QMT November/December 2015 by Cranbrook Media

QUALITY MANUFACTURING TODAY

www.qmtmag.com November/December 2015

WE OFFER SPEED AND CONFIDENCE IN MANUFACTURING That’s why Hexagon Metrology has changed to Hexagon Manufacturing Intelligence

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CONTENTS

Nov/Dec 2015 News and Comment

Events 5 Zapping the gap at JLR

Faster reporting for JLR parts

Hand-held measurement of gaps and profiles maintains premium quality

Making sure that prototype pressings fit the bill

Winning the data war

3D assessment of tree trunks

Lights out, but not in the dark

Digital microscopy unlocks bone mysteries

Director/Publisher Dawn Wisbey Email: dawn.wisbey@qmtmag.com Tel: +44 (0)20 8289 7011 Mob: +44 (0)7974 640371

Best practice approach to performing a measurement

Design and Production Manager Rob Tremain Email: studio@qmtmag.com

Multiple methods are centre stage

IT Director Pat Coyne Email: pat.coyne@qmtmag.com

Setting the scene for EPMC

Building in cruise ship quality

No compromise on quality

Making the cut

GTR accelerates inspection

A light touch

First article inspection

Test solution for injection device

Making sure the right people get the right information

Front cover: Hexagon Manufacturing Intelligence Website: www.hexagonMI.com

Editor Andy Sandford Email: editorial@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 ÂŠ Cranbrook Media Ltd

Qualitative wood assessment for early determination of use

Integrated in-cycle measurement at a Dutch subcontractor

How one of our QMT/Olympus Technology Grant winners used their award

The fourth in our series of article from NPL

Tensile and compressive strength tests on geo-materials

How EPMC became the event it is today

Using quality tools at Meyer Werft

Martin-Baker ejector seats must never fail

Harness testing at a UK saw blade manufacturer

Measuring F1 composite components

ASDEC has the capability to measure vibration where others fear to tread

Optical measurement shapes up at a plastic moulder

An automated system speeds up product release at Owen Mumford

Products 37

QMT Nov/Dec2015 www.qmtmag.com

NEWS initiative is a valuable first step into a working environment for a young person, which stands them in good stead for the rest of their lives.

EDITOR’S COMMENT A matter of scale I think we probably have one of the largest scale production metrology stories to have graced our pages in this issue of QMT with our feature on how Meyer Werft ensures accuracy in the build of its cruise ships. At the other end of the scale, we have a story on how a non-contact laser Doppler vibrometer was used to measure delicate X-ray optics components. We also get both mechanical and biological. In the more familiar world of automotive manufacture we have two stories on ensuring quality at Jaguar Land Rover – one on fit and flush measurement and one on characterising prototype pressings. Away from our more usual topics we also have an article on how advanced microscopy is contributing to research into bone strength and osteoporosis. The team were able to carry out the research as a result of winning one of the 2014 Technology Grants awarded by Olympus in conjunction with QMT – we will give you news of the 2015 winners in our next issue. In the meantime, as the autumn leaves are falling and the nights are drawing in, tuck up warm with QMT and have a good read. Andy Sandford Editor QMT

TRAINING Earn While You Learn at Cutwel Engineering tool and metrology equipment supplier Cutwel has been supporting its local area by launching an apprenticeship programme. Cutwel is working with Bradford based ATA (Apprenticeship Training Agency), which assists it with the recruitment process and helps qualify the right candidate for a role within the business. As well as Cutwel’s own development scheme for new staff which involves system and product training, trainees are also partnered with CMS of Batley whose tutors visit the apprentices on site to deliver NVQ training and qualifications. Cutwel says the apprenticeship

The West Yorkshire based tooling supplier would recommend an apprenticeship to anyone looking for employment as not only do they gain key skills, they also earn while they learn, receive paid holidays and have the opportunity of permanent employment afterwards. It says that at Cutwel as they feel apprentices are not only a short term solution, they are part of the team and there are high expectations of them all. Two former Cutwel apprentices, who are now fully qualified and permanent members of staff, were selected to be ambassadors for The Bradford Apprenticeship Hub. Some of Cutwel’s apprentices (qualified & present) also featured in a short film for Bradford Council to demonstrate what apprenticeships can involve and the many benefits of them. These will be used www.cutwel.co.uk

APPOINTMENT Export sales manager appointed Bowers Group has appointed Richard Grocott to the position of Export Sales Manager. A qualified mechanical engineer, he has over 10 years’ experience in the metrology sector. In his most recent role as International Sales Manager for Solartron Metrology, he was responsible for sales in Europe, the Middle East and Africa, in particular South East Asia and the Far East, where he developed markets within the automotive, aerospace and consumer electronics sectors. In his new role, Richard will be responsible for the sale of Bowers products into international markets. www.bowersgroup.co.uk

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TRADE SHOW New shows expand IMTS The International Manufacturing Technology Show 2016, which will take place from 12 to 17 September next year in Chicago, is expected to be one of the largest in the show’s history, say the organisers. Early results indicate exhibitor participation and floor square footage already contracted for next year’s fair exceed previous years with 1,382 exhibitors and 1.256 million net square feet (constituting a 22% increase and an 8% increase, respectively) already registered.

The show is expecting more than 100,000 visitors from 112 countries and features a dedicated quality assurance pavilion Hannover Fairs USA will be providing three additional shows during the fair making it a total five show line-up. New this year will be; Surface Technology North America, covering the full range of industrial surface treatment and finishing; ComVac North America, focusing on compressed air and vacuum technologies; and Industrial Supply North America, covering the entire spectrum of industrial subcontracting and light construction. www.IMTS.com

EVENT LIVE in Hong Kong The first HxGN LIVE event in the Asia Pacific region opens its doors in Hong Kong from 18 to 20 November.

