Multi-functional profile measurement reduces costs

Precise measuring instead of calculating an approximation can be facilitated by an innovative technology for the optical measurement of gaps and fold edges. The CALIPRI profile measurement device developed by the Austrian company NextSense uses no less than three laser lines for the scanning of profiles. This allows for the swivelling of the measurement device and enables measurements from different perspectives. The swivelling capability, which is unique on the market, permits the device to analyse body gaps or even the fold edges of sheet-metal body parts that form gaps.

The CALIPRI method offers a huge technological advance compared to other methods. Other methods record gaps from only a few perspectives and calculate the missing data by mathematical approximation methods – and owing to the “missing perspectives”, they cannot analyse fold edges at all. The multifunctionality makes possible the continuous use of the device across all body production stages.

Less is more – at least in premium-class vehicle construction. Because less clearance means more customer satisfaction: lower noise level and improved appearance are quality criteria that influence the buying decision. With “invisible” gaps and thus more hidden and more complex gap contours, the measurement requirements do indeed grow. And it's just exactly for these requirements that the Graz-based specialist for optical sensors, NextSense GmbH, has developed the CALIPRI method. By way of its swivelling capability, the CALIPRI makes the spatial scanning of complex gaps possible. Now the method has been extended by the possibility of measuring, alongside body gaps, also the fold edges of metal sheets.

Advanced CALIPRI method

Christoph B?hm, NextSense Marketing Manager, on the rapid development: “Right after its launch, CALIPRI was an immediate huge success. A contract worth millions from a car manufacturer in the premium class was 'merely' the beginning. Spurred by this demand, we developed the method in such a way that now fold edges are measurable as well.” Actually, this enhancement of the device software optimally utilises the most notable feature of the CALIPRI method: the ability of the measurement device to swivel. Regardless of whether it is hand-held or installed on a robot arm – CALIPRI can be moved freely over the component and combines the segments recorded by the laser into a complete profile that has been recorded even deep down.

The method affords the user several advantages: The measurement result is free from mathematical extrapolations; within a few seconds, it delivers a greater accuracy than any alternative methods. Concurrently, the flexible movement of the easy-to-use device allows for the measurement of significantly more complex gap contours than were hitherto possible. An advantage that is of increasingly greater importance, as Christoph B?hm relates: “Ever narrower body gaps improve both the efficiency and appearance of a vehicle. This is reflected in tightly folded body parts and gaps with complex contours that are difficult to access. But these tight radii of a sheet-metal fold in particular are hardly measurable with existing optical methods.” The NextSense method, by contrast, can do it effortlessly: Moving the device over the fold radius allows for a seamless recording and quick calculation of the desired dimensions.

Twist to view

A crucial element of the CALIPRI's mobile flexibility is the patented tilt correction. It automatically compensates for any tilts and twists of the measurement sensor. Thus the devicenike