FRS Robotics introduces an adaptive robot cell that automates the ultrasonic inspection of fold glue joints of Audi vehicle doors. By innovating adaptive robot control software, FRS adds the required robot intelligence to continuously take valid ultrasonic measurements along the folded door edge.

Metrology plays an important role in verifying the quality of sheet metal stamping and assembly operations. Certain vehicle door types consist of metal sheet inner and outer parts which are glued, plied and welded along the door edges. Ultrasonic inspection is performed manually to verify correct glue bonding. Audi asked FRS Robotics to automate the ultrasonic quality control of the doors’ fold glue joints.

As a result, FRS introduced ‘Robotic Ultrasonic QC’ which applies adaptive sensor positioning to obtain valid measurements. Based on contact forces and ultrasonic measurements, FRS continuously adjusts the position and orientation of the ultrasonic sensor in real time.

Concretely, inspections in the FRS robot cell start with an operator positioning a door on an elementary stand or table. Adaptive robotic inspection does not require precision fixation nor clamping of the door. The operator manually moves the robot arm to bring the ultrasonic sensor to the position where the inspection starts and clicks a button to begin automated inspection. Alternatively, the robot moves autonomously to the starting position and starts inspection. Inspection continues along the door edge until the quality control of the fold glue joints of the car door is completed.

The FRS robot cell is able to execute ultrasonic inspection of series of vehicle doors – handling geometric variations in production. Switching to a series of another door type requires clicking a software button. Overall, the FRS robotic software is able to automate a range of ultrasonic and other manual quality control applications, which have not been automated so far for technical or economic reasons.

For more information, visit FRS Robotics website.