AR offers the automotive industry many options. For this reason, Porsche AG and VISCOPIC came together during the STARTUP AUTOBAHN innovation program. The requirements of the car manufacturer were to find a scalable solution that adapts to the constantly changing requirements of the prototype environment at the Porsche Pilot Center.
When assembling a rotor, so-called laminated sheet metal stacks are placed on a shaft. For electromagnetic reasons, there are many different versions of these laminated sheet metal stacks, which have little geometric differences from one another. What makes this so difficult is that these differences cannot be recognized by the human eye and a high degree of variance arises regularly. Technicians face the challenge of not recognizing the order in which the many parts must be assembled. Porsche normally uses the Poka-Yoke principle for this, however it is not possible to implement this in the special component design. This is why Porsche and VISCOPIC have developed a digital Poka Yoke to support the employees. As part of our collaboration, the following steps were initially identified: 1) A feasibility study to identify the geometric differences with a high-resolution camera and the automatic extraction of the geometric features from the CAD data. 2) The construction of a prototype assembly workstation with automated component recognition. 3) Application-related realization of the final demonstrator and creation of the augmented reality workflow for digital support of the employees.
Together we created a demonstrator that offers the opportunity to counteract incorrect installations, using a prototype. With the VISCOPIC Computer Vision Setup, the sheet packages can be scanned individually and the scanned images are compared with the CAD originals. This information is then forwarded to VISCOPIC’s augmented reality software, which instructs the operator and reduces the error rate. This innovative approach serves as a universal tool that can be applied to many other types of components. Based on the generic solution, this setup can be used to recognize a large number of components that are based exclusively on CAD component data.
Within 100 days, we developed a completely new technology based on a generic solution and integrated it into the Porsche Pilot Center, which offers Porsche employees enormous added value.
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