A novel application of 3D scanner technology could help to speed retooling of automotive assembly lines. Researchers at Würzburg University are collaborating with a team at Volkswagen AG to streamline changeovers from one model to another.

In the past, automobile manufacturers dedicated an assembly line to one car model at a time. Models did not change much from year to year, so complete changeovers were not necessary every year.

Volkswagen assembly line in 1960.The industry has evolved to produce multiple car models in smaller quantities. Retooling a production line is time-consuming, and no product rolls out the door in the meantime.

Andreas Nüchter, a computer scientist at Wurzburg, has developed a three-step process for evaluating an existing line and determining what changes are necessary. He sends a 3D scanner through the production process. The images are converted to a three-dimensional model of the production line. Then auto plant engineers can evaluate where to make changes to accommodate a different car model.

Volkswagen tested this approach on two models, Tiguan and Crafter. After evaluating the models, the VW engineers realized that they would need to make major changes to avoid collisions in the production hall.

Nüchter points out that evaluating the scan data is the time-consuming part of this evaluation method. He and his team are at work on ideas for automating as much of this step as feasible.