GOM Automotive Testing

GOM mbH
Optical Metrology in
Automotive Testing
June 2014

2-2-Frame Setup / Frame 1 Frame Setup / Frame 2
Full-field 3D Coordinate Measurement
Static 3D-Deformation Analysis
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Optical Metrology in Automotive Testing
GOM
Page 2
Agenda
GOM: Optical Measuring Techniques
Dynamic 3D-Deformation/Motion
Analysis

GOM is a global partner for optical 3D metrology
with over 20 years' experience
GOM
Page 3
GOM – Optical Measuring Techniques
Company structure
· Development,
manufacturing and sales
· Over 300 employees
· 7 GOM branch offices in
Europe
· 45 dedicated partner
offices worldwide
· More than 7,000
installations
· Measurement technology
for companies from the
automotive and aerospace
industries as well as from
the consumer goods
sector

Material Testing
ARAMIS
ARGUS
TRITOP
PONTOS
ATOS
GOM
Page 4
GOM – Industrial 3D Metrology
Measurement systems
Full-field
3D Digitizing
3D Shape and Dimension
Inspection
Dynamic Component Testing
Full-field
3D Strain
Measurement
Deformation
Analysis in
Sheet Metal
Forming
Mobile
Optical CMM
Dynamic
3D Analysis

Inhouse development,
production, sales,
training concept & support
GOM
Page 5
All under one roof
Development Production Sales Training Support

3D3 mDMeeassssuyrsetemmee nt 3D software Industrial know-how
systems
GOM
Page 6
Solutions from a single source
ATOS
Professional
ATOS
3D measurement
system
Free
software
Tool
& mold
making
Injection
molding
Sheet metal
forming
Parametric
software
Integrated processes from data acquisition to evaluation and application

Optical Metrology
Systems
Overview

GOM
Page 8
Application areas and results
3D geometry measurement
Shape and dimension inspection
Material testing
Material parameters
Component testing
Simulation comparison

GOM
Page 9
GOM measuring systems
Component testing
ATOS
ATOS ScanBox
TRITOP
ARAMIS
PONTOS
PONTOS
ARAMIS
TRITOP ARGUS
3D geometry measurement Material testing

Component testing
3D geometry measurement Material testing
GOM
Page 10
GOM measuring systems and evaluation software
Viewer and evaluation software
ATOS
ATOS ScanBox
TRITOP
ARAMIS
PONTOS
PONTOS
ARAMIS
TRITOP ARGUS

ATOS 3D Scanner
Full-field 3D Coordinate
Measurement

GOM
Page 12
Fringe projection technique: ATOS 3D digitizer
· Optical 3D scanner for three-dimensional
component measurement and inspection
· Non-contact and independent from object
size, surface characteristics and
component complexity
· Full-field, precise 3D coordinates
· Injection molding and
plastics industries
·Sheet metal forming
industries
· Casting industry
· Tool and mold making

GOM
Page 13
ATOS: Measurement process in three simple steps
Step 1
Measurement
Step 2
Alignment
Step 3
Evaluation
All 3D measurement data and
inspection results in compact
format for exchange and further
analysis
Free GOM Inspect software Colleagues and customers

Reverse Engineering
Additive Manufacturing
GOM
Page 14
ATOS 3D Digitizer
3D measurement data for follow-on processes
3D Mesh (STL)
High resolution for finest details
Measurement of small radii
CNC Machining
Data for follow-on processes
Quality Control

TRITOP
Static 3D Coordinate
Measurement

GOM
Page 16
TRITOP
3D Measuring system for static deformation analysis (point-based)
TRITOP
Static deformation analysis
· Measurement of individual points
Measurement and evaluation of
· 3D coordinates
· 3D displacements
· Vector fields
· Visualization of results
on CAD data and camera images
Replacing
· Conventional distance sensors
Movement and deformation analysis

Design Load tests
CAD
Mold & tool
making
Simulation Injection-molded
TRITOP
Assembly: joining process and distortion
Component tests: distortion/failure, static loads
GOM
Page 17
TRITOP
3D Measuring system for static deformation analysis (point-based)
Load tests
· Thermal = climate chamber
· Mechanical = rigidity analysis
Deformation analysis
· Before/after assembly
· Impact of joining process
Inspection and optimization of
· Material/material combinations
· Design and structural analysis
(construction)
· Mounting concepts
parts
Assembly

GOM
Page 18
TRITOP – Static 3D Deformation Measurement
Environmental Testing of Components
· System: TRITOP High Resolution
· Environmental-testing of the Front End in
a climate chamber.
· Temperature range: 20°C – 85°C
· Reference temperature at 20°C
· The Front End stays for several days in a
climate chamber at a given temperature.
· After that the Frond End is measured
again at reference temperature to
determine the deformation.

