QUALITY MANUFACTURING TODAY
www.qmtmag.com June/July 2016
Process monitoring without the bottlenecks
Reduce bottlenecks and scrap with quick and easy process monitoring using the Renishaw Equator™ Join hundreds of manufacturers worldwide who have increased flexibility and inspection capacity with the low cost Equator comparator. • Low cost increase of inspection capacity • Flexibility to inspect multiple parts • Insensitivity to workshop temperature change
Process Monitor software for the Renishaw Equator allows users to view an instant status monitor bar chart of last measured features, historical results for the feature selected, and three status displays allowing management of re-mastering. The limit for re-mastering can be set on the basis of temperature drift, time since last master, or by number of parts measured.
• Easy integration into automated cells • Low cost of ownership - no periodic calibration or maintenance
For more information visit www.renishaw.com/equator
Renishaw plc New Mills, Wotton-under-Edge, Gloucestershire, GL12 8JR United Kingdom T +44 (0)1453 524524 F +44 (0)1453 524901 E uk@renishaw.com
www.renishaw.com
CONTENTS
June/July 2016 News and comment
4
Events 5 Inspecting digital models
Digital inspection with 3D software improves quality and cuts cost and time to market
Metrology for additive manufacturing:
10
In the right place
14
Measuring up to nuclear requirements
15
Off-line, in-line, at-line
16
Pole position
19
A blow for contact gauging
20
Prof Richard Leach at the AM revolution and what it means for metrology
Front cover: FEI Web: www.avizo-inspect.com Email: info@fei.com Tel.: +33 556 13 33 88 Data courtesy: CyXplus Digital inspection 3D software: Avizo Inspect Editor Andy Sandford Email: editorial@qmtmag.com Director/Publisher Dawn Wisbey Email: dawn.wisbey@qmtmag.com Tel: +44 (0)20 8289 7011 Mob: +44 (0)7974 640371 Design and Production Manager Rob Tremain Email: studio@qmtmag.com IT Director Pat Coyne Email: pat.coyne@qmtmag.com Website: www.qmtmag.com Media enqiries media@qmtmag.com QMT Magazine is a multi-media business magazine for the quality, measurement, inspection and test industries, supported with a fully searchable interactive website www.qmtmag.com. QMT Mobile: website is available in mobile-optimised form. Log on with your phone and you will be directed automatically to the mobile pages. QMT App: download Quality Manufactory Today app for iPad and Android tablets
@QMTMAG Quality Manufacturing Today is published by Cranbrook Media Ltd. Registered company No. 06048241 Registered office: N.J. Ruse Associates, Eagle House, Cranleigh Close, Sanderstead, South Croydon, CR2 9LH Printers: Circle Services Ltd © Cranbrook Media Ltd
6
Rotary tables can be a vital component in inspection
Nuclear AMRC applies high precision CMM
Complexity in measurement does not mean you have to sacrifice quality
Precision weighing trims race-car performance
A bespoke air gauging system measures Rotork’s aluminium gear cases
ISO/TS 16949 – clearing up the confusion 22 What the eligibility change for the auto standard means in practice
Roughing it in the workshop
24
Tracking machining performance
25
Probing pays dividends
26
Continental accelerates inspection
28
Portable arm good practice
29
Monitor keeps an eye on finishes
30
Products
31
A robust shop-floor CMM meets inspection challenges
Researchers use a laser tracker for machine tool studies
A subcontractor makes the most of its advanced machine tools
Multi-sensor CMMs upgrade inspection at a Hungarian automotive manufacturer
Use the tool to its full potential
Measuring surface roughness when coating adhesion is critical
QMT June/July 2016 www.qmtmag.com
3
NEWS
EDITOR’S COMMENT As I expected, the Control show was a real treat. We have showcased some of the new offerings launched at the show in our products section and, following a discussion with Dr Kai-Udo Modrich of Zeiss at the show, he has also written an article for us looking at how metrology is moving onto the production line, into the cloud and towards a connected manufacturing enterprise. The theme continues with one of the new products we feature, Etalon’s Multiline, which shows how smart technology can create metrological networks where machine tools can continuously monitor and correct their operations. As Dr Modrich pointed out at the Zeiss press conference, metrology is the interface between the physical world and the digital world. And if you want more cutting edge technology we’ve got it, as Professor Richard Leach from Nottingham University talks us through the challenges we face to apply metrology to additive manufacturing – a vital step in making it a viable production technology. All this and case studies on air gauging, surface characterisation, probing, laser scanners and trackers. I hope you enjoy your read of QMT. Andy Sandford Editor QMT
BUSINESS NEWS Accolade for quality experts Automotive and aerospace industry quality management specialist G&P has been named as one of Britain’s fastest growing companies achieved
through international sales growth. For the first time in its 22-year history, the business which helps manufacturers and their suppliers around the world reduce costs and improve quality levels, has been listed in the Sunday Times HSBC International Track 200, which ranks Britain’s mid-market private companies with the fastest growing international sales. Ranked 107th, G&P recorded an annual sales growth over four years of 100% per year, with international sales representing more than 40% of the group’s total sales. G&P now employs more than 1,300 people around the world with many staff located within manufacturing facilities where the company provides a range of front-line services to control and improve production quality and reduce costs. www.gpqm.com
ACQUISITION AICON snapped up Hexagon AB has acquired the Braunschweig-headquartered AICON 3D Systems, a provider of optical and portable non-contact 3D measuring systems for industrial manufacturing. AICON’s customer base includes automotive manufacturers and companies in the aerospace, shipbuilding, renewable energy and mechanical engineering markets. Its technology portfolio includes portable coordinate measuring machines for universal applications and specialised optical 3D measuring systems that enable efficient, high-precision monitoring, quality assurance and control in manufacturing production. With over 140 employees, AICON has a direct presence in Germany, subsidiaries in China, Korea, Japan, and the US and a network of resellers worldwide supported by its field support resources. Hexagon President and CEO Ola Rollén said: “AICON is a recognised brand with strong core technical competence across its development teams and its scanner portfolio is a strategic fit. We also see opportunities for international expansion of AICON’s wider portfolio throughout Hexagon’s global footprint. www.hexagon.com
ran from 26 to 29 April at Messe Stuttgart saw 150 new products launched by the world’s leading metrology and quality companies. See our product news pages for QMT’s pick of the show. Industry 4.0 was high on the agenda and many of the new products were from the rapidly growing sector for industrial image processing, which now accounts for 25% of Control’s exhibition portfolio. QMT is an official media partner of Control, which will return to Messe Stuttgart from 9 to 12 May 2017. www.schall-messen.de
NDT Conference and exhibition The British Institute of Non-Destructive Testing (BINDT) is hosting its 55th Annual British Conference of Non-Destructive Testing (NDT), at the East Midlands Conference Centre and Orchard Hotel, Nottingham, UK, from 12-14 September 2016. The event will see experts in NDT and related technologies meet to exchange experiences, ideas and the very latest developments that will shape the future of NDT. There will be three parallel technical sessions covering a broad range of NDT technologies and applications. A free-to-attend table-top exhibition of NDT-related products will run alongside the three-day event. Over 50 companies are expected to exhibit, showcasing the latest products, innovations and technology in NDT. www.bindt.org
SERVICE UK Service Centre goes live FARO Technologies has opened a new service and calibration centre in Rugby, UK.
EXHIBITION Control figures up Control 2016 attracted 26,809 visitors from 92 countries, 3.5% up on 2015, and featured 914 exhibitors. The 30th edition of the show, which
4
www.qmtmag.com
FARO UK’s move to the spacious new facility was prompted by ever rising sales, the recent introduction of
QMT June/July 2016
NEWS several advanced new products and a desire to deliver even higher levels of customer care. The hi-tech equipment installed at the Centre means that procedures such as the repair and calibration of FARO equipment that was previously undertaken in Germany will now take place in the UK. David Homewood, Director of Sales EMEA, said: “Our new, centrally located Service and Calibration Centre will allow us to offer even greater levels of service and to ensure that our customers receive their equipment back very quickly. Our specious new facility will also allow us to carry-out a wide range of in-house product demonstrations.” www.faro.com
BUSINESS NEWS Creaform expansion Creaform’s engineering division is expanding to meet the increasing demand for its expertise, particularly in design, engineering and simulation. In the past 15 months, Creaform Engineering has created 50 new jobs, increasing its workforce by 42%. It has also set up new offices in California, started operations in India, and opened a testing/prototyping facility in Montreal area. It is also investing in new value-added skills to its offer, such as automation, electronics and software development. Creaform Engineering is recruiting mechanical and electrical engineers and technicians, automation experts and FEA engineers for its offices in Canada, the United States, Europe and India. David Gagné, Division Vice-President, Engineering and Metrology Services at Creaform, said: “From initial design to simulation to production, Creaform Engineering ensure that product development projects are aligned with our customers’ product visions, specifications, compliance standards—and bottom-line objectives.” www.creaform3d.com
EVENTS 25 – 26 July 2016 CMSC Nashville, Tennessee, USA
•
Embedded Vision in industrial and non-industrial applications and Automation 4.0 are two issues that are expected to be a key focus for industry over the next 5 years as machine vision becomes ever faster, the camera resolutions improve and interfaces are increasingly powerful. Over 400 exhibitors are expected to attend Vision, and companies already registered include Allied Vision, Basler, Baumer, Cognex, Edmund Optics, IDS, Keyence, MVTec, Opto Engineering, ProPhotonix, Sensopart Sick, Silicon Software and Stemmer Imaging. QMT is an official media partner of Vision 2016. www.messe-stuttgart.de
EDUCATION Aiming for pole Hexagon Manufacturing Intelligence UK is helping a group of university students to fine-tune the design of a single seat racing car for a top educational motorsport competition. The 24-strong team from the University of Sunderland is using a Hexagon Manufacturing Intelligence TIGO SF co-ordinate measuring machine and ROMER Absolute portable measuring arm for a range of measurement and inspection tasks. Based at the university’s Institute for Automotive and Manufacturing Advanced Practice (AMAP) facility, the SU team is aiming for success in the Formula Student contest set to take place at Silverstone in July.
