Quality through projection

In the manufacturing industry, we are seeing a strong trend towards individualization and an increasing number of variants. This complicates assembly and post-processing and makes work more difficult for employees. As automation is often difficult to implement here, dynamic laser or video projection can provide a remedy. It displays work steps directly on the component. In this way, processes can be digitized and comprehensive documentation guaranteed.

Simple digital worker guidance, such as with the help of pick-by-light systems or the display of instructions on a screen at the workstation, is already standard in many manufacturing companies. However, where individual customer requirements or the increasing number of variants make it difficult to automate work processes, intelligent systems are needed to support workers in their work.

The dynamic laser and video projection is particularly ideal for applications that require a spatial context: it displays work instructions, CAD data or other important information directly on the workpiece in the correct position and with an accuracy of up to 0.1 mm - even if the component is in motion. In this way, even complex worker guidance processes can be mapped and a high level of accuracy guaranteed. It is also possible to evaluate 3D data in the context of a component and document work processes precisely.

The strengths of dynamic laser and video projection

In general, digital worker guidance using laser or video projection is recommended for short cycle times, high variant diversity, complexity or employee turnover. It also helps with physically demanding or monotonous tasks and ensures significantly greater safety. Complexity can increase rapidly even with a low number of variants - for example, because many add-on parts or manual work steps are required. An illustrative example is the ITER fusion energy research project: countless sensors and connecting cables have to be fitted to the reactor chamber, and a total of 150,000 welding points have to be set - with a maximum deviation of 2 mm. Thanks to dynamic laser projection, the assembly team can master this challenge. The employees use the system not only to display the attachment points for the welding equipment, but also to visualize the position of components that are to be attached by spot welding. In addition, the laser projects further instructions such as part and welding numbers. The project is so complex that it would be impossible to manage without digital worker guidance.

With very short cycle times, the use of dynamic laser and video projection can be worthwhile even with low complexity. For example, a Japanese car manufacturer uses innovative worker guidance when assembling cable harnesses on various headliners. Although this task is uncomplicated in itself, the worker is under great time pressure: he has to recognize immediately which model is being used and where he has to attach the wiring harness. The projection helps him to do this and avoids errors.