HxGN LIVE is Hexagon’s international user conference, a forum for customers to access information about the latest trends in geospatial and industrial enterprise technologies. Dedicated

QMT Nov/Dec2015

NEWS to helping manufacturers to harness the potential of new technologies, the Metrology/Manufacturing track aims to enable customers to work with greater speed and confidence – ensuring that quality drives productivity. Sessions will focus on trends specific to the automotive, aerospace, electronics, heavy industry and energy, machinery, and tooling and automation sectors. While over 3,500 people from more than 70 countries attended the Las Vegas event in June 2015, HxGN LIVE Hong Kong marks the first time that the conference has been held in Asia. With Hexagon Metrology’s large and growing customer base in the region, the company is keen to take the opportunity to engage further with local manufacturing professionals and leaders, giving them the chance to influence the ongoing development of the technologies their success is based upon. HxGN LIVE offers three days full of inspiring keynotes, insightful sessions and industry networking events alongside new technology previews and expert consultations. Hexagon Metrology will also be demonstrating highlights from its large product portfolio in The Zone technology expo. hxgnlive.com

CMSC New name for CMS event The Coordinate Metrology Society, the membership association for measurement professionals, has announced that the Coordinate Metrology Systems Conference will now be known as the Coordinate Metrology Society Conference. The name has been changed to align the event with the society. www.cmsc.org

INSPECTION Chinese order for Tecnatom The Spanish company Tecnatom is to supply a robotised NDT system to the Harbin Hafei Airbus Composite Manufacturing Centre (HHACMC). Located in North East of China, the plant produces composite parts for the A350 XWB and A320 programmes.

The new Taurus Twin inspection system incorporates two robots which move on a set of 15 meters linear tracks. This is the second Tecnatom system in this plant, and follows a Cartesian system with two vertical arms that offers the possibility of multi-technique: pulse-echo phased-array and water jet transmission inspection. www.tecnatom-ndt.com

TESTING Lab acquisition J A King, an ISO 17025 accredited precision measurement company, has acquired Accurate Laboratories, an Oklahoma City-based calibration and inspection laboratory. The purchase of Accurate Laboratories helps expand J A King’s calibration and repair ability nationwide www.jaking.com

STANDARDS New ISO 9001:2015 published The latest edition of ISO 9001, ISO’s flagship quality management systems standard, has just been published. This concludes over three years of revision work by experts from nearly 95 participating and observing countries to bring the standard up to date with modern needs. With over 1.1 million certificates issued worldwide, ISO 9001 helps organizations demonstrate to customers that they can offer products and services of consistently good quality. It also acts as a tool to streamline their processes and make them more efficient at what they do. Acting ISO Secretary-General Kevin McKinley explains: “ISO 9001 allows organizations to adapt to a changing world. It enhances an organization’s ability to satisfy its customers and provides a coherent foundation for growth and sustained success.” While earlier versions of ISO 9001 were quite prescriptive, with many requirements for documented procedures and records, the 2015 version is more focused on performance. www.iso.org

QUALIFICATIONS Euspen qualification route The European Society for Precision Engineering & Nanotechnology (euspen) has is creating a new post graduate educational programme aimed at the certification of precision engineers, which will be recognised throughout Europe. The European Certified mainly post

EVENTS 9 – 11 November EPMC Manchester, UK

•

18 – 20 November HxGN LIVE Hong Kong

www.epmc.events

•

www.hxgnlive.com

11 – 15 April 2016 MACH 2016 Birmingham, UK www.machexhibition.com 26 – 29 April 2016 Control 2016 Stuttgart, Germany www.control-messe.de

•

13 – 16 June 2016 HxGN LIVE Anaheim, California, USA

•

25 – 26 July 2016 CMSC Nashville, Tennessee, USA

hxgnlive.com

•

www.cmsc.org

• QMT is a media partner Bsc and MsC Precision Engineering Course Program (ECPECP), will be branded the euspen ECP2 certification. The program will consist of a range of short courses aimed at degree qualified precision engineers with a minimum of two years’ work experience. The intention is to provide a structured approach to continuing professional development within precision engineering, and allows qualified engineers an industry recognised qualification which will promote greater transfer of their skills and careers within Europe. www.euspen.eu

LOGISTICS MACH to Control Bearing in mind the proximity of the two events, QMT has reached an agreement with DB Schenker whereby exhibitors at MACH can have their stands, exhibits and other materials transported directly from the NEC in Birmingham to the Control venue at the Stuttgart exhibition centre. For more information please contact QMT’s publisher Dawn Wisbey dawn.wisbey@qmtmag.com

QMT Nov/Dec2015 www.qmtmag.com

AUTOMOTIVE

Zapping the gap at JLR

Prestige cars such as the Jaguar F-Type must have world-class build quality.

Hand held measurement systems have transformed inspection techniques for Jaguar Land Rover

S Measurements taken with the GapGun range from small interior features to complex seal gap sections

ince 2005, Third Dimension has worked in partnership with Jaguar Land Rover (JLR) to implement its GapGun product to help develop the world-renowned quality of its vehicles. Alan Olifent, Dimensional & Process Verification Manager of JLR, said: “GapGun is the ideal tool for quickly and accurately measuring small gaps and profiles throughout the car. It is important that these dimensions are monitored closely. “No-one wants to see poor fit, experience wind noise or rain coming in through a seal in any car and this applies doubly to our luxury vehicles. We have used it extensively in our new Evoque range where it has saved time and money throughout the production process.” Using GapGun’s laser triangulation technology, high precision measurements of seals, gaps, steps and radii are produced on a variety of features and surface finishes of a car during production. With its high speed data collection, processing and ability to output measurement data such as dimensional profile and deviation from nominal, GapGun has significantly improved the rate of response to component variation. This in turn has added real value contributing to record car production volumes for JLR to meet the growing demand from emerging markets such as China. Before GapGun, JLR, like other automotive manufacturers, had used manual tools such as ‘carrot’ (taper) gauges and vernier callipers. However to take such measurements with the precision required for today’s competitive automotive market, manual tools are simply not up to the job. They are too difficult to calibrate, are reliant on the use of skilled operators and therefore compromise the reliability of the results. CMMs are still widely uses, but the overall process consumes a lot of time and specialist resources, involving; a complex set-up in a controlled environment and removal of the car from the production line. In contrast, GapGun allows measurements to be taken on the production line

with data collected in a third of the time. Aside from speed and portability, GapGun’s interchangeable measurement heads are a key factor in its ability to take a wide variety of measurements. These range from small interior features such as gaps between the buttons on a steering wheel to complex seal gap sections between the door and body of the car. The flexible nature of the GapGun meant it was quickly integrated within JLR’s existing system. GapGun generates a customer specific reference for each measurement point on the car. As it measures, a text file of the data collected under each reference is transferred to a PC via GapGun’s WiFi. The results data is then fed into the JLR system and included in the overall metrology trend data report. Operators at JLR favour the clip on battery which allows complete portability, for example to reach high measurement points on 4x4 vehicles, where measurement data is stored internally and later downloadable to a PC. Additionally, audible and visual indicators such as the onscreen compass and green LED’s ensure optimal positioning of the GapGun relevant to the part. This allows the shop floor operator to understand measurement conditions instantly. Third Dimension also provided JLR with a service package covering measurement planning, bespoke software, hardware, tooling, and training, analysis of data and support. www.third.com

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QMT Nov/Dec2015

Expand

your capability

More capability, more throughput, more confidence. Renishaw’s one-stop retrofit service offers: • Direct hardware and software support from Renishaw • Unparalleled choice of 3 and 5-axis sensor systems • Rapid exchange service on all system elements • UKAS accredited calibration • Renishaw scales, readers, thermal compensation and reference sphere For further information please visit www.renishaw.com/cmmretrofit

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AUTOMOTIVE

Faster reporting for JLR parts

Bob Rose, Quality Manager at Birmingham Prototypes inspecting a pressed aluminium engine bay mounting plate for a Jaguar car on the Nikon Metrology LK V 15.10.8 coordinate measuring machine in Redditch.