GOM
Page 19
· Measuring the gap size change an the
flush change.

GOM
Page 20
· Measuring the gap size change an the
flush change.

PONTOS
Dynamic
Deformation Analysis

GOM
Page 22
PONTOS
3D Measuring system for dynamic deformation analysis (point-based)
PONTOS
Dynamic deformation analysis
· Measurement of individual points
· 3D coordinates
· 3D displacements and deformation
· Speed, acceleration
Replacing
· Acceleration sensors
for low-frequency applications
Dynamic component behavior
· Static to highly dynamic
· 6 DOF analyses
Validation of FE simulations

GOM
Page 23
PONTOS – Dynamic Deformation Analysis
3D Measuring system for dynamic deformation analysis (point-based)
Typical Appilications:
· Door, hood and closures tests on vehicles
· Measurement of the dynamic engine motion and
deformation
· Crash applications such as head impact, leg impact and
pendulum tests
· Vibration analysis of vehicle components
· Measurements of movements of vehicle components
· Deformation measurements of suspension components
· Deformation measurements on engine test bench
· Stiffness measurements of components

GOM
Page 24
Door Slam Analysis
Application: Door Slam
· Determination of door deformation during
the door slam process
· Behavior of the door lock mechanism
· Compression of the seal  aproving door
seal concept
· Determining the closing speed
· Determination and optimizing steps for
reducing the Door closing speed
∙ About 80 3D measurement points
∙ Setup time: about 40 minutes

GOM
Page 25
Door Slam Analysis
· Measuring Frequency 500 Hz
· Evaluation time: about 10 minutes

GOM
Page 26
Door Slam Analysis
· CAD
· Comparison to CAD
· Link CAD meshes
to components
· Animation

GOM
Page 27
Crash Testing: Sled Crash
· Speed analysis of different
components
· 3D movement of
components
· Deformation of
components
· 6-DoF (Angle) analysis of
components
· Trajectories of
components

GOM
Page 28
Crash Testing: Sled Crash

ARAMIS
Full-field Deformation
Analysis

GOM
Page 30
ARAMIS
Measuring system for dynamic deformation analysis (full-field)
ARAMIS
· Full-field measurement
· Full-field 3D deformation
· Full-field strain
· Material parameters
Replacing
· Strain gauges
Dynamic component behavior
· Static to highly dynamic
· Bulge tests and failure analysis
Definition of material parameters
and validation of FE simulations

Design Load tests
CAD
Mold & tool
making
ARAMIS
Determination of material parameters
GOM
Page 31
ARAMIS
Application: Determination of material parameters
Parameters for virtual development
· Material characteristics (e-module, anisotropy, …)
Local measurement for precise determination of
material parameters
· Tensile, pressure, shear, bending tests
High-resolution, non-tactile measurement
· Detailed full-field information
Inspection and optimization of
· Input parameters for simulation
· Simulation results
· Product development
parts
Assembly

GOM
Page 32
ARAMIS
Application: Determination of material parameters
Design Load tests
CAD
Mold & tool
making
parts
Assembly

Design Assembly
CAD
Mold & tool Load tests
making
GOM
Page 33
ARAMIS
Application: Component Testing with static and dynamic loads
· 3D displacement and deformation
· Strain and failure behavior
Optimization of
· Component reliability and construction
· Material/material combinations
· Function inspection
Comparison with FE simulation
parts

Design Assembly
CAD
making
parts
GOM
Page 34
ARAMIS
Airbag Testing
· Measuring the Airbag deployment to evaluate the deformation of the cover from the
passengers airbag
· Evaluate the speed and strain of the cover from the passengers airbag

Design Assembly
CAD
making
parts
GOM
Page 35
ARAMIS
Airbag Testing
· Measuring the Airbag deployment to evaluate the deformation of the cover from the
passengers airbag
· Evaluate the speed and strain of the cover from the passengers airbag

GOM
Page 36
ARAMIS
Tire Testing
· Measure the deformation of tire wall
· Determine strain of tire wall
· At speed from 0km/h up to more than
300km/h
· At different wheel loads

GOM
Page 37
ARAMIS
Tire Testing

GOM
Page 38
ARAMIS
Tire Testing
ARAMIS System an Rollenprüfstand

ARAMIS PONTOS TRITOP ATOS
GOM
Page 40
Static and Dynamic Load Tests on Plastic Components
Summary
Static and dynamic
deformation analysis
· Point-based and full-field
Replacing conventional distance sensors
Comparison with simulation
· Point-based and full-field
Optimization and acceleration of the
development process

Component
Thank you for your
attention
info@gom.com
www.gom.com

GOM Automotive Testing

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