Off-Highway and Commercial Vehicles
From complex components to fully assembled vehicles – we enable automated quality inspection for the commercial vehicle and off-highway industries.
Challenge: Large component dimensions, robust application requirements.
Benefit: Our measurement technology solutions guarantee precise testing, even for large structures - directly in the production process and without wasting time.
Intelligent Quality Assurance Throughout the Entire Manufacturing Process
The manufacturing of commercial vehicles places the highest demands on quality, process stability and efficiency. Large vehicle structures, numerous model variants and complex assembly processes require reliable quality control across all stages of production. NEWSTON offers high-performance inline measurement technology that integrates measurement and inspection processes directly into production, thereby enabling end-to-end quality assurance.
Comprehensive Inline Quality Assurance
Our robot-guided measurement systems inspect geometries, gaps, flushness, and surfaces directly in time with the production cycle. Continuous monitoring allows defects to be detected immediately and processes to be corrected early on. This reduces rework, prevents scrap, and ensures stable manufacturing processes.
Our solutions support commercial vehicle manufacturers throughout the entire production process, including:
- Geometric measurement of structural components and assemblies
- Inspection of frames, cabs, and vehicle bodies
- Inspection of function-critical features
- Full-surface 3D digitization of complex assemblies
- Automated surface inspection
- Measurement of gaps and flushness
- Quality control in final assembly
- Traceability and process documentation
Data-Driven Process Optimization
Modern inline measurement technology continuously provides quality data that can be used to monitor, analyze, and optimize manufacturing processes. After all, a smart factory can only be realized in the long term with reliable and robust measurement data. Early detection of process deviations supports closed-loop quality control, even across different production lines. This results in stable processes, higher equipment availability, and improved product quality.
Metrology Goes Inline
Our AICell trace measures complex features such as bolts, edges, holes, or hidden geometries, as well as functional dimensions on vehicle bodies and structural components. Using the high-speed 3D sensor AIMax cloud II and innovative tracking technology, it captures highly accurate measurement data in real time. The result is dense 3D point clouds. This correlation-free measurement system, together with its accompanying software, enables flexible configuration of statistical analyses.
The AICell scan measurement system digitizes the entire body-in-white of truck cabs. Multiple optical 3D sensors capture the geometry from different angles and generate high-resolution, traceable 3D measurement data. Relevant inspection features can be automatically derived from the comprehensive point clouds, and deviations from the CAD data can be reliably detected. This creates a geometric digital twin of the component, enabling a comprehensive assessment of manufacturing quality.
Smart Process Control
In Focus Area II - Smart Process Control - our product portfolio offers additional capabilities for your production processes: From individual parts to complete vehicles. The AICell measures complex features such as bent edges or a welded nut behind sheet metal. Automated surface inspection using AICell surface also operates reproducibly within cycle time and detects even the smallest defects and deviations. The foundation for closed-loop control and active process control is rounded out by gap and flush measurement with the AICell gap and flush. Our dual-head sensors, AIMax twin and twin UV, capture geometric dimensions on a wide variety of surfaces, such as metal, glass, plastic, painted, or unpainted. The AIMax triple head goes one step further and also provides vehicle coordinates for the features.
Our modular inline measurement solutions can be flexibly adapted to different production lines and integrate seamlessly into automated manufacturing environments. This enables commercial vehicle manufacturers to lay the foundation for efficient, reliable, and data-driven production.