Case Study Made to Measure: BMW in Leipzig Measurements Can Be Done Directly at the Item on Its Wish List Other Than the Leica Assembly Line

Case Study Made to Measure: BMW in Leipzig measurements can be done directly at the item on its wish list other than the Leica assembly line. In the past, a certain number T-Scan: namely, they wish the laser trackers 2 of cars had to be taken off the assembly line, were easier to install in difficult-to-reach creating logistical problems and causing places. Just recently the technicians had to 3 additional costs. install the laser tracker in a horizontal position However, the Leica Geosystems measurement when they needed to probe underneath the system is not only used in chassis building, it car, and this is something the laser tracker is equally at home when analyzing the entire was not built for. However, Illemann has a car. In order to do this, the chassis technicians solution for these applications as well: Leica conduct measurements of a completely Geosystems has developed an accessory into varnished car for their colleagues – a solution which the laser tracker can be installed so that that is both efficient and fascinating to it can operate in a horizontal positon. observe, as the mobility of the laser tracker is Good news can also be reported from at full display; the vehicles do not have to be Leica’s service department. Thanks to their 1 brought into a specific measuring room and commitment to developing the necessary are left on the assembly line instead. software interfaces, they earned additional Photo 1: Thanks to the Leica Laser Tracker and Leica T-Probe, BMW can now probe new car series economically, as they do not have to stop the assemby line and praise. From past experience, BMW knows can measure directly at the production plant. ”A ‘real’ measuring machine!” that Leica Geosystems service jobs are Photo 2: Chassis technicians conduct probing at a completely varnished car. With a few exceptions, the Leica T-Probe is performed quickly and extremely efficiently. Photo 3: Due to its flexibility, the Leica T-Probe can reach a wide range of surfaces and points, even those from hidden sight. used for practically all measuring tasks; the However, Leica Service has not made a single Did you know…? technicians appreciate this intelligent solution trip to Leipzig yet because everything has and use it for analytical measurements of both worked out according to plan and without Since March 2005, the BMW plant in By Simon Moser ”If you keep in mind what the main job of the mechanical connections belong to the past. small and large objects. Due to its flexibility, a glitch. Leica’s training concept also wins Leipzig produces up to 700 vehicles team is, namely, consultancy and support With the Leica T-Probe, even recesses and the Leica T-Probe can probe all kinds of praise: it is very practice-oriented and a day – currently the BMW 3 series Thanks to the new Leica T-Probe, a “Walk- in measurement safeguarding for chassis cavities can be measured with an astonishing points and surfaces. Therefore, it is not really contains more hands-on training” than sedan, the BMW 1 series three door, Around” armless and wireless mobile CMM, building, our laser tracker certainly is the precision: the length measurement precision surprising that the chassis measurement merely theoretical learning. Therefore, BMW’s coupé and convertible. More than 5,400 the use of Leica Geosystems laser trackers optimal tool for the multiple application areas is +/-0.06mm (2 Sigma) in a measuring technicians follow their vision to further next goal is to improve their probing skills employees work in the plant which was in the automotive industry is gaining due to its mobility and versatility. volume of up to 15m (49ft). When the LTD800 develop the Leica T-Probe and combine the with the existing equipment and further awarded several times for its innovative more and more momentum. In the newly By using the combination of a Leica Laser is used together with Leica T-Scan, Leica’s system with optical sensors; it is their goal increase their efficiency. architecture by Zaha Hadid. high-speed hand scanner, small and large constructed BMW plant in Leipzig, Germany, Tracker and a Leica T-Probe, the Leipzig team to put the Leica T-Probe into the “hands” Quelle: BMW this combination of a laser tracker and a could optimally reach its goal, as they now objects as well as complex surfaces can be of a robot and automate certain processes. Love at first sight Leica T-Probe convinces with its mobility, have a full-fledged 3D mobile coordinate measured simply and quickly with minimal “The advantages of the Leica T-Probe in the ”Our measurement system has fully met the www.bmw-werk-leipzig.de its measurement volume and its accuracy, measuring machine that does not block preparation times and regardless of surface automotive industry show pretty impressive expectations of the BMW measurement especially in chassis building. anything in the measuring area,” explains material. Objects can also be digitalized for results, especially at the BMW plant in technicians. With the Leica Laser Tracker Joerg Illemann, Leica Geosystems Sales reverse engineering applications. Just having Leipzig. Thanks to its multiple application and Leica T-Probe, they can probe new car Setting up a measurement facility according Engineer responsible for BMW in Leipzig. bought a Leica Laser Tracker, the Leica T-Scan areas, the Leica T-Probe has lead to some series very economically, as they do not have to one’s own ideas and visions in a newly built is on top of the wish list for BMW Leipzig. true ‘light bulb’ moments. I will never forget to stop the assembly line and can measure automotive plant, that must be the dream of A lot of Metes and Bounds: the Leica The impressive metrology equipment this experienced and seasoned measurement directly at the production plant. every dedicated technician in measurement Laser Tracker amassed by