Close-ups of the Jaguar prototype pressing being inspected using the Nikon Metrology LC15Dx laser scanning head.

Multi-sensor machines speed inspection and reporting on prototype pressings

irmingham Prototypes has invested in two Nikon multi-sensor CMMS following a significant increase in orders for the supply of prototype pressings and bracketry, notably to Jaguar Land Rover (JLR). The goal of the automotive and aerospace pressings specialist was not only to measure the sheet metal parts more quickly but more importantly to speed subsequent report generation. The investment has also resulted in the establishment of a new subcontract service offering laser scanning and inspection work. Based in Redditch, UK, Birmingham Prototypes started working directly for JLR two years ago. To receive its supplier’s code, the subcontractor needed to be able to fulfil the OEM’s stringent quality control requirements in respect of first article inspection reporting and PPAP (production part approval process) documentation. These required an increase in the number of reports that had to be produced as well as more detail on component accuracy and repeatability than is requested by other customers in the automotive, aerospace and other sectors. In the past, using a manual CMM, report generation was a laborious process requiring entry of data and drawings by hand into Microsoft Office applications. A single report took anything from an hour to half a day. In 2013 managing director, Mick Adams decided to install a Nikon Metrology LK V 15.10.8 ceramic bridge co-ordinate measuring machine to automate and speed the reporting process. It also allows inspection cycles to be completed faster and without operator attendance after components have been fixtured, saving further time especially when measuring a batch of identical components.

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A Nikon Metrology LC15Dx laser scanner is the company’s default method of inspecting pressings. It allows high accuracy resolution of freeform surfaces and geometry. For measuring tight dimensional tolerances and

QMT Nov/Dec2015

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For more information: www.nikonmetrology.com

NIKON METROLOGY I VISION BEYOND PRECISION

AUTOMOTIVE

The Nikon Metrology MCAx measuring arm with a handheld laser scanner inspecting part of an aircraft seat.

sometimes for initial job set-up, a touch probe is picked up automatically from the stylus changer on the LK V 15.10.8 by a Renishaw PH10M motorised indexing head. Most drawing tolerances on pressed parts at Redditch are fairly open, ± 0.25 mm being typical on surfaces and ± 1 mm for trim edges. Only hole positions are measured to within tens of microns. The LK CMM is capable of measuring to an accuracy that is at least an order of magnitude better than is required for these applications.

Data handling and reporting

The CMM control screens, showing on the left hand screen a CAD model with hole comparisons and on the right hand screen a global comparison of the measured data against the CAD model. Different colours denote where each measurement is within the tolerance band.

Nikon Metrology’s multi-sensor CAMIO V8 software in use at Redditch produces industry-standard DMIS programs that support both laser scanning and touch probing. The software applies the optimum measurement strategy based on the feature and sensor selected. For measuring complex surfaces, it automatically generates scan paths that result in fast and smooth laser scanning that closely follows the part surface, with full machine simulation and collision detection. CAMIO also has instant, highly productive reporting functionality based on standard templates. Tabulated tables, graphics and form plots derived from scanned point clouds and touch probing are combined in a single, concise report. Nikon Focus 10 software manages the point clouds acquired during laser scanning and allows inspection data to be compared against the customer’s original CAD model. A typical pressing, such as a prototype aluminium engine bay mounting plate for a Jaguar car, comprises seven to eight million points. Focus software produces annotated, colour deviation maps showing how the 3D scanned model correlates with and deviates from the original CAD file. For such global comparisons, a 0.1 mm grid is generally selected by Birmingham Prototypes’ quality manager, Bob Rose.

Faster scanning with an articulated arm

Early in 2015, Birmingham Prototypes installed a Trumpf 5-axis laser profiling machine so that it could bring in-house the laser cutting work it was subcontracting at a cost of £350,000 per year. Mr Adams commented,

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“Practically every job that comes off the machine is a unique prototype that needs to be inspected, a job that was previously done by the laser cutting subcontractors before parts were delivered to us. “As our CNC CMM needs to be programmed for each new part, making it more suited to our low volume, pre-production runs, it made sense for us to invest in a manual measuring system to check the output from the Trumpf laser. “Rather than choose another static CMM, we decided to install a portable co-ordinate measuring arm, a MCAx from Nikon. It is twice as fast at producing inspection results for a one-off part.” The facility is used in-house on a dedicated steel table in the quality control room. It often inspects or reverse engineers components and fixtures for other manufacturers that have requested subcontract measuring to be carried out, a service that was introduced two years ago when the CNC CMM arrived. The measuring arm has extended the scope of the service by allowing off-site inspection at customers’ premises of fabrications that are too bulky to be transported easily. The MCAx 7-axis, counterbalanced arm with continuous rotation is used mainly with a digital laser scanner at Redditch, together with Focus 10 handheld scanning and inspection software. Occasionally a touch-trigger probe is employed if additional accuracy is needed. The arm is equipped with absolute angle encoders for high precision and the model at Redditch has a four-meter diameter measuring envelope. Features of the equipment are the ability to reliably scan steep sided and reflective components, temperature stability and zero warm-up time.