MACHINE VISION Looking into the future Machines that not just see, but understand their environment are on the horizon, say the organisers the Vision exhibition, which takes place from 8 to 11 November at Messe Stuttgart. Vision team leader Florian Niethammer says: “Products that previously were only being tested in research centres are increasingly starting to penetrate the market.,
As an Innovation Partner of Formula One’s Red Bull Racing, Hexagon also arranged for the students to boost their preparations for the event with a trip to the team’s headquarters at Milton Keynes. www.hexagonmi.com
www.cmsc.org
12-14 September 2016 BINDT Annual Conference Nottingham, UK www.bindt.org 28 – 29 September 2016 TCT + Personalize Birmingham UK www.tctshow.com
•
2 – 3 November 2016 Advanced Engineering Birmingham UK www.easyfairs.com
•
8 to 11 November Vision 2016 Messe Stuttgart, Germany www.messe-stuttgart.de 9 – 12 April 2017 Control Messe Stuttgart, Germany
www.control-messe.de
• QMT is a media partner
RESEARCH Metrologist recognised University of Huddersfield researcher, Dr Hussam Muhamedsalih has been awarded the Worshipful Company of Scientific Instrument Makers’ Beloe Fellowship. The London-based Worshipful Company of Scientific Instrument Makers is a modern livery company with roles that include aiding government policy in measurement standards. It makes several awards, the highest of which is the Beloe Fellowship, which supports an outstanding post-doctoral researcher with £5,000 per year over three years. Dr Muhamedsalih is working on improvements to the interferometer, which has exceptional potential in many areas of advanced manufacturing, such as solar energy, printable electronics and medical devices. His three years as a SIM Fellow is now underway, although he will be invested at an event in October, when he will don the ceremonial robes. www.wcsim.co.uk
QMT June/July 2016 www.qmtmag.com
5
COVER STORY
Inspecting digital models Digital inspection with 3D software reduces time to market and improves quality at a lower cost
C
Right, fibre analysis. Courtesy of School of Engineering ANU (Australian National University)
6
oordinate measuring machines (CMMs) are still largely used to measure the accuracy of manufactured parts. They can only assess what is visible and accessible on the surface of the part, and so they are used mainly to measure actual part surface deviation from an accurate nominal model. CMMs do not let you look inside the structure of a particular material, piece of rock, or mechanical part. X-Ray tomography has been around for close to five decades. The detector and source technology improvements, in addition to reconstruction advancements during the past few years allow for acquisition of highresolution, high-quality data that are able to deliver important information to characterise a material or detect indications inside a part. From medical CT, to micro-CT, nano-CT, and also Transmission Electron Microscopy (TEM), all ranges of resolution allow you to look at different levels of detail inside the sample. The data acquired from these techniques are digital samples onto which different analyses can be performed in order to better understand the structure of the material and to look at potential defects. Whether you are looking at a ceramic filter and analysing its porosity and permeability, examining a piece of wood and characterising its strength based on fiber orientation and length, or studying a composite fan blade from a jet engine to find gluing and weaving defects or foreign object debris, all of these characterisations and detections are now possible on these digital models through advances in software solutions, such as Avizo Inspect.
The main CT revolution is the ability to acquire good data that lead to meaningful and accurate numbers that help researchers understand the material, or the manufacturer to more quickly integrate new materials in their production. This new understanding of the material or the part is of utmost importance to increase the development cycle of new materials, to more quickly understand and correct a defect during failure analysis, and to speed up the design cycle of a new part. It also helps control quality during the manufacturing process. Reducing the development cycle decreases costs and allows for faster adoption of new technologies. The ability to monitor quality increases productivity and allows for delivery of higher yield at the end of the production line. It also provides greater assurance of delivering products that conform to quality standards, reduce the risk of failure, follow increasing safety regulation, and decrease the cost of defects. The analysis process begins with a visualisation phase. The 3D data is loaded into Avizo Inspect, and different 3D visualisation techniques allow the quality of the acquisition to be assessed. Achieving good numbers
www.qmtmag.com
QMT June/July 2016
Providing world-class metrology products, services and solutions With over 80 years’ experience and representation in over 100 countries, Mitutoyo are recognised as the world’s foremost manufacturer of precision measuring equipment and a provider of related services. Visit us online at www.mitutoyo.co.uk s at ...
see u e and
Com
HALL 4
| S TA N D
C20
DIMENSIONAL METROLOGY CITY & GUILDS AWARD (Level 2) Mitutoyo alongside City & Guilds exclusively offer the first National Qualification in Dimensional Metrology Find out more, or book your place at www.mitutoyo.co.uk/education
COVER STORY
Above, The Recipe mechanism allows for automatic generation of reports, right, example of custom recipe for porosity analysis. Data courtesy of RX Solutions
8
relies on good data from the acquisition system, while optimising parameters of the CT acquisition is crucial for producing a good digital model. Type of material, source power, beam path, and phase contrast filter are all important and dependent upon what we are viewing. And, of course, resolution is highly important. Small cracks in a part will not be ‘visible’ if the crack width is smaller than the resolution of the CT. (It has been observed that an indication will be detectable in the digital data if its size is at least three times larger than the CT resolution). The visualisation phase also allows for correcting artifacts linked to the acquisition process, if necessary. Algorithms can be applied to correct for charging or beam hardening, for instance, or to remove the infamous ‘ring artifact’ caused by a dead pixel on the detector. Looking at the 3D data allows you to begin understanding the conformation of the part and to detect visually obvious defects or indications. Next is analysis, where meaningful numbers are computed from the data in order to characterise or quantify. Here, the application can perform the same kinds of measurements as produced by a CMM, but on the digital model. Distance, diameters, and angles can be directly measured on the 3D visualisation. This is also where pores are going to be quantified in the porous material, computing their location, size and shape, and distance to the surface of the part. In addition, clusters will be localised. All of this information helps characterise the material by assigning, for instance, properties of permeability or strain. These analyses are more often a succession of image processing algorithms, each brick of processing linked to the results of the previous, generating a workflow from the CT data that will produce a spreadsheet with the numbers to understand the data. Avizo Inspect introduces a recipe mechanism that allows for automating such quantification or inspection workflow. Once a workflow has been created for a particular type of material and analysis, that workflow
www.qmtmag.com
can be added to a library of recipes. Identical analysis on similar parts or materials can then be automatically re-played without further development. Traceability is also of great importance in the inspection process. Tracing where a particular result is coming from, what processing has been applied in order to produce it, documenting the results of an analysis, and archiving and sharing them are important Avizo Inspect functions. The Recipe mechanism allows for automatic generation of reports, where the inspection workflow can export visualisation snapshots of the data and spreadsheets resulting from the quantification or analysis process. Each intermediate result and final result can be archived, so a full trace of the process is available for later review. This inspection automation mechanism can then be integrated onto the production line. While Avizo Inspect can be used off-line or near-line, it can also be directly connected to the acquisition system. Each time new data are pushed from the CT acquisition, an acquisition service pre-processes the data, splitting it into individual parts in the case of multi-part acquisition, registering data to a reference model, and reducing some acquisition artifacts that may be present. Once a part has been pre-processed, it is sent to an Inspection application that will run a scenario that can be a combination of visual inspection and Recipes. An operator in visual mode can accept or reject a particular step of the inspection scenario, while a part can be automatically accepted or rejected depending on the numbers produced by the Recipe according to some nominal and tolerance information. The inspection scenario is created through a Designer application that defines all of the different steps of the inspection workflow and the combination of visual inspection and Recipes. A Reviewer application allows for reviewing rejected parts and confirming rejection. Good CT data is nice, but achieving accurate and meaningful numbers is the true aim. Characterisation and inspection of these data through Avizo Inspect reduces the design cycle, shortens time to market for new material and new parts, and allows for early detection of defects, enabling you to look forward to increased yield and better quality out of the production line. www.avizo-inspect.com
QMT June/July 2016
InSight L100 The ultimate CMM laser scanner combining productivity and accuracy ✓ Increased productivity Capture large surfaces in a short time ✓ Premium accuracy Measure features with the highest detail ✓ Scan any material Cope with glossy surfaces or color variations ✓ Better insights Easy to understand part-to-CAD deviation reports
Higher resolution, larger field of view The InSight L100 CMM laser scanner offers the best possible combination of speed, accuracy and ease-of-use. Suited for both surface and feature measurement, the InSight L100 quickly delivers accurate data and insightful part-to-CAD comparison reports even on shiny or multi-material surfaces.
NIKON METROLOGY I VISION BEYOND PRECISION NIKON METROLOGY UK LTD T +44 1332 811349 - sales.NM-UK@nikon.com NIKON METROLOGY EUROPE NV T +32 16 74 01 00 - Sales.NM@nikon.com
www.nikonmetrology.com
ADDITIVE MANUFACTURING
Metrology for additive manufacturing:
the key to commercialisation Above and right, often objects manufactured using AM would be difficult, if not impossible, to manufacture using conventional subtractive machining
*Professor Richard Leach is in the Manufacturing Metrology Team at the Faculty of Engineering, University of Nottingham
10
Professor Richard Leach* looks at the revolution that is going on in manufacturing and what it means for metrology
I
n additive manufacturing (AM) objects are formed, not by removing material, but by forming the desired shape in a layer-by-layer process. This way of producing a shape has many benefits over the subtractive techniques, but without doubt, the biggest benefit is the ability to produce almost any desired shape. And this design freedom also applies to internal features, allowing advances in areas such as light-weighting for aerospace, internal cooling channels for automotive and designed-in porosity for medical implants. AM is still at an early stage of development. There are many examples of consumer products using AM with plastics, but, if AM is to be used in earnest in high-value, advanced manufacturing, for example, in the aerospace or medical industries, then it will be metals and ceramics that will be the gamechangers. However, right now, the integrity of metal or ceramic parts is not equivalent to that expected from more traditional subtractive manufacturing techniques. AM parts made from metal powders tend to have high surface roughness values and can suffer from undesired material characteristics (for example, high porosity or large numbers of defects). Also, where one would not dream of manufacturing a part with subtractive techniques without a dimensional tolerance scheme, it is still not clear exactly how to apply tolerance principles to AM parts. This is where we get to metrology. The following are some of the primary reasons why we put so much effort into measuring what we manufacture:
www.qmtmag.com
• To know whether a part is fit-for-purpose. • To allow assembly of complex components • To allow control of a manufacturing process • To avoid unnecessary scrap material and redundant processing time;
• To improve energy-efficiency • To give customers confidence in a product;
From the metrology standpoint, AM is no different to subtractive manufacturing. In fact, I would argue, that a lack of metrology in current AM machines and processes is hindering the commercialisation of the resulting products. The last bullet point above is especially relevant in this context, for example, an aerospace manufacturer is not going to ‘fly’ a turbine blade made using AM without the high degree of confidence that metrology can supply. However, for some of us that have been in this game for a while, the current dearth in AM metrology is not a surprise. I have spent my career playing catch-up with all the wonderful machining processes that are developed. Metrology is almost ubiquitously thought of last. So
QMT June/July 2016
SOLUTIONS DE MÉTROLOGIE
3D SCANNING FOR THE SHOP FLOOR AND ASSEMBLY LINE
Visit us @ Northern Manufacturing, Manchester, 28-29 Sep, Stand D8
DÉCOUVREZ LE MEILLEUR BRAS DE MESURE. LE VÔTRE. Visit us @ TCT Show, Birmingham, 28-29 Sep, Stand B32
Conçue spécifiquement pour l’inspection dimensionnelle en atelier, la machine de mesure tridimensionnelle (MMT) portable HandyPROBE Next MC offre une exactitude impressionnante et une polyvalence exceptionnelle.
