Virtual clamping in automotive production line measurement

Mechanical clamping of a production part in production line measurement causes numerous functional problems in automotive industry quality control. It kills flexibility and brings non-value adding costs. Being able to mathematically model the effect of clamping to the part, these problems could be overcome. Empirical research using statistical and 3D-analysis show, that the effect of mechanical clamping can be estimated accurately with a locally linear model using finite element analysis. The accuracy of this mathematical estimate is sufficient for production line use. Experiments, supported by Daimler AG, have been done using a production line measurement system. Using a mathematical model to estimate the behavior of the measured part while clamped is called virtual clamping.

► Eliminating the traditional mechanical clamping devices yield major benefits.
► Clamping can simulated with a locally linear model created with FEM analysis.
► Empirical study shows that virtual and mechanical clamping correlate accurately.
► Adjusting the process to fit final assembly can be done more accurately virtually.