Other departments served

The Nikon CMMs have greatly enhanced quality control of sheet metal parts at Birmingham Prototypes and allowed the firm to increase turnover by launching subcontract inspection and reverse engineering. They are backed by ISO 9001:2008 quality management accreditation, which has been held for over 10 years. The move to laser scanning has improved not only the firm’s sheet metalworking activities, but also its additive manufacturing service using a Dimension 1200es 3D printer. The laser scanner generates a CAD model of components for which there is no drawing or electronic data. It is altered as necessary, STL files are exported for printing the plastic part layer by layer and the customer is given both the component and the CAD file in any format. The factory also houses four Hurco CNC machining centres including 5-axis models to manufacture prototype tooling and low volume production components around the clock. The output from these machines is also checked on the Nikon Metrology CMMs. www.nikonmetrology.com

QMT Nov/Dec2015

NEW ACCRETECH SURFACE, FORM AND ROUNDNESS SOLUTIONS FROM BOWERS GROUP RONDCOM TOUCH WITH TABLET COMPACT ROUNDNESS MEASURING INSTRUMENT

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DATA MANAGEMENT

Winning the data war

An operator at a food manufacturer conducts quality checks on chicken nuggets using the InfinityQS ProFicient Manufacturing Intelligence platform, which is powered by Statistical Process Control (SPC) software

Eric Weisbrod of InfinityQS International says that knowing the data is only half the battle – getting the right information to the right person wins the war

anufacturing is a complex industry, and most companies are swimming in data. With data on things like production, sales, marketing and logistics seemingly taking top billing, how does an organisation ensure visibility of its quality data? Knowing more information is generally a good thing; however, knowing the right information at the right time is what really makes a difference. For manufacturers, knowing what information to collect, when to collect it and how to present it is critical when making decisions. Manufacturers collect quality data for a number of reasons – they may be trying to meet industry regulations, improve customer relationships, or drive product and process improvements. Regardless of the reason, the real value comes from making the information available and visible to the appropriate individuals. Organisations should present the data in a format that allows users to make the best-possible decisions based on the information. For instance, plant operators may only have interest in real-time, shop floor data that help them know when to make

adjustments to processes, whereas, quality directors would be interested in obtaining Key Performance Indicators (KPIs) to present to senior management. These KPIs could reveal areas for cost savings across the enterprise.

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QMT Nov/Dec2015

Achieving results

Ensuring that the right individuals are accessing the right data and using them the right way can save a company hundreds of thousands of pounds. In fact, an established tyre manufacturer in the United States achieved more than $400,000 (approx. £264,000) in annual savings on one plant’s line simply by analysing the dimensional data of components. How can you achieve these types of results? The first step to improving data visibility at all levels is to collect the data. The key is to realise that it’s not always better to collect all the data available. Many pieces of equipment and systems are able to output information, so there is often a great deal of data available. This can be both a blessing and a curse. Take a careful look at the data available and make sure those you collect are actionable and clear indicators of your

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DATA MANAGEMENT Job roles and getting the right data Every person within the quality department fills a very different role, requiring the use of varying information on a day-to-day basis to provide value to the organisation. 1. Shop floor operator

Operator: Control Charts are best used in real time and are an action chart. Comments have been used in this chart to track operator actions as they resolved a problem

Engineer: Box and Whisker plots are an excellent tool for comparing different products, machines and, with proper data normalisation, even disparate features.

Data typeÂ - Shop floor operators utilise direct measurements from processes or products. This information is entered manually, collected from a measurement device or reported automatically from a process loop control or similar mechanism. Data presentation - Data for shop floor operators must drive immediate actions to continue making products. A control chart that tells the operator when to make process adjustments is extremely useful, and clearly outlines what actions are needed to maintain optimal production and quality levels. Data use - As data are collected, the resulting trends on control charts can be used to make pro-

cess adjustments to ensure minimal waste and efficient production. For example, a leading snack food manufacturer in the U.S. was able to use the data collected from its production lines to better control variability and waste, saving more than $1 million (approx.

neers extend beyond simple control charts as they strive for process improvement. Normalised control charts, group control charts, box and whisker plots, histograms and Pareto charts are all ways for quality engineers to make decisions about their processes and products. Data use - Quality engineers perform deep analyses with the goal of process improvement, which ultimately improve efficiency. Over the course of one year, a global wire and cable producer focused on data collection and analysis on specific production lines in two of its manufacturing plants to identify ways to reduce process variation and improve raw material usage, while maintaining or improving the quality of the products. With a centralised quality platform powÂŁ924,000) in just one plant. ered by SPC, the manufacturer 2. Quality engineer drove out variations and retarData type - Quality engineers geted raw material usage through most often use the same data set analysing process capabilities and collected by shop floor operators. implementing the use of control Data presentation - Interested charts. in process behaviour, quality engi-

process or product performance. Once you are collecting the appropriate data, the next step is to make the data available to those who need them in a useable format. The best way to do this is with a centralised enterprise quality hub. An enterprise quality hub will serve as a data collection repository that will support quality initiatives like continuous improvement, Six Sigma and Lean Six Sigma. When the right information is presented to the right people at the right time, decisions will be made that benefit the organisation from the shop floor to the board room.

This technology offers many benefits, including the following: Process improvement: With all data in a single repository, it is possible to standardise and compare data from different pieces of equipment, sites, vendors and products. This is especially helpful for manufacturers with suppliers located across the globe. Using a quality hub, manufacturers can aggregate supplier data to verify that the parts or components received are of the highest quality before they become part of a final product. For example, by collecting information from its suppliers in China via a cloud-based quality hub, a U.S. bicycle manufacturer was able to obtain a real-time view of data within the supplier network. This enabled the company to correct quality issues before products were shipped, thereby creating a leaner manufacturing environment and considerably reducing costs. Reporting and analysis: A single repository means everyone is using the same data to make decisions. The real-time data used by operators to notify them when to make process adjustments are the same data used by managers and leaders at the site level and beyond to facilitate audits, address quality issues and recalls, and set long-term strategy

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QMT Nov/Dec2015

Eric Weisbrod is technical services manager at InfinityQS International

DATA MANAGEMENT 3. Quality manager Data type - Quality managers need to focus on recent issues and their resolution. Exception reporting helps quality managers focus on problem areas, shows how they

affect customers and determines who can help resolve issues. For companies that embrace process improvement, these exception reports will typically catch issues before they affect product. Data presentation - Most quality managers start with reports that outline the exceptions affecting their products’ quality. Text-based reports that provide summaries of issues are a great starting point, but charts like Pareto charts, histograms and box-and-whisker plots provide additional details about where specifically the issues are occurring. The ability to quickly identify if a certain production line, shift, production run (e.g. lot, batch, production order) or product line are having the issue is critical in identifying suspected bad product and, ultimately, resolving

the issue so products can be delivered to customers with minimal delay. Data use - The most common use of data is to provide reports to the company and customers

about their products’ quality. Typical day-to-day operations mean reporting that all is well. But, if a quality issue arises, these reports show what happened and how things were resolved. Additional tools can provide understanding of the root cause of the problem and the preventative actions taken to ensure it won’t happen again.

