Accurate inspection of parts with emphasis on evaluating the geometric dimensions of critical features
Research: Jaroslav Miklušák - MECASYS, Matúš Madleňák - MECASYS Technology, Pavol Gužík - MECASYS Design, Dominik Zilka - MECASYS CAM Program
Summary
MECASYS was approached by a leading international manufacturer of plastic components for the automotive industry, with manufacturing plants in 22 countries, to address the need for accurate and reliable dimensional stability control of its products. The main challenge was to design and develop measurement jigs that would enable repeatable measurements of key geometric parameters without interrupting ongoing series production.
The aim of the project was to ensure accurate inspection of parts, with an emphasis on evaluating the geometric dimensions of critical features, thereby enhancing the quality of the output and minimizing manufacturing variations.
MECASYS delivered high-precision measuring jigs that improved inspection efficiency, reduced the risk of errors and also confirmed the company's technological competence in tackling challenging projects for the automotive industry.
Description of the problem
The customer faced repeated problems with the quality of the parts caused by the lack of precise dimensional control at previous suppliers. These inaccuracies led to production delays and complications in vehicle assembly. MECASYS was approached to design specialized measuring jigs that were guaranteed to be production-compatible, accurate, yet easily integrated into existing inspection processes.
One of the key technical requirements was to simulate the actual clamping of the parts as they would be mounted in the vehicle body. The jigs were therefore based on accurate 3D data of the bodywork and were supplemented with models of adjacent parts to allow verification of positioning, trimming and geometric constraints. To ensure error-free part handling, a special clamping mechanism was integrated into the design to allow safe and repeatable part insertion and removal without damaging the reference points.
Each fixture has been designed to allow measurement of multiple control points using deflection meters while being fully compatible with coordinate measuring machines (CMMs), including access to predefined measurement positions.
MECASYS implemented production in a controlled environment using CMM technology also during the production phases. All fixtures were checked on HEXAGON METROLOGY machines and the design verified in a 3D environment, which made it possible to guarantee high accuracy and repeatability.
The resulting jigs significantly reduced downtime during assembly, eliminated the need for additional inspection and ensured a smooth ramp-up of serial production.
Solution
The implementation of the project began with a thorough design of the mechanical design of the measuring jigs in SolidWorks software, where the mechanical properties were simulated and the shape of the structural elements was optimized. After the customer approved the proposed design, the prepared documentation was moved to the production phase - CNC machining on multi-axis machining centers of MECASYS' own machine park, which allow high-precision processing of complex geometries.
The individual components of the proposed measurement jigs were assembled into the final measurement jig, and the jig subsequently underwent an output check, including CMM measurement and repeatability analysis (MSA), which confirmed the achievement of the required reliability and repeatability when using this gauge. The use of a modular design concept allowed the inspection solution to be flexibly adapted to different types of parts, while speeding up the entire quality verification process.
The technological context of the solution:
The solution developed by MECASYS also responds to broader trends in the automotive industry, where accurate and flexible measurement systems play a key role in the digitalization and automation of production.
The automotive sector faces constant pressure to improve quality, reduce production costs and shorten cycle times. Today, flexible and scalable measurement solutions are essential to remain competitive and able to respond quickly to product changes or regulatory requirements.
Competitive advantage:
MECASYS offers solutions that overcome the limitations of traditional approaches through modular design concepts, advanced 3D technologies and automation of inspection processes. Measuring jigs in a modular architecture can be easily expanded or customized, minimizing investment costs and eliminating downtime when changing production programs.
Testing and validation:
Each measuring fixture was tested on state-of-the-art CMM Global S coordinate measuring machines from HEXAGON METROLOGY. Verification of each component and the entire jig ensured high accuracy and repeatability of measurements while adhering to the most stringent international standards.
The use of CMM technology enables automated measurement in five axes as well as continuous profile surface measurements. These processes eliminate human error and allow detailed inspection of even complex geometries - without the need for special fixtures.
Results and benefits
By implementing the measuring jigs designed by MECASYS, the client achieved a significant improvement in the quality and stability of the production process. Thanks to the precision-engineered and modularly designed jigs, all dimensional requirements within tolerances of 0.01 mm were met while optimizing internal processes.
Key benefits include:
1. Accuracy within 0.01 mm: all geometric parameters were stably achieved without the need for additional corrections.
2. Measurement repeatability: thanks to CMM inspection and MSA analysis, the ability of the formulations to provide consistent results in batch production has been confirmed.
3. Error reduction: accurate measurement and validated part clamping eliminated dimensional variations in output.
4. Fast deployment: digital design and verification in a 3D environment enabled smooth implementation without production downtime.
5. Inspection cost savings: continuous CMM measurements and shared documentation have eliminated the need for repeated initial inspection by the customer.
6. Readiness for future development: the modular architecture of the fixtures allows for flexible adaptation when products or checkpoints change.
These results have not only strengthened the reliability of the production process, but also the client's confidence in MECASYS' technical solutions.
Conclusion
The project for an automotive industry client highlighted MECASYS' capabilities in the design and manufacture of precision measuring fixtures. At the start of the project, the emphasis was on detailed 3D modelling and digital validation of concepts using SolidWorks software, which enabled the design of jigs to be optimised prior to final production. This phase eliminated the need for physical prototyping and allowed potential flaws to be detected and eliminated in the early stages.
Thanks to modular elements and precise workmanship of the measuring jigs, the client achieved consistent quality and efficiency. Controlling deviations using CMM technology ensured high reliability and minimized manufacturing errors.
Measuring jigs designed by MECASYS enabled precise clamping and inspection of plastic parts with minimal deviations. Their robust design and compatibility with coordinate measuring machines have significantly improved production processes.
Subsequent production on multi-axis CNC machines and thorough quality control via coordinate measuring machines (CMMs) ensured the accuracy and consistency of the results. A CMM output report and MSA analysis was produced for each measuring fixture, guaranteeing the client the required accuracy and repeatability of production. These measures contributed to reducing errors, speeding up inspection processes and increasing product reliability.
With this project, MECASYS not only met the client's specific requirements, but also demonstrated the ability to provide customized solutions that meet stringent quality standards. This supported the client's growth and competitiveness in the market. In the context of current trends in the automotive industry, where the emphasis is on digitalization, automation and flexibility, MECASYS solutions represent a strategic advantage for future development and success in the global market.
Your needs, Our expertise
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MECASYS designs and delivers customized measuring jigs - reliably, flexibly and in accordance with the demanding requirements of your production.
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