In manufacturing, every step in the production process is an opportunity to save time and money. Precisely projecting a beam of laser light onto surfaces, laser projection technology efficiently guides manufacturing operations, saving money in applications such as assembly, templating and inspection.

Virtek Vision International has over 31 years delivering laser projection systems that drive manufacturing efficiency in composite ply layup, paint masking, 2D and welded assembly, and placement of components or materials.

Figure 1: The Virtek Iris 3D system significantly advances laser-guided assembly with new integrated vision technology, innovative FlashAlign functionality and superior laser-line visibility. Source: Virtek Vision

Aerospace, heavy equipment fabrication, prefabricated construction, sheet metal, heavy transport and wind industries all benefit from Virtek’s ISO certifications. Virtek works with top OEMs and also develops flexible solutions for smaller businesses.

As the pioneer in laser projection, Virtek continues to innovate with unique patented technology that includes the first laser projection system with integrated vision: the Virtek Iris™ 3D with Vision Positioning System (VPS).

Figure 2: The Virtek Iris SPS projects a laser outline on even the largest parts to accurately guide operators through part assembly, digitizing, verification and paint masking tasks. Source: Virtek VisionTAI in Europe installed the VPS as part of an early adopter program. “We are very familiar with laser technology and its benefits and began the journey with Virtek with their LaserEdge® solution for several projects over a decade ago. We felt it was a natural progression to move to the new Iris™ platform with the new state of the art vision- based laser technology when we had a need for a new project,” said Türker Dölek, composite production chief, Turkish Aerospace Industries (TAI) Inc. “We are seeing significant benefits with the flash align feature saving time during alignment as well as the systems are demonstrating an increase in throughput resulting in cost savings.”

Precise positioning

Virtek Iris SPS, guides technicians through the assembly process, drawing a 3D laser outline indicating position of an assembly piece. Iris SPS eliminates manual measuring, marking and fitting by projecting laser templates a full 360 degrees around even the largest work piece. Part position is taken directly from CAD data for exact as-designed placement. By referencing the most current CAD file, product design changes are easily accommodated, eliminating costly delays caused by the need to create new templates for every revision.

The system locates the exact placement area for assembly on even the most complex weldments, eliminating errors caused by using incorrect reference points on the part and automatically compensates for any movement of the Iris system or the work piece by re-positioning the projection.

Komatsu America wanted to reduce errors in manufacturing, increase throughput and efficiency to meet increased demand. They were using costly aluminum templates to guide workers in welding brackets, stand-offs and studs on large mining truck frames. By implementing Virtek’s Iris spatial positioning system (SPS), Komatsu eliminated templates, significantly accelerated their assembly process and eliminated defects by as much as 95%.

Figure 3: The Virtek LaserEdge eliminates the use of physical templates by projecting a laser outline onto work surfaces, improving the productivity of layup processes by as much as 50%. Source: Virtek VisionComposite ply layup

In aerospace, high precision is required in the ply layup process. ATK Aerospace Structures, who fabricates aerocomposites for major commercial and military aircraft programs, uses the Virtek LaserEdge® system at the output of its automated stiffener forming machines. Operators can easily verify proper ply placement and ensure that no damage has been caused by foreign objects.

Terma Aerostructures, a leader in precision composite aerostructures and components, uses Virtek laser projection systems during fabrication of composite panels for the F-35 Joint Strike Fighter. The systems ensure high final part quality, guiding the layup process via laser templating, helping bonding technicians place each layer with a high degree of accuracy and consistency.

Figure 4: The Virtek Trussline projects a laser template of the truss onto the work surface, making pre-fabricated wood and steel truss manufacturing so easy that even less experienced workers are instantly productive. Source: Virtek Vision

Wood and steel truss construction

Virtek TrussLine® allows the most complex wood and light gauge steel trusses to be assembled in minutes. The system traces a laser outline of the truss onto the work surface, highlighting the position and shape of all joints and connector plates. Eliminating the need for measuring, squaring and stringing, set up and changeover time is reduced by up to 70% and productivity is increased up to 25%.

Virtek LTG® accelerates assembly of steel or wood panels. It projects a laser template of panel members onto the work surface, illuminating locations of studs, headers, sheathing, nailing patterns, subcomponents, openings and inserts with an accuracy of ±1.6 mm (1/16 in). Visualizing the final product allows workers to achieve higher throughput and improved quality.

Quality inspection

Laser technology can improve more than just initial positioning and placement of components. In manufacturing, part quality verification is crucial. Virtek’s laser systems enhance this process too. The company’s inspection systems use lasers to measure the accuracy of two-dimensional parts and formed parts, ensuring quality control.

Figure 5: The Virtek LaserQC is a rapid inspection system for the sheet metal and gasket fabrication industry that uses lasers to ensure accuracy and quality control. Source: Virtek VisionWinston Industries LLC, installed a Virtek LaserQC® system to verify the accuracy of its custom fabricated metal parts, inspecting the first piece of every work order passing through its fabrication cell. This non-contact precision inspection system employs lasers to capture more than 500 data points per second, comparing finished parts with the original CAD files. It generates a report detailing any deviations from tolerances. Accurate to within +/- 0.05 mm (0.002 in), the system pinpointed errors immediately on the shop floor, reduced scrap and rework and improved profitability. With over $30 million of sheet work annually, Winston achieved an internal scrap rate of just 0.77% of sales. Plus the machine was perfect for reverse engineering parts that came to Winston with no prints.

And LaserQC generates detailed inspection reports validating fabricated part quality to facilitate clients’ compliance with reporting requirements of standards and methodologies like ISO, Total Quality Management (TQM), Six Sigma and lean manufacturing.

Improved bottom line and superior service

Virtek’s cutting-edge laser assisted projection and vision systems improve production efficiency, speed up fabrication, reduce defects, and decrease labor and material costs. Customers receive free lifetime support to ensure maximum performance of its systems, no agreements necessary. Virtek helps its customers beat the status quo.

#seethingsdifferently with Virtek.

Contact your local Virtek representative today or visit www.virtek.ca for more information.