AUTOMATED OPERATION AT VOLKSWAGEN WITH ATOS 3D SCANNER

Key Figures of the Volkswagen Group in 2006

Production Plants of the Volkswagen Group 2006

Production Network 2006 – Germany: Wolfsburg

Volkswagen has implemented an automated, robot-supported measurement system for suspension parts, utilizing the ATOS sensor. This initiative, presented by Dr. Boris Thielbeer, aims to enhance quality control and streamline the measurement process within the Volkswagen Group.

Enhancing Suspension Part Measurement with Automated 3D Scanning

Why Measure Suspension Parts?

Suspension components play a critical role in vehicle performance and safety. Accurate measurement is essential to ensure quality control, detect deformations, and verify part integrity — especially when analyzing components before and after vehicle misuse or accidents.

An advanced automated system has been developed to measure both front and rear suspension parts across various Volkswagen models, including the Golf and Passat. The parts scanned include:

• Rear suspension components such as:

  • Welding group subframe (1100 mm x 570 mm x 250 mm)

  • Lower track control arm (630 mm x 190 mm x 70 mm)

  • Trailing link (450 mm x 170 mm x 50 mm)

  • Bracket (230 mm x 170 mm x 70 mm)

• Front suspension components such as:

  • Subframe (920 mm x 400 mm x 200 mm)

  • Steering knuckle (250 mm x 250 mm x 200 mm)

  • Track control arm (400 mm x 350 mm x 60 mm)

The main objective is to detect and assess significant part deformation, which commonly occurs due to operational stress or improper usage.

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From Manual to Automated: A Leap in Measurement Efficiency

Traditionally, the measurement of suspension parts was a labor-intensive task. Manual processes included:

• Marking measurement points with a center punch

• Taking linear measurements using a marking gauge

• Assessing angles with a circular level device

These methods, while functional, were time-consuming and prone to human error. In contrast, the automated scanning system dramatically enhances efficiency and repeatability.

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Robot Station Setup: Tailored for Precision

The system is built around a custom robot station featuring:

• A rotation table with a diameter between 640 mm and 1000 mm

• An irregular point grid with an average spacing of 60 mm

Initial setup included the dismounting of a legacy robot, with collaboration from production departments to reinstall and initialize the system. Technical support from Jürgen Herrmann (GOM) was instrumental in integrating the robot with the ATOS 3D scanning system.

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Automated Scanning and Evaluation

The system leverages pre-programmed measurement routines for various part types. One of its key features is macro-based automation provided by the ATOS software suite. This enables streamlined scanning, data processing, and evaluation — significantly reducing operator input and ensuring consistent, high-quality results.

By replacing outdated manual methods with a high-precision automated system, the process of measuring suspension components has become faster, more accurate, and far more scalable. This is a crucial step in ensuring automotive safety and quality, especially for complex part geometries and real-world deformation analysis.

Conclusion and Summary:

• The implementation of the robot-supported measurement system with the ATOS sensor represents a significant step towards enhanced quality control at Volkswagen.
• The system offers improved efficiency and accuracy compared to traditional measurement methods.
• Future improvements are desired, including:
  • “Better documentation of built-in python functions.”
  • “Floating license.”
  • “Better support of standard Linux systems.”
  • “Improved backup functionality.”