around product quality. Anyone who has lived through audits and quality issues knows that sifting through filing cabinets for results is a tremendous waste of time and resources. In one case, a pharmaceutical manufacturer had such an abundance of paper files that it actually had to store them in a cave outside of the city where it was located – quite literally burying its data. You can only imagine how tough it was to find the right information in a timely manner. With a quality hub, all data is in one place for quick access and in a format that makes it easier to conduct audits and report quality information to customers. Systems management: A centralised enterprise quality hub simplifies the administration and management process instead of maintaining multiple quality systems on-site at each facility. To best meet the evolving needs of an organisation, it is ideal for the quality department to manage the quality system and make adjustments as needed. Furthermore, having all qualityrelated information, such as control limits, specification limits and sampling plans, in one place means it is easier to know that various departments and facilities are operating using the same standards. One consumer packaged food and beverage company

4. Quality director Data type - Quality directors need to provide summarised and aggregated Key Performance Indicators (KPIs) to give senior management an overall view of operations. Data presentation - Senior management often needs to evaluate data from many sites, processes and suppliers, so it is ideal to present data in a concise summary. Dashboards with aggregated data in Pareto charts, line charts, box and whisker plots and gauge displays are effective ways to summarise large amounts of information in real time. Data use - Primarily, these aggregated data are used to make strategic improvements to help the overall business. Examples of these improvements include compliance, traceability, product giveaway, downtime reduction and scrap. A U.S.-based electric motor distributor reported a 13-percent reduction in overall scrap costs by gaining access to the right data through its quality system.

Quality Manager: Pareto charts allow users to understand where the biggest issues are. In this example, 6 Lots will likely need to be inspected before sending to customers.

Senior Management: Colorcoded dashboards give senior management the ability to understand performance ata-glance.

utilises a cloud-based quality system to monitor production across all of its facilities. With the ability to instantaneously make adjustments—anytime, anywhere—and react to variances and out-of-spec issues as they arise across different plants, the organisation reported a sustainable $2.1 million (approx. £1.94 million) in savings due to waste reduction. With a quality hub, the right data are available to the right people across the enterprise – shop floor operators are accessing real-time control charts with actionable data; quality engineers and process owners are gauging opportunities for process improvement; quality managers can provide reports to customers; plant managers have high-level metrics to know how their plant is running; and quality directors are gaining the manufacturing intelligence needed to help senior management impact the bottom line. As a result, your organisation will have the power to make data-driven decisions that positively affect the company as a whole. www.infinityqs.com

QMT Nov/Dec2015 www.qmtmag.com

LARGE SCALE MEASUREMENT

3D assessment of tree trunks

Up to four Ensenso cameras are located over the tree trunk in the measurement system and record images from the side

The assessment of the quality of wood at an early stage is essential in determining the ultimate use for a particular piece of timber and its consequent value Wood that can be used for solid floorboards, for example, has far higher value than that which suffers from damage such as heart rot or cavities and which can only be used as veneer wood. 3D imaging of freshly cut tree trunks provides a cost-effective contribution to the evaluation and classification of the wood.

The camera software delivers a single 3D point cloud containing data from all the Ensenso cameras used

Making measurements

Jörg Elektronik GmbH, a well-established supplier of log yard electronic and automation systems has integrated Ensenso N20 3D stereo camera from IDS Imaging Development Systems GmbH into its measurement equipment. Up to four Ensenso cameras are located over the tree trunk in the measurement system and record images from the side (Figure 1). The trunk can be moved through the system to build up the 3D data or the system can be moved over the trunk. The images captured by the two sensors in each of the Ensenso 3D units allow the 3D coordinates for each pixel in the field of view to be calculated using the triangulation principle. The images from multiple Ensenso cameras can be combined using high performance algorithms to simultaneously capture a view of the tree trunk from different sides, reducing shadows and extending the picture field. The camera software delivers a single 3D point cloud containing data from all the Ensenso cameras used (Figure 2). Ensenso N20 3D stereo cameras The Ensenso N20 3D stereo is equipped with two high-resolution 1.3 megapixel CMOS sensors in a very compact housing. It provides a wide field of view, allowing imaging of large volumes and for working distances of up to 3

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metres. Utilising the “projected texture stereo vision” principle, a powerful, built-in projector with blue LEDs casts a random point pattern onto the tree trunk in order to allow stereo matching. The GigE data interface permits image data to be transmitted over cable lengths of up to 100 metres.

Getting results

The ability to identify tree defects is essential in establishing a tree grade. Tree defects directly affect tree grade because they reduce the length of defect-free stems in the first log cut above the stump. In addition, there is a relationship between the external features of the bark of the tree such as branch scars and wounds and the size and location of wood defects in the trunk. Based on the 3D data generated during the measurement run, a variety of log data are computed to assess wood quality so that foresters and sawmill owners can easily determine the value of the trunk. Early determination of the properties of the wood by 3D measurement allows a quick, accurate and efficient optimisation of the cutting of the trunk also helps to optimise the follow-up production processes. www.ids-imaging.com

QMT Nov/Dec2015

IN-PROCESS CONTROL

Lights out, but not in the dark

Bart van der Sande and Ad van Riet in front of the Mazak Variaxis 630 5X II

Integrated in-cycle measurement and post processing corrects for variation during lights out machining Based in Veldhoven in the heart the Dutch technology belt, subcontractor Van Riet Metalworks specialises in the prototype and series production of steel and non-ferrous mechanical parts. In this market, accuracy is paramount and so the company invested in a Mazak Variaxis 5 axis machine tool with an automated pallet system which allows it to reduce the amount of human handling and so increase accuracy and reduce defects. As well as streamlining its production processes, Van Riet is also able to cut labour costs and increase production by running the Variaxis unattended for 18 to 20 hours per day. To drive this powerful machine tool, Van Riet invested in ESPRIT computer-aided-manufacturing (CAM) software by DP Technology supplied by local ESPRIT reseller Pimpel Benelux.

aborted. For instance, if a measuring probe detects that a hole is too narrow, which indicates extensive tool wear, the tool is automatically replaced. In addition to Van Riet’s automatic quality-control processes, Foreman Bart van de Sande takes them a step further by measuring completed work pieces at random. “With intense usage, the tool becomes more inaccurate, but with the measurement probe on the machine you don´t see any deviation in the measurement results. Therefore, I check the machine at the same time,” he says.