NOUVEAU
■ 2 fois plus précise ■ Aucun montage de mesure rigide ■ Conception robuste pour une
bonne fiabilité en usine
+33 4 57 38 31 50 | www.creaform3d.com
▪ Dramatically reduce inspection cycle times using multiple imager arrays ▪ Increase productivity by automating measurement workflows ▪ Real-time 3D data for statistical process control (SPC) ▪ Measurement accuracy ensured by self-monitoring ▪ Easy to configure and integrate ▪ Easy set-up and transport
THE NEW FARO® FACTORY ARRAY IMAGER The FARO Factory Array Imager is a metrologygrade, non-contact scanner which utilizes blue light technology to capture millions of high resolution 3D coordinate measurements in seconds. The Array Imager multi-imager array configurations enable industrial manufacturers to significantly improve productivity and operations. Array Imager’s versatility supports a variety of deployment options. It delivers fast and consistent measurements for inspection and reverse engineering applications on parts, assemblies and tools. www.faro.com/faro-factory-array-imager
There are many CMMs.
One software makes them more powerful. Whether you have an existing CMM device or about to purchase one, Verisurf-X is the only software you need. With its 3D CAD-based architecture, flexible reporting options, and ease of use, Verisurf-X will reduce training time and increase productivity, right out of the box. No matter what you are making or measuring, Verisurf-X provides the power to drive your devices, reduce cost, improve quality, and streamline data management – all while maintaining CAD-based digital workflow.
Learn more about the power of Verisurf-X by visiting our Website, or call for an onsite demo.
www.verisurf.com • 866-340-5551
See live demonstrations at CONTROL, Hall 5, Stand 5313
www.verisurf.com • +44 (0)1684 891372
ADDITIVE MANUFACTURING
Optical instrument Figure 2 The ‘information-rich metrology’ philosophy
+
A priori information A good model
this article will tell you about the significant effort we are putting in at University of Nottingham to address the metrology requirements for AM. The activity of the Additive Manufacturing and 3D Printing Research Group (3PRG) at Nottingham is perhaps the largest AM group in the world, with around one hundred academics, research fellows and PhD students. I started the Manufacturing Metrology Team in the 3RPG in January 2015 and it is now twenty-five people strong and a significant part of our effort is to solve the metrology issues facing AM. We spent the first year reviewing what others have done in the field, what existing technologies can be bought to bear on AM and planning our future research. This has resulted in four critical review articles that are planned to be published in 2016 that cover: • Post-process optical form metrology for industrialgrade metal additive manufactured components. • X-ray computed tomography for additive manufacture • Surface texture measurement and characterisation for additive manufacturing. • in-situ process monitoring and in-situ metrology for additive manufacturing. Form metrology, the measurement and characterisation of a part shape, is critical for quality control of AM products, and for AM machine manufacturers to successfully characterise and optimise their AM processes, when new materials and part geometries are continuously developed. Shape deformation is one of the most noticeable effects following most metal AM processes due to the relaxation of thermal stresses and hence detailed in-situ and post-process characterisation methods would be highly beneficial in understanding and contributing to the aversion of these effects. Our review concentrates on the state-of-the-art in non-contact 3D optical metrology applicable to AM industries that have stringent product qualification standards, for example, in the aerospace and automotive industries. Contact systems, such as mechanical probe-based coordinate measuring machines (CMMs), have been used in such industries for many years, and can measure form to high accuracy (usually more accurately than current non-contact systems), but are relatively slow, not ideal for in-line inspection and only measure a limited number of points on an object’s surface. Our current research into AM form measurement will focus on structured light techniques (fringe projection). We will also take advantage of what I call ‘information-rich metrology’ (IRM). IRM is the combination of accurate modelling of the interaction with the object being measured with all the a priori information that is available (Figure 2).
12
www.qmtmag.com
=
Result with higher bandwidth
Making use of existing information Often when we manufacture something, and especially when we use AM, we have a large amount of information about the object being manufactured, for example, the CAD data gives us the nominal form and we have usually characterised the surface texture to a high degree of confidence. In many cases, the a priori information allows us to solve the complex mathematical problems we encounter when trying to model the interaction with the object being measured (what we call “inverse problems”).
“...allows us to get the maximum amount of form information with the minimum effort.” Our research is focusing on accurate mathematical modelling to allow us to optimise a given measurement scenario. IRM can allow us to minimise the measurement time (for example, by optimising the number of views we need to take to capture the form information) and increase the spatial bandwidth in which we measure (for example, by allowing us to measure high slope angles using multiple reflections). Our ultimate goal is to have a form measurement system, based entirely on camera technology that allows us to get the maximum amount of form information with the minimum effort. As discussed above, AM provides freedom of design that is generally infeasible with other manufacturing methods, particularly regarding the creation of complex internal features that are inaccessible to well-established measurement tools. X-ray computed tomography (XCT) is currently the best method of measurement for these internal features due to the volumetric nature of the XCT process. As AM and XCT have recently become more viable as methods of production and measurement, respectively, their combined and future work required to further establish both technologies, are research topics for my team. We are starting to apply IRM techniques to use a priori information to reduce the XCT measurement time and allow better detection of otherwise inaccessible surfaces.
Dealing with texture Whilst the form of a manufactured object is critical, it is often the surface texture that has the biggest impact on its functionality. Surface texture (often called roughness) is often the limiting factor when considering the tolerance of an AM part. Whereas surface texture height structures can be produced on the nanometre scale using precision
QMT June/July 2016
ADDITIVE MANUFACTURING
Left and below, figure 3 Examples of surface texture produced using AM techniques
subtractive textures, due to the nature of powderbased AM techniques, surface texture height structures of tens of micrometres are more normal (Figure 3 shows examples of AM textures). This throws up a number of metrology questions, some of which include: (i) Can we use conventional surface texture instruments to measure AM surfaces – high slope angles, resulting in multiple reflections and shadowing, cause problems for optical instruments? (ii) Can we use conventional filtering methods and texture parameters with AM surfaces? (iii) Can we examine the surface texture of an AM part to elucidate how the surface was manufactured – AM processes involve some highly complex physics, so this involves a significant amount of experimental and theoretical research? (iv) How can we measure surface texture in-line? There have been a number of advances over the last decade in in-line AM metrology, mainly using either thermal cameras or optical imaging (2D) methods, often to monitor the melt pool characteristics. Some of these techniques are now available on commercial AM machines. But there is some way to go before we can take advantage of full closed-loop manufacturing – the main bottleneck is measurement speed. Again, IRM can come to the rescue by breaking the measurement process down to its bare minimum and taking advantage of a priori process data. We currently have activities in in-line measurement using optical coherence tomography, focus variation methods, fringe projection, optical scattering and laser-based acousto-optic techniques. This particular area of research is likely to grow significantly over the next couple of years.
AM metrology to allow the predicted revolution to become a reality. AM processes need to be have tolerance and quality control procedures in place, starting with off-line metrology and moving towards closed-loop control using in-line metrology. In parallel with this research effort, there also needs to be international standardisation. ISO and ASTM have officially joined forces and Nottingham is an active part of the normative process. The Manufacturing Metrology Team at Nottingham is addressing many of the metrology demands and is driving its research forward using the concept of information-rich metrology. IRM will be the way to make a difference and a way to leap-frog some of the measurement speed bottlenecks that limit current measurement techniques. www.nottingham.ac.uk/research/ manufacturing-metrology
Making the revolution a reality AM is likely to have a significant impact on manufacturing and ultimately on all our lives. But, there needs to be a concerted research effort into
QMT June/July 2016 www.qmtmag.com
13
POSITIONING
In the right place
Rotary tables can be vital component in the inspection process
C
MM machines are a vital part of the modern manufacturing process across many industries; from aerospace, automotive and motorsport through to energy and nuclear. However, one important component is often forgotten, a component that can significantly increase the CMMs capability and accuracy while reducing inspection times – the rotary table. Bath-based RPI UK has been designing and manufacturing precision rotary tables since the 1950s and estimates that 80% of all CMMs in the UK using a rotary table rely on one of their devices. This includes machines manufactured by leading CMM manufacturers such as Hexagon, Nikon and Mitutoyo; and are used by leading aerospace companies such as Rolls Royce and GE. The RPI rotary tables have precision geometry with axial performance well below 0.0005mm and positional accuracies to +/0.5 arc-seconds (+/-0.00014°). These features complement the CMM machine enabling it to achieve even greater precision. RPI produce a range of rotary tables for various applications, including: full positioning and indexing tables; manual or NC controlled with mechanical and air bearings or a combination of both. They range in diameter from 100mm to 1200mm, though much larger bespoke tables are available. Their high geometric performance is ideally suited for assembly, test, inspection and metrology applications. RPI’s tables can handle loads up to 14 tonnes which enables fine machining and precision testing of heavy components such as aircraft engine casings. Rotary tables enable very precise measurement of many geometrical characteristics, including angle, roundness, concentricity, parallelism, flatness and runout. They are used with: probes such as plunger,
14
www.qmtmag.com
transducer, and capacitance; optical such as autocollimator, laser interferometer, and diffractometer; and electrical – oscilloscope, volt meter. RPI’s air bearing spin tables are becoming more popular and rely on air lubricated hydrostatic bearings which provide very high radial and axial stiffness. This type of bearing offers significant advantages over conventional rolling element bearings permitting operation with minimal drag, vibration and mechanical noise. The design principle of these bearings ensure axial laminar flow between shaft and housing compared with conventional orifice entry arrangements thereby ensuring exceptionally good motion geometry of less than 0.0001mm for axial and radial runout. These tables can be combined with direct drive motors and high accuracy angular encoders. The encoder couples directly to the motor control system, which has its own high-resolution interpolator ensuring precise positioning and repeatability. Some CMM applications require the component being measured to be held with its axis horizontal. RPI has a specific table for these applications which combines preloaded axial-radial rolling bearings for high rigidity in both planes with self-locking worm gearing and a high accuracy angular encoder ensuring sensitivity and fine positioning. It is possible to fit a table with a high accuracy Hirth Coupling, which provides location and angular positioning of the table-top. This delivers fast, accurate indexing between pre-set positions. Rotary tables are so accurate that they can be forgotten, when using a CMM. And that’s no bad thing for manufacturers who need precision time and time again. www.rpiuk.com
QMT June/July 2016
NUCLEAR
Measuring up to nuclear requirements Hexagon Manufacturing Intelligence has supplied an ultra-precision CMM to the Nuclear AMRC The Nuclear AMRC has taken delivery of a Leitz PMM-C 12.10.7, an ultra-high precision coordinate measuring machine that offers sub-micron resolution on large parts and samples AMRC. The Leitz CMM was chosen for its ability to inspect components and samples up to 1.2m in length and weighing up to 1,750kg. It is also equipped with a Precitec LR chromatic confocal probe for non-contact measurement of critical faces to nanometre resolutions, Profiler R sensor for automated tactile surface roughness measurement and an ultra-high precision rotary table to aid inspection and measurement of rotatives, blades, gears and splines. “We chose the Leitz because of its stability and accuracy. Quality is critical in the civil nuclear industry and the machine’s sub-micron accuracy allows us to reach a deeper understanding of the
manufacturing process,” explained Carl Hitchens, head of machining and metrology, Nuclear AMRC. “We can then use this understanding to inform, improve and optimize the process, helping companies to demonstrate that parts made by new processes can meet the quality requirements of their customers,” he added. On-machine inspection of large high value components is a major area of study for the Nuclear AMRC where a Hexagon Manufacturing Intelligence DEA DELTA, the largest gantry CMM available in any research centre, and Hexagon’s PC-DMIS NC machine tool metrology software are also in use. “Multi-sensor systems are the future so the investment in the Leitz platform not only enables the centre to be an early adopter of next generation technologies, but also ensures the research team can validate and test systems“, added Carl Hitchens. hexagonmi.com
Carl Hitchens, head of machining and metrology, Nuclear AMRC, uses the Hexagon Manufacturing Intelligence Leitz PMM-C 12.10.7.
