As automotive manufacturing advances, traditional manual quality control can no longer keep up with the demand for precision and efficiency. In a joint webinar, Eleven Dynamics and Nextsense explored the power of automated gap and flush measurement, showcasing how real-time sensor data and robotics are reshaping quality assurance on the production line.
Nextsense has evolved from handheld metrology tools to fully automated inline sensors. Integrated into the Eleven Dynamics Automation Suite, these systems deliver consistent, real-time measurements directly on the line, removing human error and enabling fast, data-driven corrections.
Inline measurement means: the vehicle keeps moving on the production line while being measured with absolute accuracy. Sounds simple, but it’s highly complex.
Challenges include:
- Varying heights and angles depending on tires, suspension, or load
- Inconsistent conveyor speeds, causing synchronization issues
- Transparent materials like glass or headlights, notoriously difficult for optical measurement
Solutions include:
- Stereo cameras for real-time position and angle detection
- Robots moving in perfect synchronization with the conveyor belt
- Calibris Breeze technology, creating a temporary fog layer on transparent surfaces, making them reliably measurable
At Audi Sport’s Böllinger Höfe, Nextsense and Eleven Dynamics deployed a multi-sensor cell integrating different Nextsense systems into Eleven Dynamics’ Automation Suite.
Results:
- Correlation-free measurements from body-in-white to final assembly
- Reproducible data without operator influence
- Maximum availability and process safety
- Perhaps most importantly: deviations are not just detected, they’re identified early enough to allow immediate correction, drastically reducing or even eliminating rework.
Errors in quality assurance are costly: from time-consuming rework to expensive recalls Automated metrology isn’t just about faster measurements—it’s about eliminating defects, reducing costs, and ensuring full traceability. It turns quality control from a necessary cost into a strategic advantage.
The joint webinar with Nextsense made one thing clear: the future of quality assurance is automated. The collaboration between Nextsense and Eleven Dynamics shows how strong technology partnerships are driving Industry 4.0 forward , and how zero-defect automotive production is no longer a dream, but a reality.
