thin steel laminations, tolerances are generally found in the micrometer range, in addition, laminations must be flat and flashless. Both parameters impact performance of the e-motor, as well as the dimension and position of the grooves.

This is why the ZEISS PRISMO multisensor coordinate-measuring machine combines tactile and optical sensors in a single system. “Thanks to its accuracy of 0.5+L/500 μm (depending on size and model), it is the ideal device for measuring laminated cores. It carries out automated high-speed inspections of component pallets without operator intervention,” said ZEISS.

Batteries

To provide quality assurance for batteries, ZEISS has developed a holistic process that can be applied to all development and production steps.

We all know that batteries play a fundamental role not only in the performance of an electric car, but also in its range and longevity. According to ZEISS, quality assurance is a complex process and this is why different measuring techniques are used to inspect battery characteristics, such as material, electrode, cell module and battery tray.

For instance, industrial microscopy is generally used to study battery materials, cell structures and potential impurities during battery development. The ZEISS Crossbeam scanning electron microscope (SEM) uses an ion beam to expose important areas of interest below the surface and analyze them in the nanometer range.

Nondestructive analyses are used for battery cells and modules during production. ZEISS reports that during this phase, mostly X-ray and computed tomography systems (CT) are used. The battery tray, which is

Read the complete article

Computed Tomography Systems

In an effort to meet the demand for NEVs that have a higher range, ZEISS explains that battery cells’ energy density needs to be boosted without increasing their weight and size. This ever-growing density must undergo additional nondestructive inspections. ZEISS uses systems that perform consistent CT scans of dense parts, including battery cells and modules. These include CT systems, such as ZEISS VoluMax 9 titan and ZEISS METROTOM.

“They generate very high-resolution 3D volume data sets, thus rendering hidden defects and characteristics in dense components, such as electrode defects, misalignments, overhangs, housing pores and particle contaminations. The latter are a major safety risk and must not be part of the final product,” noted ZEISS.

One of the greatest advantages is that CT systems solve complex measurement and inspection tasks with just one single scan. The company says this is indispensable for both battery capacity and safety.

The CT system, ZEISS VoluMax 9 Titan, is characterized for having a small footprint: it is very compact and robust. According to the company, the ZEISS VoluMax 9 Titan is equipped with a 3k detector, it can scan components measuring up to 590 x 700mm and weighing as much as 60kg.

The complete CT solution, made up of a CT system and easy-touse cross-platform software, provides 3D volume data sets with high resolution, even when the user is scanning large, dense battery modules. This CT solution can be used in a lab environment or on the production line.

Battery Tray Inspections

The battery tray is considered the core part of the body. Therefore, its dimensions have a direct impact on the dimensional accuracy and stability of the vehicle body. To this end, ZEISS provides a unique battery tray inspections portfolio that includes inline and offline metrology as well as aluminum weld seam inspections.

ZEISS reports that during milling and drilling, many features with tight tolerances need to be measured. For instance, the CALENO horizontal-arm machine combines optical and tactile sensors. This is where ZEISS EagleEye promptly records features such as holes or the position of studs.

“Tactile sensors cover optically inaccessible features, such as undercuts, with high precision. ZEISS ScanBox Series 5 and 6 are used for full-field 3D scans,” said ZEISS. These optical measuring machines automatically create a geometric digital twin that is used to carry out full inspections of prominent features in just a few minutes.

Digital Quality Data Management Goals and How to Get There

Nicolai Müller

Regional Sales Manager Latin America | ZEISS

Industrial measuring and inspecting solutions are essential to ensure reliable product quality. Today, almost every manufacturing company uses some form of quality equipment in its production process, generating gigabytes of data every day. If you were to go around and ask companies individually, probably all of them would say that Industry 4.0, or digitalization or some other buzzword, is a key priority, at least on their agenda. But the reality is that the sheer volume of quality data, and how to turn that data into meaningful and comparable information, is a tremendous challenge. This is especially true for medium and large organizations with multiple manufacturing sites across the globe and in different time zones.

Talking to different levels of management over the last few years, I have gathered a wide variety of expectations and goals when it comes to quality data management. I would like to discuss a selected number of them and what can be done to make it happen.

1. Creating a single digital workflow for all my measurements.

The standard measurement protocol only documents a single moment in time of a particular part being produced. Sure, this might be enough to meet the requirements of the customer for that part, but what if the machine operator or production manager in charge wants to identify a trend in production? He has to go back to the file folder, pull out the relevant protocols and compare them page by page. That’s a very inefficient way of working and doesn’t fit in the normal course of business during the day. Therefore, the foundation of digital quality data management is to create the conditions for converting printed measurement protocols into digital PDF files stored on a computer. But if you are already in the process to take this step, why not look for a solution that allows the machine operator to not only receive a digital PDF file but also features specific evaluations and graphical representations of the measurement data? Or that allows the production manager to evaluate trends and perform statistical analysis. Basically, integrating measurement results into the production environment.

As promising as these solutions sound when you read the usual Industry 4.0 marketing materials, there are a few steps in between that need to be taken. This brings me to the second expectation I came across multiple times.

2. Connecting all my measuring devices independent of their brand.

A successful integration between measurement machines and the production facilities requires consistent data that can be connected and clearly mapped. The typical quality room contains not only one but usually multiple devices from different manufacturers producing measurement and inspection data, often including manual or handheld measuring devices. That’s okay; there is no need to switch to a one-vendor strategy. However, you can greatly benefit from standardized and parameterized measuring programs that are based on the same semantics, and feed quality data into one central database in real time.

ZEISS offers a quality data management and reporting software called ZEISS PiWeb that allows connecting not only native

ZEISS systems but also the measurement equipment of thirdparty manufacturers, including handheld measurement devices. As a result of this connectivity, you can work with one central database for all quality data generated.