QUALITY DRIVES PRODUCTIVITY Make it perfect the first time, the ten-thousandth time, every time. HexagonMI.com
QMT June/July 2016 www.qmtmag.com
15
AUTOMOTIVE
In-line technology is now an important part of car body construction
* Dr. Kai-Udo Modrich is Managing Director of Carl Zeiss Automated Inspection GmbH & Co. KG, Carl Zeiss Industrielle Messtechnik GmbH
Off-line, in-line, at-line Dr Kai-Udo Modrich* argues that complexity in measurement does not mean you have to sacrifice quality The standards for flexibility and productivity in manufacturing continue to rise. On top of this, new versions and models are always increasing the complexity of the processes, especially in the automotive industry. Yet even under these challenging conditions, companies must still meet high quality standards to avoid defects and expensive recalls. Capturing and evaluating measuring data collected off-line, in-line and at-line enables companies to take on these challenges. The quality assurance system of the future will have to fulfill standards which are far from trivial: the system should capture quality data quickly, flexibly and reliably at different locations – in the measuring lab, near production and as an integral part of the production line. And the system should merge these data centrally and evaluate them. Based on these data, appropriate measures can be taken.
The three pillars in the measuring process Ultra-fast or highly accurate? 100% inspection or random sampling? In the production hall or in the measuring lab? Everything in good measure – that is the ZEISS motto. In the future, companies will have to sensibly combine different technologies in order to completely and thoroughly utilize the potential afforded by an overall system. This is the only way they can remain competitive when it comes to speed and quality. Three different pillars form the overall system: first, highly precise off-line technologies in the measuring lab; second, in-line measuring technologies integrated into production; and third, at-line technologies in direct proximity to the production line.
Off-line Measurements in the climate-controlled measuring lab will also be a part of day-to-day operations in the factory of the future. The reason: when highly accurate measuring machines are protected from vibrations, contamination and temperature fluctuations, they attain a level of precision that will not be achievable either in the manufacturing environment or in the production cycle for the foreseeable future. These machines will be especially sought after when companies require comprehensive analyses and/or highly precise measuring values: Can a quality problem of unknown origins be solved? Is it better to improve the design or to ensure the quality of highly sensitive products? The measuring lab is the right place to answer all these questions. The off-line measurements performed in the measuring lab are then the reference for all other measurements. Yet even off-line measurements are being performed with increasing speed, a development made possible by multi-sensor measuring machines.
In-line Just a few years ago, measuring technology operated separately from the production cycle. In the meantime, however, the importance of in-line inspection in the production cycle has grown as a means of process inspection. For example: 100% inspection integrated into production is currently being used in car body construction. This is a requirement for networked manufacturing in the age of Industry 4.0 because in-line manufacturing
Right, above and below, in-line: the ZEISS AIMax optic 3D sensor captures important quality data directly in the production line. The sensor checks e.g. not only the location of bolts but also recognizes type variants and reads data matrix codes
16
www.qmtmag.com
QMT June/July 2016
@QMTMAG
SOLUTIONS DE MÉTROLOGIE
QUALITY MANUFACTURING TODAY
DÉCOUVREZ LE MEILLEUR BRAS DE MESURE. LE VÔTRE.
Magazine
Le scanner sur MMT portable MetraSCAN 3DMC offre une précision de mesure élevée en environnement d’atelier, sans montage de mesure rigide.
The International Magazine for Quality in Manufacturing • Print •App •Web
NOUVEAU
■ 1,5 fois plus précis ■ 12 fois plus rapide avec 7 croix laser
■ 25 % plus léger ■ Prise en charge des surfaces noires,
de couleurs multiples et réfléchissantes
iTunes
+33 4 57 38 31 50 | www.creaform3d.com
www.qmtmag.com
IndySoft New QMT New Half Page 150728_QMT New Half Page 26/02/2016 12:18 Page 1
IndySoft www.indysoft.co.uk Tel: +44 (0)1908 540 638 Gauge & Asset Management Software
Tool Management Software
IndySoft Calibration Management Software
IndySoft has the ‘most complete’ Gauge Management Software available. Track Equipment as it moves about your business. Perform Calibrations using your own reference standards. Run service/maintenance events. Distribute automatic Email reminders to your colleagues. Complies with many Quality Standards.
IndySoft Europe Ltd
500 Avebury Boulevard
Milton Keynes
Buckinghamshire
MK9 2BE
United Kingdom
sales@indysoft.co.uk
AUTOMOTIVE
At-line-solutions such as the ZEISS AIBox bridge the gap between measuring and inspection technologies in the measuring lab and in the production line. They are used in close proximity to the production line, far right, Off-line: the measuring lab is as important as ever because the measuring data captured there form the reference
deliver data on the nominal-actual comparison of the geometry at-line. One example of this kind of at-line system is the ZEISS AIBox, in which attachments, such as car doors, are scanned optically. In order to protect the required high-resolution measuring technology from the influences of the measuring environment as much as possible, the measuring robot with the sensors is located in a closed enclosure.
Dr. Kai-Udo Modrich, Managing Director of Carl Zeiss Automated Inspection GmbH & Co. KG, is convinced: “In-line, at-line and off-line – all three technologies will share the measuring jobs in the future and provide a stable base for quality assurance.”
Measuring data 4.0 is able to prevent production defects before they occur. Inspection data are evaluated in real time and continuously visualized as trends in the data sequences. If statistical abnormalities are found, then the employee or the machine can react quickly to the first signs of defects. For example: a worn cutting tool can be exchanged before there are rejects. In-line inspection requires relatively high precision and image resolution from the measuring and inspection technology, even though production conditions mean dust and fluctuating temperatures – and this must all happen at a speed suitable for the production line. Currently, it is primarily optical sensors on robots which fulfill these requirements. One example is the ZEISS AIMax sensor which inspects characteristics such as the location of bolts or columns in seconds.
At-line
These days, sophisticated analysis software has become indispensable for deriving significant information from measuring and inspection data. ZEISS PiWeb software is pictured here
18
At-line solutions bridge the gap between measuring and inspection technology in the measuring lab and in the production line. Atline technology is used in close proximity to the production line and is often protected by an enclosure. The workpieces can be digitized completely and then flexibly analyzed using these metrology assistance systems designed for the production environment. For example: through random sampling, these technologies quickly and easily provide staff in car body construction with an overview of how an entire part is developing in terms of its form and position tolerances and what the freeform surface actually looks like as compared to its nominal status in the CAD model. These kinds of at-line systems save time and effort in the measuring lab and
www.qmtmag.com
In-line, at-line and off-line – all three technologies will share the measuring jobs in the future and provide a stable base for quality assurance. Metrology providers that want to offer their customer a comprehensive solution will need to make all three measuring technologies available and further evolve them. They will also need to devise customer-specific solutions to effectively combine these three approaches, ensuring efficiency and productivity. Not only will data capture change in the age of Industry 4.0, but data processing will as well: decentralized intelligent systems will pre-process data in the sensor and reduce them to the most important data before sending them onward. This is how companies will be able to minimize transfer time and prevent the mountains of data from becoming unmanageable.
