Use of projector based augmented reality to improve manual spot-welding precision and accuracy for automotive manufacturing

TLDR

The study aims to improve manual spot‑weld placement precision and accuracy by providing projector‑based augmented reality visual cues to operators. A prototype AR system was installed on the GM Holden Cruze production line, and production trials compared spot‑weld precision and accuracy with and without the visual cues. Using AR reduced the standard deviation of spot‑weld placement by 52 %, from 4.08 mm to 1.94 mm, and all welds met specification.

Abstract

This paper presents the use of a projector-based spatial augmented reality system in an industrial quality assurance setting to highlight spot-weld locations on vehicle panels for manual welding operators. The aim of this work is to improve the precision and accuracy of manual spot-weld placements with the aid of visual cues as a proactive step by the automotive manufacturer to enhance product quality. The prototype system was deployed at General Motors (GM) Holden plant in Elizabeth, Australia on the production line building Holden Cruze vehicles. Production trials were conducted and techniques developed to analyse and validate the precision and accuracy of spot-welds both with and without the visual cues. A reduction of 52 % of the standard deviation of manual spot-weld placement was observed when using augmented reality visual cues. The average standard deviation with-AR assistance (19 panels and 114 spot-welds) was calculated at 1.94 mm compared to without-AR (45 panels and 270 spot-welds) at 4.08 mm. All welds were within the required specification and panels evaluated in this study were used as the final product made available to consumers. The visual cues enabled operators to spot-weld at a higher degree of precision and accuracy.