Quality Control Embarking upon its unattended milling mission, Van Riet Metalworks integrated an automatic measurement cycle within ESPRIT, mirrored in the machine tool’s post processor, so that deviations from the required part dimensions can be automatically corrected. “When we arrive in the morning, we can be assured that the parts are correct,” says owner Ad van Riet. “So, even when the tool wears down, we don’t worry because any deviation is automatically corrected. The moment the sizes fall outside the tolerances, the controller automatically goes back to the starting line of the operation and the operation is done again. “ If a measurement is out of tolerance to the extent that correction is impossible, the operation is

QMT Nov/Dec2015 www.qmtmag.com

Measuring takes place on the machine. Thanks to the special post processor, Van Riet doesn’t have to measure repeatedly after milling.

IN-PROCESS CONTROL

Thanks to ESPRIT and a specially configured post processor Van Riet Metalworks has raised quality and made it more predicable

Right top, Integrated measurement cycle makes it possible to produce accurate products efficiently with unmanned milling, right bottom, One of the parts that Van Riet Metalworks produces by unmanned milling.

The Dutch company produces higher-grade products in shorter time with less effort.

Work offsets Process security deals primarily with eliminating error and, when it comes to work offsets, embracing flexibility makes manufacturing more efficient, especially during the machining of multiple parts with varied offsets. A work offset, or the orientation of the cutting tool – and therefore work piece – to the machine tool, is used to adjust the location of every tool loaded in the machine. On a mill, for instance, the work offset changes the position of the spindle in both the X and Y axes, and often the Z-axis, as well. With local ESPRIT support, Van Riet Metalworks adjusted the Variaxis post processor to determine the work offset of the machine tool in three different ways. Using one method, the ‘zero point’ – or the intersection of the X, Y and Z axes – is set in the middle of the table and all faces are recalculated from that point. A second method entails operating with the zero point in space, which allows ESPRIT to calculate from that point. A third method is to use one of the 300 zero points that Mazak has defined for the machine, combined with the zero points of ESPRIT. By default, the post processor for the Variaxis is written for 48 of these zero points, and Van Riet Metalworks has allowed Pimpel to customize up to 300. Even with multiple pieces on a pallet, this method ensures very precise milling operations. “With this solution, we theoretically can create hundreds of extra zero points in the machine,” says van de Sande. “For Van Riet Metalworks, accuracy is the key to success.” With a solid model, programming in ESPRIT is much easier than programming at the machine tool – and a reliable CAM simulation makes testing at the machine obsolete, van de Sande says. “You get a good product faster and eliminate error at the same time.”

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Lead-Time Reduction ESPRIT helps Van Riet Metalworks increase part quality and make production more predictable. Lead time is also shorter, and therefore the productivity of the machine higher, as complex parts can be programmed within one day. After a complex part is programmed, Van Riet needs just one product on the machine tool to fine-tune the program before milling defect-free parts unattended. With ESPRIT, the company can maximize the capabilities of the 5-axis milling cell with a robot and pallets. “The software is important to achieve continuous production,” van Riet says. “Thanks to our 5-axis machine and ESPRIT, milling these kinds of highquality components is something we can do more efficiently.” This streamlined efficiency translates into new opportunities to grow and creates greater flexibility. With the high degree of process security for its unattended milling activity, Van Riet Metalworks can even deliver repeat orders within a day. “If we have the material in-house, we can have complex repeat order pieces within a few hours if the customer is really in a hurry.” www.dptechnology.com

QMT Nov/Dec2015

Bigger and better than ever: in 2014, over 6,500 tonnes of live working machinery was on display. MACH 2016 promises to be bigger and better with new zones, innovative technologies and a vibrant seminar programme. n Purchase power: ÂŁ177 million of business was attributed to MACH 2014, and exhibiting within one of our dedicated zones is an ideal platform for generating new business with a key audience. n Key networking event: Meet face-to-face with decision makers and buyers with money to spend. n High visitor numbers: in 2014, the show attracted more than 23,000 visitors, with more expected in 2016. n Boost your profile: The MACH 2014 visitorsâ&#x20AC;&#x2122; survey showed 86% of exhibitors raised their profile, and 76% improved their relationships with customers.

TECHNOLOGY GRANT

Christoph Riedel working on the Olympus DSX500i

Digital microscopy unlocks bone mysteries One of the 2014 technology grants awarded by Olympus in partnership with QMT helped a German team understand bone fracture mechanisms Micro-indentation is a popular approach for determining the mechanical properties of a range of materials. At the Department of Osteology and Biomechanics, University Medical Center HamburgEppendorf (Germany), Dr. Bjรถrn Busse and his research group are employing this technique to investigate the mechanical properties of bone. An important step during micro-indentation is the retrospective analysis of the indentations in order to ensure that only the bone matrix was subject to indentation, rather than voids, pores

or the polymer used for embedding the samples. This was previously achieved using Electron Microscopy (EM), which involves time-consuming sample preparation. To improve the efficiency of the micro-indentation process, Dr. Busse has employed high-resolution digital light microscopy as an alternative to EM, with the Olympus DSX500i inverted digital light microscope. With 13x zoom optics, the combination of high resolution with operating simplicity vastly improves the speed and efficiency of the micro-indentation process, and

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QMT Nov/Dec2015

Figure 1: Human bone is a complex hierarchically organized composite material [2]

TECHNOLOGY GRANT

Figure 2: Four micro-indentations in cortical bone. Image was taken using the Stitching Function of the DSX500i.

presents further avenues of research – investigating the properties of cracks and their propagation that occur adjacent to indentations. These capabilities also offer possibilities throughout a vast field of applications - as advanced micro-indentation techniques translate to researching materials through all sectors of material science.

A complex structure Bone consists of several hierarchical levels, from the whole bone structure, over secondary osteons (the basic structural unit in bone) and down to the individual collagen molecules (Figure 1). This complex structure is upset in a number of diseases, for example osteoporosis. “Looking back 20 years, it was initially thought that the primary contributing factor of osteoporosis was low bone mass, leading to increased fracture risk. However, we’ve since found something different,” explains Dr. Busse: “Now we know it is not only bone loss, but also the quality of bone that is significant.” The assessment of patient’s bone samples using standard brightfield microscopy is a common method to quantify bone formation, bone resorption and bone remodeling. However, from a mechanical viewpoint this does not provide sufficient information. Scanning electron microscopy (SEM) and backscattered EM provide a quantification of the dominant mineral component in bone: hydroxyapatite. However, bone is not purely formed of this material, but also contains other components such as the collagenous matrix that provides the bone with its inherent flexibility.