A steering tool for production And one other factor will be decisive in the future: using measuring data, manufacturing software solutions will automatically provide instructions. You can already observe the first signs of this development in factories today. For example: numerous automobile manufacturers and suppliers are merging their process and quality information using ZEISS PiWeb, a central software platform. It is still the employees who decide how, for example, they should adjust the welding robot in response to deviations in the measured values. In the future, the software platform will undoubtedly initiate these adjustments independently. If, for example, measuring data are heading in a particular direction, the system will instruct the robot to change the welding parameters, e.g. the welding current or the electrode force, as stipulated by the intelligent software module. Measuring technology will gradually become a steering tool for production in the smart factory. And it will create the necessary conditions to ensure that quality does not suffer even as companies manufacture more productively and with greater flexibility. www.zeiss.de/industrial-metrology
QMT June/July 2016
MOTORSPORT
Pole position Precision weighing systems help trim race-car performance
The world of motor racing is highly competitive and one of the keys to success is to manage and optimise the balance of the race car. Mantracourt, a specialist in high precision measurement electronics, has been working with the Sébastien Loeb Racing (SLR) team to supply a weighing system that would give their cars a competitive advantage. SLR has three Citroen Elysee vehicles entered in the WTCC (World Touring Car Championship) and for several years has been using a weighing system that attaches directly to the vehicle in place of the wheels. This concept should allow an exact and repeatable adjustment of the relationship between the suspension arms and the wheel rims and tyres. However, despite having appropriate mechanical components, users found this system to be unsatisfactory, particularly due to its lack of repeatability. Didier Santo of Mantracourt distributor Mantra France proposed a weighing solution using industrial sensors and Mantracourt’s T24-ACMi-SA wireless telemetry acquisition modules and the T24LOG100 logging and
AXIOM
visualisation software application. Following extensive testing by Jean Philippe Nicolao and his team at SLR, the system was accepted as it satisfied all requirements. Mr Nicalao said: “The Mantracourt system was just what was required in terms of accuracy, reliability and repeatability. We are delighted and the system has become a vital part of our race to success.” Mantra France is currently working to add an inclinometer, which requires a 5V DC supply and has an analogue output, inside each wheel position support point. The T24ACMi-VA acquisition module will be ideal for this new application. www.mantracourt.com
T H E U K ’s B E S T - S E L L I N G C M M
From the largest UK owned manufacturer of CMMs
Aberlink make the World’s easiest-to-use CMMs... ...making 3D measurement both easy and affordable
Thousands of satisfied customers throughout the UK
For more information or to have a look at one
www.aberlink.com | sales@aberlink.com | 01453 884461 QMT June/July 2016 www.qmtmag.com
19
GAUGING
A blow for contact gauging
Bowers Group created a bespoke air gauging system for Rotork’s aluminium gear cases
20
Rotork, the market leading actuator manufacturer and flow control company, works closely with companies in the oil and gas, water and waste water, power, marine, mining, food, pharmaceutical and chemical industries across the globe. Rotork’s products and services are used throughout the world to improve process efficiency, assure safety, and protect the environment. Rotork is a specialist supplier of actuators, adaptions and accessories to the international valve and actuator industry. They provide an extensive range of valve actuators, designed to withstand the challenges of operating valves in harsh environments, including subsea and nuclear. They also provide a complete range of assembly and test services. Within its range of actuators, Rotork produces a gearcase made from aluminium alloy. Among other features to be inspected on the gearcase are seven critical diameters, six parallel and one taper, ranging in diameter from 21mm to 184mm. The size and form of these features are extremely important because when they are fitted with their mating part, a flame proof joint is formed. Each of these diameters is required to be meticulously checked for roundness and diameter, with tolerances varying between 0.020mm and 0.050mm. The results from each measurement are then collated and recorded within Rotork’s statistical process control (SPC) system. Rotork had been using a contact gauging method of measurement for many years. However, due to the abrasive nature of the material and the tendency for aluminium alloy to cold weld itself to any part that it comes into contact with, Rotork approached Bowers Group with a view to discuss the merits of changing over to a non-contact gauging method for these parts. Air gauging is a measuring system that makes no physical contact with the
component at the measurement point. Bowers Group has many years of experience in producing air gauges, and in January 2015 invited Rotork and its associates to a meeting at Bowers’ Camberley demonstration centre to discuss the merits of moving to a noncontact air gauging solution. Rotork has made substantial investments over the years in the Sylvac D300s Digital displays, and understandably wanted to retain this equipment as the preferred digital display for the measured results. At that time, Bowers did not have an air gauge system that could be used in conjunction with the Sylvac D300s display, and so the process began to develop such a bespoke solution. In conjunction with a current air gauge supplier, Bowers put a proposal forward for an eight channel air gauging station that incorporated all of the requirements stipulated by Rotork. This system would be capable of linking in with the Sylvac D300s Digital displays, as requested. Early testing of the system showed the measuring results to be extremely stable, and the system proved easy to calibrate and very simple to use. Based on these encouraging early results, Rotork placed an order for two identical systems in July 2015, and the manufacturing process began. The manufacturing process was completed in late October 2015 and the first of the two systems was delivered to HPC (a key machining partner to Rotork) for testing on the Series 2 components. Paul Dennett, Quality Engineer at HPC said: “The results are looking very good, even on the diameter 36.0mm bore which only has a 0.020mm tolerance. I must also say that the gauging is much more shop floor friendly than the old contact style gauges.” In December 2015, Rotork placed a further order for a 10 channel system based on the same principle. www.bowersgroup.co.uk
www.qmtmag.com
QMT June/July 2016
The UK’s largest meeting place for advanced engineering professionals
Join us where the familiar and the unfamiliar collide to provide“Fantastic…I new opportunities thinkacross this the engineering “…the corridors ha is the best year yet” and they are our de supply chain. Dave Withey,
“Fantastic…I think this is the best year yet” Dave Withey, Senior Project Engineer, Research, Jaguar Land Rover
Graham Mulholland,
AdvancedSenior Engineering the industry eventManaging whereDirector, Project Engineer,is Research, Jaguar Land Rover epm: technology group high-technology manufacturing sectors converge under one roof to meet and do business. “…the corridors have been full all the time, and they are our decision makers” Graham Mulholland,
Managing Director, “Fantastic show…lots of interest, not just from epm: technology group aerospace but from automotive and other sectors” Robert Richards, BDM, Metrology Software Products
“Fantastic show…lots of interest, not just from aerospace but from automotive and other sectors” Supported by: Robert Richards, BDM, Metrology Software Products
“It wa minde sport got so
LCL Elect
“It was fantastic to meet with likeminded people…especially in motor sports and hybrid power…We’ve got some great leads to follow up” LCL Electronics
Contact us about exhibiting today gg +44 (0)20 8843 8800 or visit www.advancedengineeringuk.com
AUTOMOTIVE
ISO/TS 16949 – clearing up the confusion
Richard Mount of SWINDON Silicon systems explains what the change in eligibility for the automotive quality standard means in practice ISO/TS 16949, based on the quality standard ISO9001 was first introduced for the automotive industry in 1999 and since its first publication it has been regarded as a ‘must-have’ for companies engaged in design/development and manufacture in the automotive industry. However, there has been a change in eligibility and that has caused some confusion in the industry. The governing body, International Automotive Task Force (IATF) has ruled that all fabless semiconductor companies, not directly engaged in manufacturing, are no longer eligible for accreditation. This ruling means that companies such as SWINDON Silicon Systems, a world leader in Tyre Pressure Monitoring Systems (TPMS) can no longer be accredited. So what happens now? Can it still supply the automotive industry and what quality systems need to be in place?
ISO/TS 16949 Accreditation
Despite the confusion and rumours throughout the industry, the fact remains that all fabless semiconductor companies can continue to supply ASICs (Application Specific Integrated Circuits) to the automotive industry, as before, as long as their foundry and packaging suppliers are ISO/TS 16949 accredited. World leading automotive OEMs including Mercedes, BMW, Nissan, Ford and GM are, and will continue to be, supplied by fabless companies. Richard Mount, Sales Director at SWINDON Silicon Systems says “This change in accreditation does not change our approach to quality systems and their processes, and
22
www.qmtmag.com
we now treat the TS requirements as customer requirements. We expect that this will also be the same for other companies that supply the automotive industry.”
IATF clarifies the rules for accreditation
The IATF has gone out of its way to reassure semi-conductor companies like SWINDON that specific activities that could be considered by some as part of manufacturing process are excluded. It has ruled that none of the processes listed in the table opposite on their own or in combination meets the ISO/TS 16949 eligibility: (see table).
Quality Control is Essential
However, engineers at SWINDON know that the ISO/TS 16949 methodology is built into their systems and culture and provides a wellestablished automotive baseline for business. A quality system is in place that covers the whole process from planning, design and development, through manufacture and test and customers can be assured that the company will continue to provide PPAPs (Production Part Approval Process) including manufacturing data obtained during APQP (Advanced Product Quality Planning) as it did before.
Supplying the automotive industry and its strict quality requirements
Supplying to the automotive industry means that there will always be strict and stringent quality requirements so all companies have a commitment to continually improve processes and to maintain the same tight control over product change and implementation. Companies should be in daily contact
QMT June/July 2016
AUTOMOTIVE
IATF Oversight Certification Body Communiqué 2014-004 Activity
Description of activity
1. Programming
Electronically placing the customer’s code into programmable components.
2. Test
Verification of the components to ensure they were programmed with the customer’s code using electronic test equipment.
3. Marking
Placing of the customer’s program number, revision, or any other information that the customer requests on the component using a label, laser mark or ink mark.
4. Dry Bake
Baking of the moisture sensitive components in an oven to remove any moisture they may have absorbed while they were out of the Moisture Barrier Bag during programming, and then repackaging the components in a new Moisture Barrier Bag.
5. Lead Scan
Visually scanning the components’ leads using 3D inspection to check for any leads that are bent, which may have happened during processing, or may have been received in that state from the component manufacturer.
6. Tape and Reel
Repackaging components from trays or rails to Tape & Reel to accommodate the customer’s automatic equipment for inserting the components into PC boards.
with their global suppliers to ensure that they understand every aspect of a project and that nothing is left to chance. It is also
essential to conduct frequent site visits to assess working practices and to gain a thorough understanding of the manufacturing processes being employed. It is not sufficient to know that suppliers meet TS but companies need to understand how their processes operate and that Quality is assured. So even though there have been changes with the IATF ruling on which companies are eligible for ISO/TS 16949 accreditation, in reality nothing has changed. www.swindonsilicon.co.uk
QMT June/July 2016 www.qmtmag.com
23
CMMS
Roughing it in the workshop Aberlink’s new Xtreme CMM is meeting shop floor inspection challenges at Jamestan Engineering
24
The development of Aberlink’s Xtreme CMM was prompted by the growing trend for component inspection being performed at the point of manufacture, as well as by the increasing requirement for machine operators to measure parts within the cycle time of their machine tools. The remit for Aberlink was to create an inexpensive, accurate, easy to use, CNC driven CMM that could stand-up to the rigours of harsh operating environments and be able to undertake rapid automated measuring routines. To make sure that it delivered on these aims, an early Xtreme model was placed on the shop floor of what was considered a typical target user, North Devon based Jamestan Engineering. Jamestan Engineering supplies precision machined components to the aerospace, motorsport and oil & gas industries, offering services that include multi-axis milling and turning as well as grinding and EDM. Centrally located on the shop-floor, the Xtreme trial model was available to all of Jamestan Engineering’s machine operators. Managing director Paul Jeffery said: “In addition to other tasks, we decided to use the Xtreme to take in-process measurements of the high volumes of tight tolerance aluminium rings that we produce for an aerospace customer. “As the quality of our output is all important, we were originally sceptical about the Xtreme’s ability to provide the levels of accuracy we require in such a harsh environment. Given the safety critical nature of our aluminium parts and the potential for shop-floor temperature variations, we were initially worried about the ability of the Xtreme’s temperature compensation function. “Although, by cross referencing the Xtreme’s results with those we achieved on the CMMs within our dedicated inspection department, our early fears were soon dispelled and we quickly gained complete confidence in the Xtreme’s results. “As Aberlink’s management asked us to place the CMM within a challenging environment, to work it hard and to report any problems, we were happy to oblige. Given that the Xtreme was so easy to use, our operators were soon able to recall the relevant program for the part they were
machining and to perform accurate, fast, automated CNC inspection routines. “At the end of the 6-month pre-launch evaluation period, we were happy to report that despite the harsh surroundings and the sheer amount of work it performed, the new Aberlink CMM had completed thousands of very fast and accurate measuring routines and that we had not encountered a single problem. “In fact, so impressed were we by the speed, accuracy and robustness of the Xtreme, and as the use of a shop-floor based CMM had given us so many advantages, we gave the machine the ultimate endorsement by purchasing the pre-production model from Aberlink. “Now, the use of our Xtreme CMM has enabled our inspection department to concentrate on tasks such as final inspection, as all in-process checks are now made on the shop-floor. Also, as components are now measured so soon after production our already low scrap levels have been further reduced.” Chris Davies, Aberlink Business Development Manager added, “We are very grateful for the invaluable pre-launch assistance given to us by Jamestan Engineering. Although we had carried out exhaustive in-house trials and were confident that the Xtreme would deliver the required accuracy and speed within harsh environments, it was gratifying to know that it performed perfectly within the kind of production situation it was intended for.” www.aberlink.com
www.qmtmag.com
QMT June/July 2016
MACHINE TOOLS
Tracking machining performance
A leading research institute is using a laser tracker in its work on machine tool performance The University of Huddersfield’s Centre for Precision Technologies (CPT) is widely acknowledged as a leading centre for research into precision engineering, metrology and machine tool performance. The CPT carries out research into technical problems in the field of machine tool accuracy and performance for companies such as Machine Tool Technologies Ltd (MTT). The CPT’s track record includes the development of a Volumetric Compensation System (VCS). This maps both geometrical and thermally-induced positional errors in machine tools and corrects for those errors within the machine tool controller. The multi-disciplinary CPT team has access to a wide range of specialist equipment, including a highly accurate FARO ION laser tracker portable CMM and FARO’s CAM2 Measure 10 Software. Andrew Bell, senior applications engineer at the CPT, says: “The work of the CPT has led to the development of new methods of applying the principles of metrology to machine tools. Our researchers sit on ISO and BSI technical committees as well as the government advisory board for the National Measurement System. Over the last 15 years the CPT has delivered £15 million in research and enterprise activity, published over 400 journal papers and worked collaboratively with many world leading companies. “Although the CPT’s many achievements can be attributable to the knowledge, hard work and dedication of its staff, our work has been supported by the range of advanced equipment to which we have access. Having identified the need to purchase a high-accuracy laser tracker, we considered several alternative options that were able to precisely scan large structures. The impressive accuracy specification, speed and ease of use of the FARO ION, and an excellent extended practical demonstration, convinced us that this advanced tracking interferometer was the ideal tool for our needs.
