Date:14 February 2023

Presentation
MF F266 Study Oriented Project: E-Bicycle
Quality Assurance

BITS Pilani Name(ID): Stephen Wilson (2020ABPS1835P)

Pilani Campus
The Problem

Many errors occur during production due to various reasons

• Material errors
• Robot errors
• Defective/incorrectly adjusted
machines
• Personal errors
• These errors result in:
o Increased costs
o Waste
o Low product quality
The Consequences

• Costs are passed on to the

customer
• Waste causes a high
environmental impact
• Low product quality is bad for:
o The company's image
o Customer safety
The Solution: Quality Assurance

• Quality assurance helps to

detect
• errors in production at an early
stage
• This can save costs, materials,
and time
 5W1Hs of Quality Assurance
• Who:
o Quality management of the manufacturing plant / service provider
o Supplier
o Customer
• What: Inspection strategies and quality assessment strategies
• When: During different stages of manufacturing (not covered in this
report)
• Where:
o First Article Inspection (prior to mass production)
o In-Production Inspection (during production)
o Pre-shipment Inspection (before shipping)
• Why: To ensure dimensional and geometrical accuracy of parts before
assembly
• How: Using vision-based inspection systems
Inspection Strategies: Battery

• Focus on part positioning

during assembly
• Misalignments can:
o Decrease battery lifetime
o Limit optimal performance
o Cause safety issues
Quality Assurance Method - Batteries

• Fringe projection scanning:

o Non-contact optical
measurement method
o Projects a pattern of light on
the surface
o Analyzes the deformation of
the pattern to measure shape
o Highly accurate (0.011mm
margin of error)
Quality Assurance Method - Batteries

• Industrial photogrammetry:
o Passive method using
multiple images from different
angles
o Uses triangulation to create a
3D point cloud
o Fast and repeatable
(hundreds of 3D points every
30 seconds)
Quality Assurance Method - Batteries

• Laser profiling and scanning:

o Uses triangulation, time of
flight, or phase shift to measure
surface
o Laser light is focused on the
surface and reflected back to a
detector
o Calculates distance based on
the angle of the reflected light
o Accuracy: 0.025mm-0.04mm
depending on scanner model
Location and Procedure For Testing:
Battery
• Integration point on the assembly line:
Right before the battery is integrated
into the frame
• Automated testing with vision-based
system:
o Scanner captures precise 3D
measurements of battery
dimensions
o Software compares measurements
to pre-programmed tolerances
o Identifies any misalignments or
deformations
Inspection Strategies: Bicycle Frame
• Focus on weld quality:
o Poor welds can lead to:
 Frame failure
 Safety hazards
• Other considerations:
o Material composition
o Dimensional accuracy
Quality Assurance Methods for
Bicycle Frames
• Automated ultrasonic testing
(AUT):
o Uses sound waves to detect
cracks and voids in welds
o Fast, efficient, and non-
destructive
• X-ray radiography:
• Creates an image of the internal
structure of the weld
o Can detect internal defects that
may not be visible on the
surface
o Requires specialized
equipment and training
Location and Procedure for Testing:
Bicycle Frame
•Integration point on the assembly
line: Right after the welding process
•Automated testing with a
combination of:
o Robotic arm with vision
system: Inspects for visible
defects like misalignment or
gaps in welds
o Ultrasonic testing equipment:
Inspects for internal cracks or
voids in welds
 Recommendations
•Invest in automated testing
equipment with vision systems
and non-destructive testing
capabilities
•Train personnel on quality
assurance procedures
•Implement a culture of quality
throughout the manufacturing
process
•Continuously monitor and
improve quality assurance
processes
 Future Considerations

•Integration of artificial intelligence

(AI) for real-time defect detection:
o AI-powered vision systems
can analyze images from
multiple cameras at high
speed
o Can identify subtle defects
that may be missed by
human inspectors
o Enables real-time process
control and defect
correction
 Future Considerations

• Machine learning to predict and

prevent defects:
o Machine learning algorithms
can analyze historical data
to identify patterns and
trends
o Can be used to predict when
defects are likely to occur
o Enables preventative
maintenance and process
adjustments to reduce
defects
Conclusion

• Implementing quality assurance

for the bicycle frame and battery
can lead to:
o Reduced costs
o Less waste
o Improved product quality
o Enhanced customer
satisfaction
o Potential for significant CO2
emissions reduction