Measuring mechanical properties Mechanical properties of bone can be investigated using a micro-indentation device on plastic-embedded bone samples. Once a probe is impressed into the material at a known load, a variety of mechanical properties can be calculated from the indentation depth and the corresponding load. The indentations are measured from multiple locations across the bone sample to provide a more accurate representation. The indentation depth increases with each cycle, and a load over displacement curve is created from the data.

The composite structure of bone gives rise to a range of key properties providing toughness mechanisms that could be helpful under different loading conditions. Dr. Busse explains: “Once this material is deformed and the energy is absorbed, this information is stored within the indentations, and our aim is to try and uncover this.” This information includes: First cycle indentation distance – the indentation depth of the first loading cycle Total indentation distance – the maximum indentation depth during the last loading cycle Loading and unloading slope – the force/ displacement plot shows dynamic information Energy dissipation – measuring the material’s response to indentation, this reflects elasticity Porous structures in bone become infiltrated by plastic when the biopsy samples are embedded for preservation. When these samples are ground and

Broadening the horizons of material research into bone Bringing together researchers from around the campus for an interactive exchange of information, Olympus provided a full workshop at the University Medical Center Hamburg-Eppendorf. Dr. Busse invited other groups working in similar fields who were interested in the possibilities of digital light microscopy in bone research. The specialist team from Olympus was also present. One interesting application explored was from a colleague of Dr. Busse working with mice, who wished to image the whole jaw and teeth. With the interface between the teeth, the bone and the jawbone, this large structure has a complex morphology, while the jaw itself has a round shape. This is therefore challenging to image, and macro-photo images are not ideal, since they lack detail. With the ability to image large samples in high resolution, 3D imaging and analysis using the Olympus DSX500i allowed the teeth and the jaw bone to be imaged at the same time, and a direct comparison therefore made between two experimental groups.

QMT Nov/Dec2015 www.qmtmag.com

TECHNOLOGY GRANT

Figure 3: Surface of a hip joint implant after explantation. Image taken using the Darkfield mode of the DSX500i.

polished, a true bone surface is exposed on top. However, there are also regions of plastic. “So we were looking for some kind of tool to verify that we hit the bone, not the plastic. In the past we used SEM, but this is labour-intensive in terms of sample preparation, and we were looking for a faster and easier way of checking we indented the correct region.”

Digital light microscopy

Visualizing micro-indentation testing of bone in the laboratory. (From back to front) Dr. Busse with medical students Mr. Kilian Stockhausen, M.Sc. and Mr. Christoph Riedel, B.Sc. operate the Olympus DSX500i system via the touchscreen interface.

Medical student Christoph Riedel explains the process of analyzing indentation samples on the electron microscope (EM): “Samples need to be coated, then we put them into the microscope and apply the vacuum. This all takes time. “Now with the Olympus DSX500i, we just put the sample on and go. The system is very easy to use, with everything controlled using the mouse, and we find this far easier than a standard light microscope.” Multiple indentations are made on each bone specimen, and using the DSX500i, it can be determined quickly how many indentations have hit bone, helping the researchers decide if more indentations are required. Sometimes EM and digital light microscopy can be complementary, with the backscattered EM providing additional information on mineral composition. However, the EM does not provide quantitative information regarding the depth of the indent. “With the DSX we also get depth information. If the bone tissue is softer and has a lower mineral content or is harder and more brittle, this information is reflected in the depth of the indents,” says Mr Riedel. The Olympus DSX500i incorporates a variety of digital capabilities that facilitate workflow. For example, the stitching function vastly expands the field of view, with hundreds of individual capture areas automatically assembled into a single wide-field 3D image, which can then be rotated, expanded and reduced on the digital screen view (Figure 2). Christoph Riedel says: “I used the stitching function to provide a representative overview, locating the indentations and to know where I am on my sample. We also used the stitching function for other projects, to get an overview of bigger structures.” Dr. Busse adds: “In our research we encounter a lot of different specimens, like implants or different bone sections, etc. To adapt to different sample conditions, the ‘Best Image’ function proved useful to speed up the process of finding the most appropriate image settings.” This provides an on-screen display of multiple capture settings, allowing the user to pick the most insightful imaging technique. “When we want to see abrasion particles or edges, we often use darkfield imaging, which can provide better results for specimens of low contrast (Figure 3). For

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other specimens we used the DIC [differential interference contrast] mode, as this really highlights the scratches on certain surfaces.”

Inverted microscope Dr Busse says biopsy samples can come in a range of different shapes and sizes, and an inverted system provides a high degree of flexibility. “We are not restricted to a specific sample size or shape. While a typical bone biopsy size from the iliac crest is approximately 2.5 cm long x 2 cm thick, including the plastic embedding, we also perform experimental research on bones of different dimensions. Complete cross sections from the femur can be 3-4 cm in diameter, and even samples of this dimension can be handled by the DSX500i.” An additional potential application is implant analysis. “After a fracture, patients usually need an implant to fix the fracture. This is a complex procedure, and we are interested in the interface between the metal and the bone.” In general, these implants remain in the body for approximately 15-17 years, before another loss in bone mass can be observed and the insertion of a new implant is required. “We analyze these retrieval parts thoroughly, since they offer crucial information on why the implant may have failed and how it can be optimized in the future,” says Dr Busse.

The future of bone material research There are many avenues to explore with digital light microscopy. A recent study by Dr Busse’s group compared untreated osteoporotic bone to bone treated with anti-resorptive agents and healthy bone. Interestingly, using the micro-indentation device triggered the propagation of cracks at the boundary of the indents. “You can experimentally induce these changes, which may change from disease to disease. This is something we would like to look into in the future, as we believe we could gain additional information using digital light microscopy, especially with 3D analysis and measurement of the indent depth.” Overall, the process of micro-indentation material analysis has been streamlined with quick and efficient assessment of indentation location using the Olympus DSX500i, which can translate to a variety of material science and industrial inspection applications. Moreover, a range of sample shapes and sizes can be analyzed on the inverted platform, and now the release of the new DSX510i introduces several new features such as the ability to fit two objectives instead of just one. This allows researchers to switch seamlessly between the 10x and 40x magnifications, inspecting the sample at a higher resolution with minimal effort. With a host of digital capabilities this technology presents many opportunities to drive research into the mechanical properties of bone. www.olympus.com

