Measuring Product Dimensions during Assembly

Abstract

During the spring term of 2021 a thesis was carried out at Volvo Trucks GTO. Volvo Trucks is one of the largest and most successful actors in the automotive industry and delivers trucks all over the world. The company offers trucks that can be customized and adapted according to the customer wishes.

Offering highly customizable trucks puts a lot of stresses on the system which requires that CAD-drawings, component documentation and all databases are synchronized and updated according to the changes done on the truck. It has been observed within the company that the actual dimensions of the trucks do not always coincide with the system dimensions. The deviations in dimensions of the truck causes problems during transports as the trucks either exceeds or fall under the system dimensions.

The objective, having the above in mind, has been to achieve a better understanding of how different measurement techniques can be used as an automated system for industrial inspection. Using the system, the aim was to collect data to enable a root-cause analysis on the deviations.

In the project, different sensors have been tested in order to identify a capable sensor for a future automated system. During the project it became apparent that the objective of using the sensor for collecting data could not be achieved. There were several factors that led to this conclusion. But mainly it was due to the lack of time, but also due to the difficulties faced when calibrating and programming the sensor to achieve reliable and accurate measurements. However, the struggle of trying to use the sensor provided a lot of knowledge and data which was considered to be of great value for Volvo. The collection of data and analysis was still accomplished, using a manual ruler stick which worked better than expected.

Some pre stated factors and causes, and consequences were justified by the measurements and analyzation of data, while others were rejected. A recommendation for the one who will continue in the footsteps of this project, is that they should continue collecting data, both from measuring in Tuve and reports from carriers. The reports should also be improved and documented more carefully to make sure that important information is not being lost.

Abstract (Swedish)

Under vårterminen 2021 genomfördes en avhandling på Volvo GTO. Volvo Lastvagnar är en av de största aktörerna inom fordonsindustrin och levererar lastbilar över hela världen. Företaget erbjuder lastbilar som kan anpassas och modiferas efter kundens önskemål.

Att erbjuda lastbilar med hög anpassnings- och förändringsgrad innebär en hel del påfrestningar på systemet vilket kräver att CAD-ritningar, komponentdokumentation och alla databaser synkroniseras och uppdateras enligt de ändringar som gjorts på lastbilen. Det har observerats inom företaget att lastbilarnas faktiska dimensioner inte alltid sammanfaller med systemdimensionerna. Avvikelserna i lastbilens dimensioner orsakar problem vid transporter eftersom lastbilarna antingen överskrider eller faller under systemdimensionerna.

Målet, med ovanstående i åtanke, har varit att uppnå en bättre förståelse för hur olika mättekniker kan användas vid ett automatiserat system för industriell inspektion. Med hjälp av systemet var syftet att samla in data för att möjliggöra en rotorsaksanalys av avvikelserna.

I projektet har olika sensorer testats för att kunna användas i ett framtida automatiskt system för inspektion. Under projektets gång blev det uppenbart att målet att använda sensorn för insamling av data inte var möjlig. Det fanns flera faktorer som ledde till denna slutsats. Främst berodde det på tidsbrist, men också på de svårigheter som uppstod vid kalibrering och programmering av sensorerna för att uppnå tillförlitliga och exakta mätresultat. Strävan att försöka använda sensorerna gav dock mycket kunskap och data som ansågs vara av stort värde för Volvo. Trots problemen och hindren så genomfördes datainsamling och analys med hjälp av en manuell linjalsticka som fungerade bättre än förväntat.

Vissa, på förhand givna faktorer och orsaker, och konsekvenser bekräftades av mätningarna och analysen av data, medan andra avvisades. En rekommendation för den som kommer tar över projektet är att fortsätta samla in data, både från mätningen vid Tuve och rapporterna från transportörerna. Dessa rapporter bör också förbättras och dokumenteras mer noggrant för att säkerställa att viktig information inte förloras.

Popular Abstract

During the spring term of 2021 a thesis was carried out at Volvo Trucks GTO. Volvo Trucks is one of the largest and most successful actors in the automotive industry and delivers trucks all over the world. The company offers trucks that can be customized and adapted according to the customer wishes.

Offering highly customizable trucks puts a lot of stresses on the system which requires that CAD-drawings, component documentation and all databases are synchronized and updated according to the changes done on the truck. It has been observed within the company that the actual dimensions of the trucks do not always coincide with the system dimensions. The deviations in dimensions of the truck causes problems during transports as the trucks either exceeds or fall under the system dimensions.

The objective, having the above in mind, has been to achieve a better understanding of how different measurement techniques can be used as an automated system for industrial inspection. Using the system, the aim was to collect data to enable a root-cause analysis on the deviations.

In the project, different sensors have been tested in order to identify a capable sensor for a future automated system. During the project it became apparent that the objective of using the sensor for collecting data could not be achieved. There were several factors that led to this conclusion. But mainly it was due to the lack of time, but also due to the difficulties faced when calibrating and programming the sensor to achieve reliable and accurate measurements. However, the struggle of trying to use the sensor provided a lot of knowledge and data which was considered to be of great value for Volvo. The collection of data and analysis was still accomplished, using a manual ruler stick which worked better than expected.

Some pre stated factors and causes, and consequences were justified by the measurements and analyzation of data, while others were rejected. A recommendation for the one who will continue in the footsteps of this project, is that they should continue collecting data, both from measuring in Tuve and reports from carriers. The reports should also be improved and documented more carefully to make sure that important information is not being lost.

• author: Koca, Serhat and Andersson, Hilda
• supervisor: Christina Windmark; Andrii Hrechuk; Henrik Paulsson; Bas De Craene
• organization: Production and Materials Engineering
• alternative title: Inspektion och Måttagning av Produktdimension under Produktion
• course: MMTM05 20211
• year: 2021
• type: H2 - Master's Degree (Two Years)
• subject: Technology and Engineering
• keywords: Production, Inspection, Vision Technology, Quality, Product Dimension, Measurement.
• report number: CODEN:LUTMDN/(TMMV-5318/1-64/2021
• language: English
• id: 9053135
• date added to LUP: 2021-06-14 13:48:26
• date last changed: 2021-06-16 23:42:20