Optical surface measuring system reflectCONTROL

3Dfor the automotive industry

Overview
reflectCONTROL Automotive enables fully automatic inspection of painted car bodies through robotic stations that detect, 3D-measure and classify typical paint defects. The systems provide precise, repeatable measurements and can be integrated with automatic processing and marking equipment to form a complete automated workflow from inspection to post-processing.

Key capabilities
reflectCONTROL Automotive performs full-surface defect detection and appearance evaluation with high positional accuracy, enabling exact localization for automated rework and traceable quality data.

Features

• Defect detection up to the edges < 1 mm
• Measures design edges and contrast roofs
• Adapts to opening angles of movable components (doors, flaps)
• Large measurement area > 98 % of outer surface
• High positional accuracy of detected defects
• 2-in-1: defect detection & appearance evaluation

Performance
The system achieves a detection rate of > 98.5 %, reproducible regardless of body color. It ensures broad area coverage and detects small defects near edges while maintaining high repeatability.

3D reconstruction and data
Unique 3D reconstruction assigns height, depth and volume to each defect. Acquired measurement data are exported in XML format for integration into customer quality systems and traceability.

Appearance evaluation
Appearance assessment is performed from captured images without additional hardware. The non-contact evaluation is fully integrated, repeatable and supports an unlimited number of measurement positions for full-surface appearance measurement of any vehicle type.

Automation & integration
The solution integrates with robotic processing and marking systems to enable a fully automated chain from detection to automatic post-processing (e.g. robot grinding), supported by high positional accuracy for downstream actions.

Technical specifications

• Product: reflectCONTROL Automotive (automated surface inspection system for painted car bodies)
• Detection capability: defects < 1 mm from edges
• Area coverage: > 98 % of outer surface
• Detection rate: > 98.5 % (typical)
• Functions: defect detection, 3D measurement, classification, integrated appearance evaluation
• 3D outputs: height, depth, volume per defect
• Data export: XML output compatible with quality systems
• Integration: robotic systems, automatic processing and marking; supports automatic post-processing
• Appearance evaluation: non-contact image-based, no additional hardware required