the BMW plant makes a lot of technician who said with astonishment that On top of all, the Leica T-Probe has increased technology. For the 11 people of the The laser tracker from Leica Geosystems is sense because the construction area has to the Leica T-Probe was a ‘real’ measuring the already broad range of applications of measurement crew from quality management an easy-to-transport, mobile coordinate be provided with enormous amounts of machine,” reports Illemann with pride. the laser tracker considerably, and its ease in chassis building, this dream has now come measuring system. Thanks to its built-in accurate information. Among the team’s of use simplifies the integration into the true – in the newly constructed BMW plant in laser interferometer, measurements can be tasks are random tests to check the Leica Tracker and Leica T-Probe proven measurement processes,” concludes Illemann, Leipzig. Within the scope of their “Geometrical carried out extremely quickly and with great production runs for a whole car series as well and tested adding with a smirk: “The BMW measurement safeguarding in chassis building” project, they precision. Regardless of whether single as analytical measurements. Also important The combination of a Leica Laser Tracker and team and the Leica T-Probe, that was love at purchased traditional fixed CMMs as well as points or entire surfaces are being measured: is conducting metrology jobs quickly and a Leica T-Probe as full-fledged coordinate first sight.” innovative mobile optical measuring systems. from a single position, the laser tracker efficiently, using the best-suited measuring measuring machines with “built-in mobility” For the flexible LTD800 Laser Tracker from can measure objects with a measuring tool available. and no need for dedicated space has been Leica Geosystems, this was a perfect working volume of up to 80 meters (131ft) in diameter superbly proven and tested. Crucial for this environment. and with an accuracy of +/-10 ppm Mobility as an unbeatable advantage judgement are the measurement volume and (μm/m), at a measuring rate of up to 3,000 Since its laser tracker purchase in mid-2004, the accuracy of the system. This is an area in points per second. Application areas for BMW Leipzig has used its Leica Geosystems which the Leica Laser Tracker scores extremely Leica’s laser trackers are for example high equipment in multiple application areas: well, having earned as much respect in terms precision tool design and construction or during the start-up phase of the plant in which of measuring accuracy as any other measuring geometrical tests in the automotive and the 3 series car is being produced, the laser method. All in all, a Leica Laser Tracker aerospace industries. Due to the integrated tracker was used to inspect the production competently holds its ground with the best of Absolute Distance Meter (ADM), periodical equipment. The system will be used for this three-axis CMMs. The handling and operation measurements, repetition tests and similar job in the future as well, for example when of the system are also fully impressive: unlike jobs can be carried out with full automation; new production lines for upcoming BMW a photogrammetric system, the Leica Laser the position of the laser tracker is always models are needed. This is also true for the Tracker is independent from the position flexible and can adjust to the size of an assembly line: here, the team has used the of a camera or from its configuration; the object or to possible limitations of available tracker’s flexibility to measure specific points latter could be the source of errors for an space. at each car in order to assure compliance. unseasoned user. The laser tracker is simple The Leica Laser Tracker’s easy mobility allows to set up and is immediately ready to use. At On the wish list: the Leica T-Scan for easy verification of specific car functions, the same time, measurement technicians can Leica Geosystems’ “Walk-Around” armless for example adjusting default gaps on car calibrate and check the system. However, Jörg Illemann, Sales Engineer at Leica Geosystems: and wireless Leica T-Probe, which can doors. In order to obtain useful measurement the biggest advantage of a laser tracker “Our measurement system has fully met the expec- results, such reference measurements need tations of the BMW measurement technicians. With measure practically any object anywhere with compared to a fixed measurement machine is the Leica Laser Tracker and Leica T-Probe, they can six degrees of freedom (6DoF), has played an to be carried out with many cars in a series. its mobility. probe new car series very economically, as they do important role for BMW when they chose The unbeatable advantage of the Leica Despite being fully satisfied with their Leica not have to stop the assembly line and can measure the Leica system; interfering cables or Laser Tracker: thanks to its mobility, these T-Probe system, the Leipzig team has another directly at the production plant.” Whether building the fastest car, the biggest plane, or the most precise tooling, you need exact measurements to improve quality and productivity. So when it has to be right, professionals trust Leica Geosystems Metrology to help collect, analyze, and present 3-dimensional (3D) data for industrial measurement.

Leica Geosystems Metrology is best known for its broad array of control and industrial measurement products including laser trackers, Local Positioning Technology (LPT) based systems, hand-held scanners, 3D software and high-precision total stations. Those who use Leica Metrology products every day trust them for their dependability, the value they deliver, and the world-class service & support that’s second to none.

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Due to continuing product development, Hexagon Metrology reserves the right to change product 749537 specifications without prior notice. Printed in Switzerland. September 2008