Munich. The motorsport department at BMW has long worked hand
in hand with series development – and this remains the case for the
quality controls on the newly-constructed BMW M4 DTM for the 2017
season. BMW Motorsport uses the same cutting-edge 3D measuring
technology that is applied to production models at the BMW Group
Plant Munich.
As if by magic, the two robotic arms work their way up and down the
new BMW M4 DTM, scanning the chassis and all its aerodynamic
components millimetre by millimetre to create the perfect 3D model –
fully automated. This advanced measurement system was used for the
first time in the development of the new BMW 5 Series. It has now also
been used extensively by the engineers at BMW Motorsport.
Down to the last detail.
The fully-automated, optical measurement cell – the only one of its
kind –provides the perfect quality control after the assembly of a
race car. With such a sophisticated car as the BMW M4 DTM, which is
assembled completely by hand, it is vital that all the dimensions are
observed and implemented correctly. This is to ensure that the complex
aerodynamics work as planned and tested but also to adhere strictly to
all the specifications in the regulations. The optical measurement
cell is the perfect tool for this task as it works incredibly
accurately and saves a lot of time compared to previous procedures.”
In series like the DTM, all measurements regarding the cars are
regulated right down to the exact millimetre. Any discrepancies from
the dimensions specified can result in penalties as severe as
disqualification of the car in question. This makes it imperative
that, even as early as the development stage, measurements must be accurate.
Measurement precision: 100 micrometres.
The design of the state-of-the-art measuring cell features two
robotic arms, which can move freely and can both move sideways along
the car on rails. This set-up allows the simultaneous use of two
small, flexible robots, each equipped with two sensors, in a
relatively small space. Compared to previous procedures, in which
robots were only ever able to handle one side of the car at a time,
and only with one sensor, the measurements now take roughly half the
time and are completed within a matter of days.
The sensors first record reference points and then scan individual
fields of about 80 x 80 cm in size. Based on these measurements, a
computer then automatically creates a three-dimensional image of the
entire car, which can be compared with the design plans. This way,
possible differences, tolerances and the smallest of discrepancies can
be identified. The measurement accuracy is under 100 micrometres,
roughly the thickness of one human hair. Because the measuring cell is
fully automated, it is also possible to perform inspections outside
standard working hours, to receive results as quickly as possible and
potentially gain a crucial edge over the opposition.
3D measurement of the BMW M4 DTM captured on film.
We have recorded the 3D measurement of the new BMW M4 DTM. You can
view the video here:
You can view our time-lapse video with this link: