G A P

THE REVOLUTION IN GAP & FLUSH MEASUREMENT as accurate and user-independent as a CMM

WORLDWIDEUNIQUE.

Previous systems

The Calipri method

• The profile is only par tially captured, without information about the depth of the gap

• The gap contour and radii have to be extrapolated

• Faulty information in the case of changes of radii or contour

• Everything that’s visible will be recorded• The result is the entire gap contour• Precise and reproducible measurement

results

» RECORDING OF THE COMPLETE GAP PROFILE

» GAP & FLUSH DIRECTLY FROM THE MEASUREMENT DATA

» NO USER INFLUENCE

» VERY PRECISE MEASUREMENT RESULTS

» COMPARABLE AND TRACEABLE

» REPRODUCIBLE AND FAST

» TOLERANT USER GUIDANCE

» BROAD RANGE OF EVALUATION ALGORITHMS

» SAME MEASUREMENT RESULTS FROM ALL PLATFORMS

» INLINE AND OFFLINE

MAX

When measuring, the operator simply moves the Calipri sensor by hand over the gap. In so doing, the intelligent measure-ment system, which is based on image processing techniques, continuously re-cords and subsequently connects the in-dividual segments of the gap contour. By dint of 3 laser lines, the Calipri method automatically compensates for any lop-sidedness and twists of the sensor. Thus the measurement results are reproducible and free from user influences. Because the depth of the gap profile is measured, the gap width can be calculated without the need of additional assumptions, e.g. bead radii. Changes in terms of the radii therefore do not result in falsifications of the measurement results.

Calipri Gap is the first gap and flush mea-surement system that measures the con-tour of the gap from several perspectives. Thus even the depth of the gap contour is recorded. The measurement results become more accurate and better repro-ducible.Flexible, definable evaluation algorithms allow for compatibility and traceability to gauge, inline results and CAD data.

GAP AND FLUSH MEASUREMENT

THE CALIPRI METHOD

Depending on the target of the measure-ment, operators need different types of calculation of gap and flush. For the comparison with manual measurements, for instance, different measurement rules are required than for the comparison with CAD data or measurements of inline fa-cilities. The completely captured gap profiles and flexible measurement rules allow for gap and flush calculations that deliver values comparable to other sys-tems. The picture below shows an ex-cerpt of existing measurement rules.

EVALUATION ALGORITHMS

Inspection plans can be prepared easily and intuitively. A graphic user inter face guides throughout, from the selection or input of the measurement object (e.g. type of car body, measurement cycle, etc.) to the measurement and subse-quently to the handover of the measure-ment values to the quality assurance system of the operator. The visualization of the measuring points shows the body or component with the measuring points to be measured. The results are colored according to the stored limits. The entire work flow is automated and secure for transmission.

The Calipri Gap enables the additional recording of local profile sections, e.g. design edges or columns. The measure-ment values are calculated by dint of customized evaluation algorithms. Op-tionally, the recorded profiles can be ac-curately examined online with the Calipri Analyzer. The Calipri Analyzer is a special sof tware for the quick display and mea-suring of Calipri profile data. Intuitively easy, a measurement profile is visual-ized, measured and compared with a sec-ond profile. “Magnetic” stencils, which are exactly positioned on the profile, are especially helpful in this respect.

USER-FRIENDLY

RECORDING OF GENERAL PROFILES

The Calipri Gap is available in different versions. The Calipri Gap Portable, for instance, is carried on the body; the Calipri Gap Inline is permanently installed. All systems feature the same kind of measurement profile recording and the same evaluation algorithms. Therefore it is ensured that the profiles are mea-sured in the same way and the same measurement values are calculated from them, independent of the version used.

VERSIONS

CALIPRI GAP PORTABLEThe Calipri Gap Por table is a por table solution for your gap and flush measure-ments. 100% mobility and great flexibility characterize this version. The Calipri Gap Por table is delivered ready for use.

The scope of delivery includes:• sensor• connection cable• por table computer unit (tablet PC)• carrying strap• self-test and calibration device• hard-top case with foam inser ts for all components• user manual• installed measurement sof tware

Measurement duration:< 5 sec.

Communication:WLAN 802.11b/g

10/100/1000 MBit Ethernet

Bluetooth V2.0

Operating system:Microsof t® Windows® 7

Output formats:XML, CSV (Excel) and PDF

Battery:Lithium ions, Hot Swap,

operating time per battery

approx. 3.0 hrs.

Ambient conditions:Temperature – operation: +5° C to +35° C

Temperature – storage: -20° C to +65° C

Humidity – operation: 20% to 80%

no condensation

Atmospheric moisture – storage: 8% to 90%

no condensation

Impact strength: 100 G

Safety class: IP 54

Laser:Red, 660 nm, class 2M

Conformity:CE

Optional barcode and RFID reader

Accuracy:+/- 0.1 mm

Internal resolution:0.01 mm

Dimensions (W x H x D):Sensor: 86 x 72 x 188 mm

Computer unit: 300 x 230 x 50 mm

Weight:Sensor: 500 g

Computer unit: 2,300 g

Measurement range:for all standard gaps,

approx. 50 x 50 mm

and for special profile forms

TECHNICAL DATA OF THE CALIPRI GAP PORTABLE

CALIPRI GAP PORTABLE

CALIPRI GAP INLINE MOBIL

CALIPRI GAP INLINE

CALIPRI GAP ROBOT

VersionTablet PC

USB sensorCarrying strap

LaptopEthernet sensor

Transpor tation wagon

DesktopEthernet sensor

Computer cabinet

DesktopEthernet sensor

Robot

Profile recording according to the Calipri method

High level of reproducibility and accuracy by dint of depth measurement

Measures the entire contour

Measurement values compatible to manual measurement, measurement facility and CAD

Non-contact method

Wide range of evaluation algorithms integrated

Integrated self-test

Inspection plan manager

Application for body shell work and installation

Measurements even on small surfaces (e.g. ledge) by dint of integrated 1-laser line mechanism

Training expenditure in days 2 1 1 -

Automatic inspection plan selection and body number detection (by way of SPS)

Manual input of the body number

Option: Input of the body number by RFID or barcode laser

Online expor t of the measurement data (by way of SPS)

Offline expor t of the measurement data

Long sensor cable option

Display and data-input option on the sensor

Flexible system, interfaces and output formats customizable by the customer himself

Speed-optimized system for inline mea-surement directly on the production line. Inspection plans are automatically star t-ed by the SPS; measurement data are au-tomatically expor ted. This robust system for operators requires only little training expenditure.

This version combines the advantages of the Calipri Gap Por table and the Calipri Inline systems. The system is mobile by dint of a workshop wagon and is likewise speed-optimized. Optionally, the car body number can be read in with a bar-code or RFID reader.

Fully automated measurements by dint of the robot-guided system. Owing to the Calipri method, the setup of the robot is simplified, since the system compen-sates for lopsidedness and twists.

CALIPRI GAP INLINE

CALIPRI GAP INLINE MOBILE

CALIPRI GAP INLINE ROBOT

FASC

HIN

GBA

UER

& S

CHAA

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THE MEASURE OF ALL THINGS

NextSense Mess- & Prüfsysteme GmbHStraßganger Straße 295, 8053 Graz, Austria

Tel. +43.316.232 400-0, Fax +43.316.232 400-599Mail office@nextsense.at, www.nextsense.at