The CPT’s measuring routines often demand high standards of precision over large distances. The required levels of precision is achievable as the FARO Laser Tracker ION has a volumetric accuracy of 0.049mm at 10m and a diameter range of110m when used with selected targets. The flexible Laser Tracker ION is able to be used in restricted enclosed spaces. Andrew Bell explains: “As we need to take measurements inside machine tools when making both static and dynamic performance checks, in addition to its speed of use and accuracy, it helps that the FARO unit is relatively light. Also that it has a range of versatile mounting options enabling it to be used in awkward and confined areas.” The FARO ION is an extremely accurate, portable coordinate measuring machine that is ideal for a multitude of measuring tasks, such as machine tool alignment, press alignment, jig and fixture alignment and robot verification. The Laser Tracker is able to quickly generate accurate trend analyses’ of distortion and other changes in a machine’s operation. The advanced Tracker uses a laser beam to measure the coordinates of large components, equipment and machines in 3D using a spherical reflector. The light weight FARO ION features an extended measurement range and uses ADM (Agile Absolute Distance Measurement). ADM is said to be the fastest method for calculating a position in 3D in real time, enabling rapid measurements to be taken in a dynamic mode when a machine is running. www.faro.com
QMT June/July 2016 www.qmtmag.com
25
PROBING
Probing pays dividends
A Renishaw NC4 non-contact tool setting system is reducing set-up time at QEP
Subcontractor Quality Engineered Products invested in Renishaw probing to make the most of its new advanced machined tools
Renishaw TS27R tool setting probes are saving QEP up to 85 minutes per set-up
26
Having built its reputation in high-volume precision pressing, Quality Engineered Products (QEP) took the decision eight years ago to move into the competitive world of subcontract precision machining. The company, based in Cinderford (UK), started out with vertical machining centres and CNC lathes. Then, in 2015, a major investment in state-of-the-art machine tools provided the opportunity to fully exploit technology and make significant gains. With newly installed machine tools including a Mazak Nexus III Series horizontal machining centre and Mazak Integrex i-200 multi-tasking machine, the task was to maximize their efficiency. Having won a major contract to machine a range of sand-cast aluminium parts for its customer Cannop Foundry, the time was right for QEP to develop the potential of its Renishaw probing systems. QEP was already familiar with probing, having used it on its vertical machining centres for the past four years. Manufacturing Director, Dave Marfell, was looking to take its application to new levels and use Renishaw probing not only for tool setting, but for part alignment before machining and in-process gauging. The time savings that this
would generate equate to almost 20 weeks of production annually. “We recognised the potential of the Renishaw probes very early on,” says Dave Marfell. “We now see probing as an integral part of our manufacturing process and while some people may see in-process gauging as lost time on a machine, we look beyond that and see massive benefits for our business and we are reaping the rewards. We sometimes forget how difficult life was without probing.”
www.qmtmag.com
QMT June/July 2016
Confidence in results
An example of this difficulty is highlighted in the first probing procedure, that of tool setting. QEP – like many other manufacturing businesses – previously set tools manually on the machine, using feeler gauges to set lengths against datum points on the part or machine and trusting the tool manufacturer for diameter data. This information then had to be manually input into the machine control and offsets set. In all, Dave Marfell suggests that each tool could take up to six minutes to set, with typically 15 tools – a mixture of drills, end mills and indexable cutters – in each set-up. QEP now uses both Renishaw NC4 non-contact and TS27R contact tool setting probes, capable of ±0.10 µm 2σ and 1.00 µm 2σ repeatability respectively. Now each tool probing cycle (including diameter measurement) takes less than 30 seconds, and every tool can be checked in quick succession, with data being transferred automatically to the CNC. Another major benefit of on-machine tool setting is the elimination of human error. “Using the oldfashioned methods of paper or feeler gauges, no two people would get the same result, so you would then have to take test cuts to
PROBING
Manual alignment of parts and inspection on a CMM has been replaced by Renishaw RMP60 and RMP600 probing systems, saving valuable time
confirm any offsets. With the Renishaw probes we can be confident we have correct and consistent data and we are saving in the region of 85 minutes per set-up, just on tool setting,” says Mr Marfell.
Increased productivity
The contract with Cannop Foundry involved machining a range of aluminium sand-cast components in five different designs, with typically 50-off per batch. Cannop Foundry supplied the fixturing along with its method of setting the castings, which can vary due to the sand casting process. This method involved a high degree of manual intervention using setting plates and a reliance on the operator to ‘get it right’, as well as being time consuming. Dave Marfell recognised that there was potential to maximise labour efficiency by introducing Renishaw probing to the process. “We looked at the existing process and realised that we could release a significant amount of time by probing the part once it was transferred into the machine. This freed up the operator to work on other things, such as deburring and visual inspection of parts. It’s here that some would baulk at the machine downtime as we now spend between 60 and 90 seconds probing before machining starts, but we have given the operator over five minutes back to do other things, and again we have eliminated any potential for human error from the process which, in part, is helping to reduce scrap by 25%. So, those few seconds we spend probing the part for alignment are fully justified.” With tools and part set, attention turned to inspection. QEP’s routine was to check 1 in 10 parts on a co-ordinate measuring machine (CMM), a process that would take at least 30 minutes. While this part was being checked they had two options; to stop the machine until the part had been verified, or to carry on machining and ‘quarantine’ parts until the
sample had been checked. Both have their obvious drawbacks. Mr Marfell says: “Our challenge was to streamline the process and ensure that we could verify every single component that we delivered. Over a 12-month production run we estimated that using the CMM would result in 270 hours of lost production time.” By switching to in-process gauging using Renishaw RMP600 and RMP60 probing systems, QEP can check the same 1 in 10 parts on the machine. The probing cycle is two minutes per part, which represents a significant productivity gain compared to the previous method, saving around 2 hours 20 minutes per batch. Subject to conditions, QEP can achieve repeatability of 0.25 µm 2σ using the RMP600, and 1.00 µm 2σ using the RMP60. AS9100-accredited QEP has put in place procedures to ensure that what it does with its Renishaw probing systems is fully documented and appraised on a regular basis. Dave Marfell takes a pragmatic view to all of this: “We can control the quality of our machining, irrespective of the machine types we buy or the age profile of the machines we have in service. We have put in place standard procedures that verify what our machines are doing, backed up by the Renishaw probes and measured against standards. These procedures confirm the confidence that we now have in probing across a range of disciplines and the time we have released as a result allows us to add value for our customers, which can only be viewed as a win-win situation.” By fully embracing Renishaw probing systems QEP has maximised labour hours by eliminating unnecessary human intervention, removing bottlenecks around the CMM inspection process, and reducing scrap and potential rework of parts. www.renishaw.com/machinetool
QMT June/July 2016 www.qmtmag.com
27
AUTOMOTIVE The two Nikon Metrology ALTERA 8.7.6 CMMs installed in the measurement laboratory at Continental Chassis & Safety, Veszprem, Hungary
Continental accelerates inspection A Hungarian automotive manufacturer has upgraded its inspection capabilities with multisensor CMMs
The dense point clouds acquired with the LC15Dx are compared to the nominal CAD of the sample. All deviations are visible in an easy-to-interpret colour map
Laser scanning the plastic body of an ABS (automatic braking system) speed sensor using a Nikon Metrology LC15Dx digital laser scanner
28
The quality department at the Chassis & Safety division of automotive company, Continental in Veszprem, Hungary, recently invested in two Nikon ALTERA multi-sensor coordinate measuring machines (CMMs) fitted with LC15Dx laser scanners to upgrade the inspection capabilities of its measurement laboratory. The company needed a high capacity system capable of rapid inspection cycles combined with fast surface scanning with accurate feature measurements, the aim being to gain more comprehensive insight into the company’s products. These include includes electronic and hydraulic brake and chassis control systems, wheel and engine speed sensors, airbag electronics and electronic air suspension systems. Day to day tasks in the measurement laboratory include feature and surface inspection, linear dimension measurements and GD&T (Geometric Dimensioning and Tolerancing) analysis to monitor production quality from the shop floor and assist in new product development. The quality department processes approximately 1,600 inspection reports per year, each consisting of around 20 measured parts, but needed to gain quicker, more comprehensive insight and obtain more information per report. Previously a single CMM with touch probes was handling the majority of inspection tasks. Measuring technician Peter Somogyi and quality engineer Tamas Brunner explain that its main limitation was its slow speed and that that the software was not up to their standards in respect of automation and the latest GD&T. With so many measuring tasks to process, the single tactile CMM was unable to keep up with throughput, let alone provide the level of insight necessary. Mr Tamas calculated that they needed to halve inspection cycle times, and the quality department was also keen to use multisensor technology in its reorganised facilities. The decision was made to install the two Nikon multi-sensor ALTERA 8.7.6 CMMs, each fitted with Nikon’s most accurate digital laser scanner, the LC15Dx, complemented by CAMIO software. The 1.9 micron accuracy of the LC15Dx was the main deciding factor in choosing this equipment. It is perfectly suited to inspecting Continental’s wide
www.qmtmag.com
range of component shapes, sizes, materials and surfaces. Enhanced Sensor Performance ESP3 eliminates the need for component preparation, such as powder spraying of dark or multi-coloured plastic parts, and the Nikon lens provides sharp detail to allow shapes, edges and features to be measured. The new CMMs also include a TP200 tactile measuring probe. A Renishaw ACR3 change rack ensures smooth, automated exchange between tactile and non-contact probes, controlled by Nikon’s CAMIO acquisition and processing software. As all measurement data is stored and available for reprocessing or further analysis, the new inspection system serves as an important tool in handling potential customer claims. The quality of the new inspection process has introduced increased insight into critical dimensions, cavities and functional features of parts, enabling faster corrective action. Mr Somogyi says: “The multi-sensor CMM allows almost all types of measurements to be completed on one machine, whereas previously we needed to use multiple inspection facilities such as tactile probe, microscope, projector and conturograph.” Tamas Brunner says the software is an important benefit: “The graphical reporting is quick and easy to understand. Parts need to comply to many different tolerances and the reports provide clear information.” Since the twin, multi-sensor CMMs were installed in the quality department, the new equipment has already provoked interest from Continental’s Moulding Competence Centre, which is evaluating how optical inspection can speed pre-production and development cycles. www.nikonmetrology.com
QMT June/July 2016
TRAINING
Portable arm good practice
