87 “Firstly, because of their many years of expertise in the windshield and HUD sector and, secondly, because we were able to obtain hardware and software from a single provider.” This complete package ensured that all software-hardware interfaces are working perfectly and that the test bench meets the specifications defined by ARRK Engineering in terms of both hardware and software. Conventional windshield test benches are not up to this challenge, as they usually have to meet less stringent requirements. “We had to modify our software accordingly in order to realize the required test scope and measurement sequences,” confirms Jonathan Guthmann, Project Manager Vision/HUD at GEFASOFT. “We also equipped the system with comprehensive access options and interfaces for our own extensions, so that our colleagues at ARRK Engineering can keep it state of the art in the future and adapt it to the challenges of new HUD generations.” The second major requirement was the flexible design of the test stand. In order to improve the workflow when inserting a new HUD projector, GEFASOFT designed an automated conveyor line for moving the projector from the change position to the test position. In addition, the so-called windshield master (windshield cut-out usually made of stainless steel), which imitates the topology of the windshield for the test purpose, can be moved into a safe changing position and replaced in a few simple steps. “The windshield itself is also becoming increasingly important as part of the overall HUD system,” explains Hensle. “That’s why we designed the new test bench on the basis of a windshield test bench.” As an alternative to the windshield master, it is also possible to place the entire windshield for testing – regardless of manufacturer or vehicle type. “This will become very relevant for future 3D or AR HUDs, as ever larger areas of the windshield will be used as a contact-analogue projection surface,” adds project manager Alexander Düring, GEFASOFT. Investing into the future: test bench measures 5 times more precisely than required For the two-dimensional photometric measurements, an LMK 6 color camera from TechnoTeam was installed. It not only has a high-resolution sensor, but has also been equipped with a lens that features a large field of view (FOV) for this purpose, complementing the standard setup for distortion measurement. “We originally wanted to use a measuring robot to guide the camera,” recounts Hensle. “However, its articulated arms were not able to meet the strict specifications for the measurement tolerances.” The camera is therefore now guided by a linear system, which achieves a positioning inaccuracy of less than a tenth in all camera positions with a maximum travel distance. In addition, high priority was given to the mechanical stability of the test bench, which weighs around 3.5 tons. As a result, such high measurement and repeatability accuracy can be achieved in the series testing of HUD projectors that the measurement capability limits specified by the OEMs are undercut by a factor of five, as has been proven in relevant test series. Thanks to the optimized alignment of hardware and software by GEFASOFT, the high-precision measurement, including the documentation and traceability of the results, is fully automated and does not need to be monitored manually. It is therefore no longer an issue to run longer tasks such as luminance measurements, which can easily take three to four hours, simply overnight. “In GEFASOFT, we have gained an experienced project partner who was able to reliably realize our ideas of a highly automated yet flexibly expandable HUD test bench. We are now prepared for new generations of HUDs – be it AR HUDs, which were presented by OEMs at the IAA, or future technologies, for which the testing of the windshield as part of the complex overall system will become increasingly relevant,” concludes Hensle. Further information at https://www.gefasoft.com and https://engineering.arrk.com A mobile 3D coordinate measuring device complements the new HUD test bench. GEFASOFT Automatisierung und Software GmbH GEFASOFT Automatisierung und Software GmbH, headquartered in Regensburg, develops, manufactures and sells automation systems for complex tasks in all industrial sectors. Its core competences are applications with ultra-modern image processing and laser systems. The focus is on the global automotive, semiconductor and electronics industries as well as medical technology. All services relating to the creation of automation systems, from conceptualization and planning to assembly, commissioning, testing and installation at the customer‘s premises, are carried out by our own staff. After-sales service is provided by an in-house service team and local partners in Brazil, Malaysia, India and China. In addition to a facility in Nittendorf for parts production and assembly, the company also operates a branch in Mexico and Hungary. ARRK Engineering ARRK Engineering is a globally active development partner for the automotive and mobility industry, specializing in end-to-end and comprehensive support of the entire product development process – from the concept phase through series development to validation and system integration of mechanical and electronic components. The share of development tasks from the fields of e-mobility, autonomous driving and software development in a digitalized development environment has been growing steadily for years and is becoming increasingly important. Through highly efficient project management, we achieve the set development goals together with our customers. As part of our developments or as a separate service, we supply prototypes and pre-series tools for small quantities. We rely on the long-standing, interdisciplinary expertise of our 1,800 employees at locations in Germany, Romania, the Netherlands, Malaysia, Japan and China. As a member of the international ARRK Group, we have additional resources available worldwide to support our customers in international markets as well.
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