Development of a New Optical Measurement System for Curved Tube Inspection

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HJ Machine & Pattern (HJMP), located in Waterloo, Ontario, is the leading manufacturer of manufacturingjigs, die, patterns and tools. Since established in 1975, HJMP has supplied inspection and assembly fixtures toTier 1 & 2 automotive organizations who supply the final product to all major car manufacturers.In automobiles, many types of curved tubes are used, such as power steering lines, fuel rails, thin brakelines to large exhaust pipe. It is essential to inspect them correctly by measuring the tube shapes anddimensions for the production of correct parts and prevention of the scrapping of good parts. Traditionally,these measurements were conducted with the help of inspection fixtures; however, the measuring resultsdepend very much on the operator. Also it can only decide 'pass or fail', and cannot derive the information onthe overall dimensions and tolerances (bend data). HJMP plans to develop a new inspection system that can notonly make the pass/fail decision but also derive the 3D bend data accurately with minimumoperator-dependence, through the collaboration with University of Waterloo.Therefore, main objective of the project is to develop an optical tube measurement system that canaccurately measure the 3D geometry of curved tubes and derive the measurement report. It will be pursued byinvestigating two stage of solutions: The first stage is to integrate the optical technology with conventionalinspection fixture, mainly to make pass/fail decision accurately with minimal operator dependence. The secondstage is to develop an optical system that will capture the images of the tube with several high-resolution digitalcameras and convert the image data to key dimensions of the tube.The proposed optical measurement system will equip HJMP with new type of inspection technology, andprovide an opportunity to develop a new market. Upon completion, HJMP would be equipped with enhancedcompetitiveness and productivity to excel in the competitive market with its improved technology, pricing anda new solution, thus contributing to Canadian economy, by adding jobs and expanding exports.