Insphere explains the basics for using a portable arm to its full potential Portable measurement arms are a well-established and trusted technology delivering fast and accurate 3D coordinate measurement data in an evergrowing variety of industrial applications. However, some companies have doubts about their capability or are not using their arm to its full potential. Arms such as Faro, Nikon or Romer arms are highly portable and can be set up in almost any work area and controlled through intuitive software interfaces. They can use contact probes to take measurements, much like a traditional CMM, or they can incorporate a non-contact laser-line scanner to gather detailed information on freeform surfaces. Operators use arms to check components against tolerance requirements, or in some cases to reverse-engineer digital models from a physical sample. Their flexibility and speed of operation make portable arms a valuable tool, for example they can make it cost-effective to perform in-process checks at key stages of manufacture, rather than depending solely on an ‘all-or-nothing’ inspection of a finished part. These new opportunities to use data intelligently to improve manufacturing processes can significantly reduce production costs. However, the speed and flexibility of using an arm can mean that good measurement practices are not always followed. Measurement errors can occur, with the potential to disrupt manufacturing processes or allow bad parts to be wrongly accepted – carrying obvious risks of both financial and reputational damage. Portable arms tend to be used in settings with little or no control of environmental conditions, and by operators who may have their own ways of doing things, potentially affecting results. Processes might not be controlled through adequate work instructions, and results are often recorded in an
QMT June/July 2016
ad-hoc fashion that can be difficult to review or validate. Either through staffing changes or through loss of faith in arm datasets, it can be the case that organisations lose confidence in their arms, leading to reduced usage. Portable arms can become wasted assets, resulting in a poor return on their capital investment. Insphere Ltd offers a one-day course on portable arm good practice that aims to tackle some of these well-known issues. The course includes: • The foundations of good measurement • Measurement planning for arms (set up, reach checks, probe selection) • Environmental considerations, introducing measurement uncertainty • Field checks, operator controls, data collection strategies • Work instructions, equipment maintenance and calibration • Good practice probing methods and laser line scanning to minimise errors (including practical exercises). • Measurement system analysis, how to generate consistent, robust and reliable data • A practical gauge repeatability and reproducibility (GR&R) method for the arm • Applying sound principles to your own applications in the future. Whilst the course is primarily classroom based, the inclusion of practical exercises helps to embed learning and ensure that concepts are understood. Insphere says that the course gives operators far more confidence in using portable arms to generate reliable data. This helps organisations to make greater use of their arms, which of course gives a better return on the investment. Insphereltd.com
www.qmtmag.com
29
SURFACE MEASUREMENT
Monitor keeps an eye on finishes When the adhesion properties are critical it is vital to be able to characterise surface roughness Monitor Coatings Ltd is a privately owned company with over 30 years’ experience in providing high quality coatings to a wide range of demanding industries, including the aerospace, oil & gas exploration and steel sectors. The company’s coatings and surface engineering are able to withstand exposure to a wide variety of chemical, physical and mechanical environments, and to deliver a range of advantages including wear, corrosion, and abrasion resistance, as well as providing thermal barriers. In addition to the traditional industries the company serves, Monitor’s research and development activities also focus on specialist markets such as biomass incineration, high temperature oxidation environments – including super critical steam turbines – and specialist mould technologies. Monitor’s Production Manager, Tom Nicholson says: “Although our key markets include, oil, gas, steel and aerospace, it is the highly sought after Nadcap accreditation that drives the quality procedures at Monitor Coatings.” This quality accreditation has enabled Monitor to achieve high level customer approvals and to be awarded prestigious contracts such as the QE Carrier Deck project in Rosyth. “Although the application of one of our advanced coatings is able to help in many ways, including increasing the life of components by up to ten fold, in addition to its formulation, a coating’s performance is very much dependent upon the quality of its application. This is why Monitor performs some of the strictest quality procedures in the global coating industry, and why we are constantly striving to further improve our quality function,” says Mr Nicholson.
30
www.qmtmag.com
“As the correct surface finish of a base material is critical to the ability of a coating to adhere to it, in accordance with our policy of continuous improvement, we recently conducted a web search for an advanced surface roughness tester that would increase our precision capability and further expand our data capture ability in this crucial area. “Having considered the offerings from several other manufactures, we identified Mitutoyo’s Surftest SJ-410 as the ideal tester for our use. An in-house demonstration confirmed the robust, portable unit’s suitability for both static surface roughness testing in our Quality Department and for use on our shop-floor, in addition to occasional off-site use. “Although the Surftest SJ-410 has many more useful features when compared to our previous instrument, its controls are very intuitive. As well as delivering improved precision in this area, the enhanced data supplied by the unit is archived and provides invaluable information for potential product development”. The portable Surftest SJ-410 surface roughness tester complies with the latest international surface roughness measurement standards. It is able to operate in 38 individual roughness parameters that conform to the latest ISO, DIN, ANSI and JIS standards. The instrument can be used in a hand-held mode or mounted on a stand, whilst a manual adjustment knob enables fine positioning of a small stylus for positioning, particularly useful when testing the inside surface of small holes. To enable records to be saved, the unit’s measured data can be downloaded to a PC via an RS-232C cable, whilst a wide range of optional accessories are also available that can further extend the unit’s application range. www.mitutoyo.co.uk
QMT June/July 2016
CONTROL PRODUCTS
Scalable automated testing At Control, Tinius Olsen gave a live demonstration of how it has increased the flexibility of its automation and system integration, by adding vertical tensile testers to its automated capabilities.
to all systems and the ‘brains’ behind it all. Horizon sends instructions to each piece of equipment and records the resultant data as it moves each specimen through the entire testing process. Once complete, Horizon will generate a comprehensive test report on the mechanical performance of the entire batch. Marketing Director Wayne Harrison told QMT: “We had a lot of interest at the show from quality managers in a whole range of industries who rapidly grasped the vast scope of possibilities and the benefit to their testing program; the other benefit our visitors saw was the power of our Horizon software and its ability to control and measure multiple testing machines.” www.tiniusolsen.com
Re-designed scanner 12x faster By adding vertical testers, it has expanded the loading range at both low loads and at high loads using its standard ST series of electromechanical test frames (from 1kN capacity to 300kN capacity) and SL series hydraulic materials testing machines (from 300kN to 1,000kN capacity). Other kinds of physical test equipment can be added to the automated testing area, such as an automated hardness tester, as was demonstrated at Control. The addition of a series of storage racks for specimens with all identifiers contained on their unique bar codes, a bar code reader and a dimension measuring system and a robot means that the entire system can be loaded with specimens and simply left alone to run by itself. Adding to the flexibility of Tinius Olsen automation systems, more test equipment can be added into the mix. If need be, additional tensile testers can be added, as an example, and be configured to perform a flexural test so that when prompted by the barcode information, the robot places the specimen into the tensile strength tester or the flexural strength tester. Alternatively, or even additionally, a hardness tester can be put into the mix so that the hardness value is measured and included in the test report. The key to the success for these scalable automated testing systems is Tinius Olsen’s powerful Horizon materials testing software, common
At Control Creaform announced a major design and performance upgrade for its new MetraSCAN 3D laser scanner. The new version is 12-times faster and can tackle black, multicoloured and shiny surfaces with metrology accuracy for applications directly on the shop floor Creaform says that the MetraSCAN 3D is very intuitive and easy to use, ensuring short learning curves and operation by any level of user. The enhanced product is 1.5-times more accurate, with a volumetric accuracy of 0.064 mm (0.0025 in.) regardless of environment instabilities. Creaform says it is also one of the fastest scanners on the market at 480,000 measurements/second – making it 12-times faster than the previous generation.
The new light, sturdy design is aimed to give shop-floor hardware reliability to give time and cost
benefits to operators. Available in 350 and 750 models, and Standard and Elite versions, users can choose the speed and accuracy to match their requirements. Thanks to Creaform’s TRUaccuracy technology, the MetraSCAN 3D’s optical-based data acquisition process provides measurement accuracy for small to large parts and assemblies that are insensitive to the instabilities of the environment. Efficient on black, multi-coloured and shiny surfaces, the system helps manufacturers to quickly address potential quality control issues at any stage of the production cycle, regardless of part complexity and material. For more in-depth quality control procedures, users can add singlepoint measurements with the new HandyPROBE Next portable CMM, which, along with the MetraSCAN 3D, is compatible with VXinspect, Creaform’s dimensional inspection software. www.creaform3d.com
Factory-wide metrology network Etalon says its Absolute Multiline Technology makes self-controlled production a reality, with selfcorrecting machine tools not just making parts but checking their dimensions too. It used Control to give visitors a demonstration of how this smart technology can create metrological networks. Absolute Multiline Technology monitors the geometric accuracy of machine tools by means of highprecision length measurements: An absolute distance interferometer measuring with sub-micrometer resolution serves as metrological centerpiece of a factory. It connects with any number of machines via a fibre optic network that may comprise more than 100 measurement channels. These measurement channels, equipped with miniature optical elements, are oriented along the machines’ axes, space diagonals and face diagonals of the machine working volume. Absolute Multiline Technology’s metrological network can cover any machine location and size – it has already been set up in factories supplying multiple machine tools with axis lengths of up to 12m. The maximum measurement range is 40 meters and the optical fibers may travel several kilometers. Due to
QMT June/July 2016 www.qmtmag.com
31
CONTROL PRODUCTS the large distances possible between the robust measurement sensors and the system electronics, measurements can be conducted under extremely rough environmental conditions. Integrated into a machine tool,
Absolute Multiline Technology can continuously monitor the geometry of the machine and initiate machine compensation in order to ensure the dimensional accuracy of the manufactured parts. To perform a standard-compliant machine tool check, a reflector from the tool magazine is interchanged, and a predefined program is executed at the push of a button to move the machine along the multiple measurement beams and thus identify their deviations. This test process takes approx. 20 minutes. Measurement uncertainty (95%) is specified with 0.5 µm per meter. While conventional interferometers can only work with a continuous measuring beam, the Absolute Multiline Technology can deal with interruptions of its eye-safe infrared beam at any time without losing accuracy. The absolute distance is recalculated in a fraction of a second. Hence, highest geometric precision is assured in the entire working volume of the machine. Thermal influences, wear, or collision-induced changes are reliably detected and compensated, if necessary. Geometric compensation is fully automatic with machine values calculated by comparison of the coordinates indicated by the machine and the length measured by the interferometers. Thanks to the machine tool’s autonomous geometrical verification in the entire working volume, it may also be used as coordinate measuring machine to inspect the manufactured components. Especially for the quality assurance of large parts, this generates significant commercial benefits: A separate coordinate measurement machine and also time consuming clamping and re-clamping processes can be omitted. www.etalon-ag.com
32
Automated car body inspection At Control GOM took its ATOS ScanBox series to a higher level with the Series 7 and 8 models which are suitable for the automated 3D digitising and the inspection of large sheet metal parts such as side panels or complete bodies-in-white.
