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Production Integrated Quality Assurance

Team leader: Dr. Alfons Schuster

Quality for production: inline, please!

Inline, of course – that's how the quality assurance of tomorrow should work. Thanks to the focus of the DLR Center for Lightweight Production Technology in Augsburg on the production-integrated real-time acquisition of manufacturing data in combination with specialised sensor systems for quality parameters adapted to the process, production can be continuously monitored and readjusted in good time before rejects even occur.

Methods for inline QA: Exploiting the full potential

Our QA methods include

  • Optical metrology
  • Computer vision
  • Laser light sectioning
  • Fibre angle measurement
  • Laser tracking, point clouds
  • Thermography (passive, lock-in, pulse, ultrasound stimulated, 3D)
  • Air-coupled ultrasound (reflection, transmission, Lamb wave)
  • Process and environmental data acquisition
  • Data storage and evaluation
  • Automated evaluation using adapted algorithms, machine learning and artificial intelligence
  • Digital twins and offline programming

We are also happy to develop tailor-made solutions with you. The holistic approach is particularly important to us – measurement data is not just data, but is directly related to reality: to components, design, construction drawings, material parameters, simulation and much more. For example, the depth-resolved 3D thermography developed at the ZLP Augsburg allows defect localisation directly in the component coordinate system. In this way, test results can be immediately fed back into design and simulation.

Full-scale and inline: The key to productivity

Carrying out measurements on large components quickly and cost-effectively and never losing sight of the big picture – that is our expertise. From a detailed CAD model that perfectly matches with reality, to tailor-made offline programs or autonomous automation solutions, through to 3D-localised measurement values on full-scale components – only the fusion of all data sources produces reliable quality. Inline and full-scale for the quality assurance of tomorrow – our vision for the future that we are already working on today.

 

PQS gallery

Depth-resolved 3D thermography

 

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High-resolution air-coupled ultrasound

 

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Lamb Wave excitation angle calculation by material simulation

 

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Air coupled ultrasound measurements on a pressure dome

 

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Automated defect detection during tape laying

 

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Inline measurement of gap and overlap in real time

 

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Autonomous production of thermoplastic components

 

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Roving inspection during fibre winding

 

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Computer vision for autonomous production

 

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Inline detection and testing of semi-finished goods

 

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Deposition control during textile preforming

 

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Geometry inspection of cut pieces

 

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Data mining in production environments

 

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Robotic fiber angle measurement

 

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Process data acquisition and monitoring

 

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Process simulation and manufacturing engineering

 

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Quality control during tape laying

 

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Quality control for resistance welding

 

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Contact
Dr. Alfons Schuster
Head of Group

German Aerospace Center (DLR)

Institute of Structures and Design
, Center for Lightweight Production Technology
Augsburg

Tel.: +49 821 319874-1050

Copyright © 2021 German Aerospace Center (DLR). All rights reserved.