In the ultra-competitive world of automotive, getting the right manufacturing technology partnerships in place is a critical factor on the road to success. Digital transformation projects have the potential to drive efficiency and productivity, but without the ability to configure solutions to the precise needs of the manufacturer, many systems simply cannot be installed.

Optimise every step

Tools and solutions from Hexagon go into the development and production today of 95% of the world’s passenger cars and light commercial vehicles. This metrology, production and automation portfolio spans every stage of manufacturing. Tailored into unique, configurable, and scalable toolkits, the capabilities from Hexagon offer companies what they need to begin building or to finalise their digital ecosystem.

A history of quality

VW Group has been globally supported by Hexagon for many years, for example with ongoing projects including automated inspection solutions for the Volkswagen Touareg, Porsche Cayenne, Audi Q7 and Audi Q8 models at Volkswagen Slovakia plant in Bratislava.

Back in 2018, Hexagon also supported Škoda in reconfiguring their inspection processes with 3D optical systems replacing tactile measurement in Mladá Boleslav, Czech Republic with two fully two automated cells ‑ predecessors of the standardised PRESTO Quality Stations.

With this platform of trust built over many years, Volkswagen Slovakia turned to Hexagon when they needed an automated inspection solution for the new generation of VW Passat and Škoda Superb models due to be produced in Bratislava. Volkswagen Slovakia’s requirement included the ability to measure 14 different hang‑on parts with guaranteed capacity for 6 complete bodies within one 8‑hours shift. 

The challenge met

Due to their Class A surfaces being in regular physical contact with the user, hang‑on parts are of critical importance. For example, the tailgate and doors not only need to move and connect with the frame securely but must promote a positive tactile experience for the end user. They also tend to have challenging geometries, which emphasises the need for highly accurate and flexible measurement capabilities.

The solution required by Volkswagen Slovakia needed to be flexible in other ways too. Not only did the inspection system need to offer best‑in‑class accuracy for measuring this range of different parts, but it also had to fit into the existing 17m x 7m of available space.

Volkswagen Slovakia’s modular solution consisted of:

• Four rotary tables which between them would cover the different typology of the parts
• Leica Absolute Tracker AT960 on a slider, tracking the Absolute Scanner AS1 mounted on the robot
• An operating system fully equipped with HxGN Robotic Automation and PC‑DMIS software

A final requirement from Volkswagen Slovakia, based on their existing agreement with the company, was that the robot arm within the inspection cell needed to be supplied by an external supplier. The Hexagon team agreed to incorporate this request in place of the standard component.

After installation, the programming process began, ensuring that the automated inspection cell functions just as Volkswagen Slovakia need it to.

Outcomes that drive success

With the inspection process enhanced with greater levels of automation, the production plant in Bratislava has benefited from improved efficiency, quality control and productivity.