Responding to the needs of the automotive industry, the new optical measuring machines can be set up and taken into operation flexibly at different locations in press shops and body plants – without permanent fixing or complicated floor anchoring. In contrast to conventional systems for the measurement of large components, which consist of heavy robots mounted on long rails, the new ATOS ScanBox systems extend the working range of the ATOS measuring head by introducing new robotic kinematics.
GOM’s 8-axis kinematics – a combination of a horizontal rail, a vertical lift and an articulated robot – allows high flexibility in positioning the ATOS sensor. As a result of these 8 degrees of freedom, the components can be measured from any perspective – including interiors
www.qmtmag.com
where space is at a premium. While ATOS ScanBox Series 7 is equipped with one linear axis, Series 8 consists of a double-robot setup, thereby providing the opportunity for a simultaneous duplex operation. Both robot-guided ATOS 3D scanners in Series 8 perform simultaneous and coordinated 3D measurements for the inspection of entire car bodies or vehicle interiors. Other innovations at Control included the ARAMIS 3D Camera for materials and components testing. This combines point-based and fullfield deformation measurement in a single system. www.gom.com
2D drawings and 3D inspection Verisurf Software and InspectionXpert Corporation demonstrated an integrated solution that lets customers choose between using 2D drawings or 3D CAD models to effectively produce and implement automated 3D measurement plans and first article inspection reports.
Verisurf Software interfaces with and drives CMMs and 3D scanners, and includes Verisurf SOLIDS, a complete 3D solid modeling application, as well as productivity features designed to streamline data capture, analysis and reporting. InspectionXpert provides powerful data extraction, ballooning, and reporting tools for quickly capturing and interpreting dimensional information from 2D drawings. Quality inspectors can efficiently handle the common occurrence of inspection dimensions and notes that are only available in a 2D drawing, such as PDF or TIFF files, but no longer need to spend hours typing inspection information into Verisurf from a 2D drawing in order to program their measurement plan. InspectionXpert quickly balloons the 2D drawing, creating the unique IDs for the Verisurf measurement
QMT June/July 2016
CONTROL PRODUCTS plan, and the powerful OCR extracts inspection information from the drawing. Inspection information is then published to Verisurf where the inspector can easily match the drawing dimension to the 3D model, create the measurement plan and begin the 3D inspection. When the 3D inspection is complete, the results can be exported from Verisurf in a variety of formats or imported back into InspectionXpert to create standard or custom inspection report formats for AS9102 and PPAP. www.verisurf.com www.inspectionxpert.com
CMM translator EasyCMM from Globus Technical Equipment is a universal CMM server that provides a communication interface between the leading brands of CMM and the major metrology software p ackages. It allows a direct plug and play facility for any combination of different CMMs and software – enabling users to match their hardware and software choices to the optimum for their applications and add different makes of CMM to existing systems. Easy CMM performs error mapping to compensate for geometric, volumetric, positional and kinematic errors in the CMM structure that affect their accuracy – covering 21 to 30 correction parameters. It also includes an I++ server so that any software supporting this protocol can communicate with numerous CMM brands and their controllers. www.globus.co.il
Quick set up for heavy parts The Inspection Arsenal Loc-N-Load quick-swap fixture system from Phillips Precision can now be ordered with air assist to allow operators to move heavy loads with just one finger across the CMM granite. Now companies inspecting heavier parts can take advantage of the magnetic puzzle-like, quick-to-swap system. The air-glide feature can be easily added to the standard 12x18” fixture plate per customer request. Additional special order size plates are 18x18”, 18x24”, 24x24”, and 24x36”. The standard fixture system includes several size docking rails, fixture plates, end caps, a unique plate for
the qualifying ball bar, and an angle plate. The hole pattern seamlessly integrates when interlocked. Plates can be ordered individually or in pre-configured bundled systems which include work holding kits. The system allows customers to start off small and add plates that can become part of the job kit for LEAN set-up reduction. www.fixture-up.com
Scalable automated shop floor imaging Showcasing the latest advancements in optical 3D measurement, robot integration, and automation technology, FARO used Control to demonstrate FARO Factory RoboImager and Multi-Imager Array. This innovative solution offers easyintegration onto the shop floor to streamline in-line and near-line quality control and inspection processes.
The FARO Factory Robo-Imager product line is the second product
launched under the FARO Early Adopter (EA) Program. Under this program, select customers who desire early access to leading-edge technologies can access new FARO products prior to full market release. They will also have the unique opportunity to work one-on-one with FARO development engineers on future product improvements and new technologies. Those interested can register for the program at: www. faro.com/ea-robo-imager. Driving these new solutions is the recently released FARO Factory Array Imager – a metrology-grade 3D sensor with blue light technology, capable of capturing millions of high resolution 3D coordinate measurements for dimensional inspection and reverse engineering applications. The FARO Factory Robo-Imager pairs a Cobalt imager with a human-collaborative robot. The solution comes in a fixed version for highly integrated in-line systems and a mobile version for near-line measurements directly on the shop floor. The Robo-Imager provides a turnkey factory automation solution for the digitization, inspection and verification of parts at any point of production. The Factory Robo-Imager was designed to maximise productivity, simplify workflows, reduce cycle times for inspection and eliminate scrap and costly rework. Specifically, the mobile version enables the inspection processes to be moved out of the quality lab and onto the shop floor, so parts can be automatically checked without delay and part deviation can be recognized earlier in the production process. The system is built with proprietary onboard processing which allows an unlimited number of imagers to collect measurement data simultaneously into a single computer. This sensor combination is known as a MultiImager Array and can be arranged in unlimited configurations to meet specific production requirements such as cycle time, coverage area, resolution, and accuracy. Combining the FARO Factory Array Imager in a Multi-Imager Array configuration can significantly reduce cycle time by expanding field of view (FOV) while maintaining highresolution and accuracy. Productivity can be increased simply by adding more sensors into the array. www.faro.com
QMT June/July 2016 www.qmtmag.com
33
CONTROL PRODUCTS
New 3D laser scanner
Mobile real time scanning
Hexagon Manufacturing Intelligence has released a new portable laser scanner for large-volume inspection applications. Created with a focus on usability, the Leica Absolute Scanner LAS-20-8 portable 3D laser scanner is designed to make gathering complex point-cloud data easier and quicker for shop-floor operators.
At Control Surphaser demonstrated the SurphSLAM mobile real-time scanning, registration and rendering system for indoor and outdoor environments. Based on a Surphaser 3D laser scanner model 10 and GeoSLAM RealTime software, the trolley-mounted system can work anywhere, providing a seamless transition between indoor and outdoor locations and on uneven or sloping terrain. The user gets real-time feedback, seeing the map being built as they walk the route to be scanned. Results are instant and a fully registered point cloud can be reviewed and downloaded after every scan. www.surphaser.com
In combination with the ultraportable Leica Absolute Tracker AT960, the LAS-20-8 laser scanner offers excellent performance for manual freeform surface inspections even on shiny metallic or dark materials. Its user-friendly features minimise training requirements and give even the most inexperienced operators complete confidence in its use. Lightweight, ergonomic and with a battery power option, LAS-20-8 is effective in measurement volumes of up to 60 metres and has an IP50 rating that allows it to be taken almost anywhere in the workshop. The scanner identifies itself to the tracker, enabling quick changes between scanning, probing and reflector measurements. A built-in guidelight leads the operator to the optimum measurement position and haptic, acoustic and visual feedbacks help ensure the best possible results. The laser intensity automatically adjusts to different surface types and operators can switch between pre-set measurement profiles using the main button of the scanner, so they can apply the right setup for each section of the part without needing to make adjustments in the software. As well as integrating with the Leica Absolute Tracker AT960, Leica T-Probe and Leica T-Scan 5, the LAS-20-8 laser scanner is backed by the same RDS interface software as Hexagon’s ROMER Absolute Arm range, enabling experienced operators of this equipment to draw on their existing knowledge for system checks, compensation and certifications. www.HexagonMI.com
34
required in arts, culture and design. A powerful projector allows for the scanning of glossy and dark surfaces without pretreatment. Tripods, turntables and photogrammetry are available as accessories to carry out automated measurements and to easier capture even large volumes. www.aicon3d.com
Most accurate arm Hexagon Manufacturing Intelligence says that a significant upgrade to its Romer Absolute Arm portable measuring arm range makes it the most accurate yet.
Entry level 3D digitization The new PrimeScan from AICON 3D Systems provides an attractive entrylevel solution for highly precise 3D digitization of industrial components. The PrimeScan is an entirely new development. It works with the AICON OptoCat software, and thus uses the same algorithms for the fast creation of highly precise point clouds with highest data quality as the highend scanner lines StereoScan and SmartScan. The PrimeScan has a compact design: the base area equals a DIN A4 sheet, and the scanner weighs only 3 kg. The working distance is short so it can be used as a desktop solution and for applications under cramped conditions in industrial surroundings. Measuring fields between 50 mm and 1000 mm mean almost every size of component
can be captured. Depending on the required resolution and precision, two, five or eight megapixel camera resolutions are available. The PrimeScan is equipped with either blue-light-technology for industrial applications or whitelight-technology for scanning with additional colour information as
www.qmtmag.com
Intended to provide absolute accuracy in high-end 3D measurement applications, the new 77 Series arm offers around 20% better scanning accuracy and 15% better touch-probe measurement accuracy than the existing 75 Series of ROMER Absolute Arm. Available in five sizes from 2.5 m to 4.5 m measuring volumes, the 77 Series features all the proven technology of the ROMER Absolute Arm range enhanced to offer best possible accuracy while retaining the arm’s user-friendly nature. The ROMER Absolute Arm can be switched on and used immediately with no warm-up or referencing required, while probe changes can be made without recalibration to maximise flexibility on the job. Acoustic and haptic operator feedback support use in harsh shopfloor environments, while the 3000 N magnetic base supplied as standard offers mounting options for all kinds of applications. Like the 73 and 75 Series of ROMER Absolute Arm, 77 Series arms are compatible with all Hexagon laser scanners, including the HP-L-20.8 and HP-L-8.9 external units and the RS3 integrated scanner. All the arms are available in 6- and 7-axis configurations, with 6-axis models ideal for touch-probe measurement and the 7-axis design suited for high-speed laser scanning. HexagonMI.com
QMT June/July 2016
NEW FEATURE FOR 2016
CAD/CAE SOFTWARE 3D PRINTING ADDITIVE MANUFACTURING MOULDING & TOOLING MACHINE TOOLS METROLOGY INSPECTION
28 SEPT - 29 SEPT 2016
REGISTER NOW
THE ONE STOP METROLOGY SHOP FARO ARM, GAGE, LLP AND LASER TRACKER HIRE
PROBES, PROBE KITS & ACCESSORIES
Training on all Faro software, Delcam, Aberlink, Geomagic, onsite inspection services using arms and laser trackers www.manchester-metrology.co.uk Manchester Metrology Ltd Unit 12,Greenside Trading Centre, Greenside Lane, Droylsden, Manchester. M43 7AJ Tel:-01616378744 Fax:-01614250944