3. Making customized reports for process-relevant measurements.

Depending on the industry segment you are in, the processes may vary, but taking the automotive industry as an example, over a thousand features are inspected in the serial process and several hundred measurement sheets per vehicle type must be stored. By storing all raw data, calculated data, inspection plans and measurement values in one database, you have laid the foundation for a fully digital workflow. This opens up the possibility of deriving measurement values into customized digital reports that are truly relevant to the day-to-day work of machine operators or production managers. Reports ideally include the approved technical drawings, information about the testing equipment, corresponding part serial and part number. With a few simple clicks, the machine operator receives exactly the values he needs to optimally control the machine, rather than having to wade through piles of paperwork.

I have seen customers who not only provide the measurement values but even include the correction values for the processing machines in their reports, values that indicate how much the machining of the part needs to be corrected to achieve the target value. Having this information available reduces user influence and operator stress, and eliminates sources of error.

4. Providing transparency and making decisions based on facts and data, not guesses.

If you belong to regulated industry segments, such as aerospace or the medical devices industry, you face the challenge of documentation and traceability from product development to final quality assurance. To avoid mountains of paper and the accumulation of information on an endless number of drives, a database solution as the central hub for all users of quality data can lead to a massive increase in process reliability, significant cost and time savings and new possibilities for documentation. By the way, this also drastically reduces the number of bad experiences during audits.

You can start off by connecting just a few coordinate measurement machines to create an easily accessible, more transparent and comparable overview of daily work in your quality laboratory. Or take it a few steps further and centralize multiple business areas in different geographical locations. Having all data digitally and globally available opens up the possibility to monitor and evaluate trends by facility, measurement device, part number or feature, either on a daily basis or over a year’s time. The logical next step would be to integrate suppliers and service providers into the database as well.

All in all, digital quality data management offers a massive efficiency boost over the old status quo, where measurement and inspection data were stored on a sheet of paper in many different places.

Inline Metrology to Bolster Smart CarBody Production

Mauricio Rosales

Carbody Sales Manager | ZEISS

Modern car body manufacturing is undergoing a tremendous change regarding the dynamics of design and implementation. Years of design and production line implementation are now in the past. Today, it is more common to find a completely new program launched in a matter of months.

It is especially critical that all production feedback during the ramp-up period be executed promptly, since any delay on the implementation could end up costing a considerable amount of money, potentially reducing the profitability of the investment.

More and more body shops are using fully integrated metrological solutions on their lines. They want to reduce the utilization rate of measuring rooms and increase the throughput of measured components. When using inline systems, the shop floor staff can immediately respond to quality problems when they arise and proactively control the production process before there is an increase in the included cost of the produced part. ZEISS’ high-precision and absolute inline solutions do not require correlation and deliver data that can be traced metrologically.

Absolutely Inline

Although inline measuring systems are already monitoring the automotive manufacturing process, they cannot control the overall product quality of the manufactured body parts as defined in the inspection feature plan. To be able to assess the quality of manufactured parts, the measurement data recorded inline needs to be correlated with the results from the measuring room in a complex, time-consuming process. The absolute measuring solutions from ZEISS do not require correlation and deliver reliable and conclusive measurement data for series production control.

Dimensional Control Process

An inline measuring system is helpful during production ramp-up and ensures process control directly in the production line. The highly accurate and fast 3D sensor may capture complex features of assemblies and bodies in real time, including bolts, edges, holes, rivets or even the position of a welding nut behind sheet metal. The new tracking technology used in the ZEISS AICell trace system, monitors the sensor position on the robotic arm with high precision, thus eliminating the need for complex correlation measurements in the measuring room. With this method, users will be able to obtain reliable, traceable measurement and inspection data from the first part produced during rampup. Depending on the cycle time and the number of robots, the system captures up to 100 features per cycle. In addition, rolling measurements and pausing programs for analysis measurements can also be integrated.

Full-Field Digitization of the Body-in-White

After the features have been measured, robot-controlled fringe projection sensors digitize the entire body-in-white from different perspectives with high precision and high detail resolution. Users can then extract process- and qualityrelevant inspection characteristics for statistical evaluations by using the resulting absolute, correlation-free and traceable data. The sensors produce full-field 3D coordinates with every

Read the complete article

More about this person

More about this company

scan. As a result, you will see a complete digitization of the body-in-white, known as a geometric digital twin. Using the full-field measurement data, the GOM Inspect Pro software automatically derives the inspection feature plan and identifies deviations between the digital twin and the CAD data. The analysis illustrates very nicely whether the chassis marriage is flush and without gaps. In the digital assembly, users can analyze the interaction of the outer skin with the hang-on parts before the actual assembly has occurred.

In tomorrow’s smart factories, measuring systems will deliver absolute and traceable measurement results inline, eliminating the need to wait for results from a measuring lab. Ultimately, these systems will provide the data needed for production control loops.

Surface Inspection Measurement

ZEISS ABIS is the tailored solution for surface inspections in the press and body shop. The system inspects sheet metal panels quickly, easily, and objectively throughout the complete process chain. A robot moves the optical 3D sensor over the parts to be inspected. The ABIS software recognizes surface defects and evaluates them according to the specification’s corporate standards. ZEISS ABIS easily inspects moving parts and is therefore ideally suited for inline use.

Conclusion

Inline metrology is essential for car manufacturing because it allows for real-time monitoring and quality control during the production process. This ensures that each component meets the required specifications, leading to higher product quality, fewer defects, and ultimately, safer and more reliable vehicles. By catching issues early on, manufacturers can minimize waste, reduce rework, and maintain efficiency throughout the production line.