Bauser Relies on Hexagon’s QUINDOS to Overcome Complex Gear Measurement Challenges
Werner Bauser GmbH uses Hexagon’s QUINDOS software to enhance its research and development (R&D), manufacturing, and quality control processes.
Image: © courtesy of Werner Bauser GmbH
Founded in 1962, Werner Bauser GmbH is a leading manufacturer of plastic gears and injection moulded parts. The company serves clients worldwide, with a focus on the automotive industry, e-mobility, and other sectors. Bauser employs approximately 200 people and operates 82 injection moulding machines, producing an average of 750,000 parts daily.
Quality assurance is of utmost importance in the plastic gear manufacturing industry as it directly impacts product performance and reliability. Computed tomography (CT) scanning, combined with advanced gear measurement software like Hexagon’s QUINDOS, provides a comprehensive solution for quality assurance and product improvement.
Bauser searched for advanced technology to ensure the highest quality standards for its products. The company uses Hexagon’s QUINDOS software to enhance its research and development (R&D), manufacturing, and quality control processes.
Challenge: Limitations of traditional inspection methods
Bauser faced significant challenges when conducting intricate measurements on their complex gear designs. Many of Bauser’s products involved small geometries with modules smaller than 0.5 mm, with the smallest standard being 0.3 mm. Conducting measurements took considerable time, requiring engineers to find ways to measure these small gears successfully and economically.
“Bauser has many products with designs that incorporate complex gears and component interactions. We needed a way to study these designs without having to disassemble the components. We also needed the ability to compare moulded parts to CAD models,” said Klaus Stein, Senior R&D Engineer at Bauser.
In addition, Bauser faced increasing customer demand for more comprehensive measurements and data. However, the company found that traditional methods like coordinate measuring machines (CMMs) had limitations in measuring small geometries and internal gears, making it difficult to gain a comprehensive understanding of the parts.
QUINDOS Reporting: Gear specific evaluations & deviation representation with colour mapping
Image: © courtesy of Werner Bauser GmbH
Solution: Implementing QUINDOS
Bauser evaluated solutions, ultimately choosing Hexagon’s QUINDOS solution due to its reputation for reliability and the expertise of Hexagon’s team. The company valued QUINDOS’s open system architecture, which facilitates data exchange between different measurement technologies.
At Bauser, Hexagon’s QUINDOS software performs various functions, including analysing point cloud data from CT scans, performing high-precision gear measurements, and comparing results to CAD models.
It’s important to note that QUINDOS gear evaluation from point cloud data is the same as when using tactile measurements. The algorithms, filters and user experience are identical and the results are comparable.
QUINDOS’s flexibility allows Bauser to integrate CT scanning with gear measurement, providing a more comprehensive quality control process.
The software’s point cloud evaluation capabilities make it easy for engineers to gather accurate measurements of small, complex gear geometries — something that was previously difficult (or impossible) to measure with traditional CMMs. With QUINDOS, Bauser can quickly adapt the measurement programs and carry out post-analysis at any time, giving engineers more flexibility when analysing STL models.
QUINDOS Gear: Measurement on CT gear mesh in CNC mode
In addition to QUINDOS, Bauser uses Hexagon’s Volume Graphics’ VG StudioMax for its CT scanning needs. This software allows engineers to visualize and analyse the internal structure of gears, providing crucial insights into potential defects or inconsistencies that may not be visible from the surface. By combining VG StudioMax for CT analysisand QUINDOS for gear measurement, Bauser has a powerful, integrated solution for comprehensive quality control.
Additionally, QUINDOS’s ability to work with CT scan data means Bauser can combine gear measurements with other quality control checks. “We use CT for geometry measurement, checking air inclusions and porosity,” Stein noted. This dual-purpose use of CT technology allows Bauser to conduct thorough quality checks without destructive testing, providing a more complete picture of part quality.
Results: Enhanced product development and quality control
By implementing QUINDOS, Bauser has significantly improved its product development and quality control processes.
Specifically, Bauser improved its ability to measure and analyse complex, small-scale gears. The company can now quickly characterize the geometry of prototype samples and compare them against functional performance during the product development cycle. The reduced design iteration time allows the company to make faster design and tooling changes.
The improved quality control process, enabled by QUINDOS, has contributed to Bauser’s reputation as a leading manufacturer of high-quality plastic gears and injectionmoulded parts.
Using QUINDOS has allowed Bauser to meet increasing customer demands for more comprehensive measurements and data, ultimately benefiting the many industries that rely on its high-precision plastic.
Image: © courtesy of Werner Bauser Gmb
Future plans
Looking ahead, Bauser plans to integrate QUINDOS into its workflow further, potentially using it earlier in the iterative design process. “Our idea is to use CT data at the beginning of the iterative process, where CT’s greater measurement uncertainty would not be a drawback,” Stein explained. “Then, in the last stage, we’ll go back to the CMM.” Stein believes this approach could further streamline the organization’s development process and reduce iteration time.
To maximize QUINDOS’ benefits, Bauser is also planning comprehensive inhouse training. This training investment demonstrates the company’s commitment to fully leveraging QUINDOS’ capabilities across its team.
QUINDOS inspection with Mesh & Point Clouds module: comparison with 3D CAD data