QMT Nov/Dec2015

The New DSX Series Discover Another Dimension. Dedicated to materials science, the Olympus DSX Series of opto-digital microscopes fuses advanced optics with the latest digital technology, creating a sophisticated yet intuitive system to capture the highest quality images in 2D and 3D. · Choose your best image – smart functionality provides a quick and easy route to the best image from a preview screen · Simple operation for everyone – on-screen viewing and touch-screen operation · Precision measurements – extract the most information from your sample Find out more at www.olympus-ims.com

Postbox 10 49 08, 20034 Hamburg, Germany | Tel. +49-40-237-730 | www.olympus-europa.com

TRAINING

Best practice approach to performing a measurement

The fourth in a series of articles designed to help QMT readers in their everyday measurement needs from Keith Bevan, the Delivery Manager for Training at the National Physical Laboratory (NPL)

Our previous article (published in QMT September/October) outlined the advice NPL gives to measurement professionals who are preparing to take a measurement. In this issue we progress to the next stage of the process and examine the questions to ask when performing the measurement. If you have followed the advice of past articles and planned your measurement well, it is likely to be successful. However, you should still think critically whilst undertaking the measurement. There are fundamental checks and good practices that should be followed. For example, using the details that you have identified in the preparation stage to set the instrument to the required measurement units. Working to the correct units is critical; to overlook this can have huge consequences. A well-known example is NASA’s Mars Climate Orbiter, launched in December 1998 to study the planet’s climate, atmosphere and surface changes. However, programming teams in the US and Europe had used different systems (imperial and metric) to calculate the spacecraft’s trajectory. So when the probe entered the Martian atmosphere at the wrong angle, it quickly disintegrated. Measurement professionals also need to

have confidence in the instruments they are using. The previous article looked at the options available to you when choosing an instrument, once you have made that choice, you need to be sure that the instrument is functioning correctly. The most basic checks can be made visually - ensure the instrument is clean; that there are no visible signs of damage and that the instrument is within its stated calibration period. Once the visual inspections are complete, check the zeroing of the instrument (if appropriate). If using a micrometer, for example, bring the anvils into contact using the ratchet and observe the reading, it should be zero – if not clean the anvils again and if necessary adjust the setting or take the instrument to the appropriate person who has the authority to make the adjustment. See NPL’s Callipers and micrometers Measurement Good Practice Guide No. 40 for more information. Ensure that you have aligned the measurement instrument to the work-piece. It is important for measurement professionals to be confident that they are measuring the features the product correctly. The next step is to ascertain whether there is an identified procedure and ensure you

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QMT Nov/Dec2015

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TRAINING

Keith Bevan is Delivery Manager for Training at the National Physical Laboratory

are following it correctly. Repeatability is key here, as the popular proverb says, ‘measure twice and cut once’- highlighting the need to ensure you have made a good measurement before committing to a potentially irreversible decision. Repeating a measurement several times allows you to calculate a mean (average) value and if the repeatability is high, the statistical uncertainty in the mean value will be low. Repeatability describes the agreement within sets of measurements where the same person uses the same equipment in, the same way, under the same conditions. However, if different measuring equipment is used, a different result may be obtained because of errors and offsets in the instruments. If different measurement professionals each had a go at measuring an item on different days using different tools, a wider range of results would not be surprising. This is known as ‘reproducibility’ and describes the agreement within a set of measurements where different people, equipment, methods, locations or conditions are involved. More information on this can be found in NPL’s Fundamental Good Practice in Metrology Good Practice Guide Number 80. Now you have confidence in your repeatability you need to determine what level of inspection is needed during your measurement. Inspection is essential to prove that the components meet the design requirements. How much you inspect is determined by the industry involved, do you assess all, or a sample? In some industries it will be impractical and unnecessary to

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measure everything but in others it will be critical to measure every dimension on every part due to the fact that the component may be safety critical, for example in aircraft components or medical component. NPL’s G ood Practice Guide number 79, Fundamental good practice guide in the design and interpretation of engineering drawings for measurement processes, has more information on determining the level of inspection needed. Once you have a set of results, you need to be confident that they enable you to make an informed judgment. You may think that it is a simple matter of the result falling within the tolerance band to prove conformance. But to be sure results conform to a specification they need to meet ISO 14253. To do so the measurement of uncertainty is needed, to determine how and where your results could be wrong. This can be difficult to evaluate, as you need to identify any possible sources of uncertainty, evaluate the uncertainty from each source and, finally, combine the individual uncertainties to get an overall figure. NPL and IMechE developed a Beginner’s Guide to Measurement in Mechanical Engineering (Good Practice Guide no 131) that includes a useful eightpoint plan to evaluating uncertainty: 1. Decide what you need to find from your measurements. Decide what actual measurements and calculations are needed to produce the final result. 2. Carry out the measurements needed. 3. Evaluate the uncertainty of each input quantity that feeds in to the final result (Type A and Type B evaluations). Express all uncertainties in similar terms (standard uncertainties). 4. Decide whether the errors of the input quantities are independent of each other. 5. Calculate the result of your measurement (including any known corrections for things such as calibrations). 6. Find the combined standard uncertainty from all the individual aspects. 7. Express the uncertainty in terms of a coverage factor together with an expanded uncertainty at a stated level of confidence 8. Record the measurement result and the uncertainty, and state how you got both of these.

Further help

This series of articles are just a microcosm of the measurement expertise and assistance a recognised external body such as NPL can offer. As well as Good Practice Guides, NPL provides a range of training programmes, available through the classroom and via e-learning. This training can enable measurement professionals confidently undertake measurements in the workplace, but also show them the wider impact of measurement in society. www.npl.co.uk

QMT Nov/Dec2015

CT SCANNING

Multiple methods are centre stage Precision motion control technology is applied at a Belgian research lab The Centre for X-ray Tomography at Ghent University in Belgium (UGCT) is using in-situ testing stages and accessories supplied by Deben for tensile and compressive strength tests on geo-materials. Professor Veerle Cnudde leads the Centre’s PProGRess team (Pore-scale Processes in Geomaterials Research), which combines conventional research techniques such as optical microscopy and SEM-EDX with non-destructive techniques such as high resolution X-ray Computed Tomography. Areas studied by the team include dynamic processes in geomaterials, related to areas such as fluid flow behaviour; fracture nucleation and propagation in rocks; carbonatation; dissolution, precipitation and crystallization processes in porous stones. The Deben CT5000 tensile/compression stage not only allows tensile and compressive strength tests to be combined with X-ray CT scanning, it also allows the investigation of freeze-thaw effects on rock samples and the effects of crystallisation of salts through the temperature controlled set-up. In combination with the latest environmental X-ray micro-CT scanner it allows for 4D analysis of these processes with both high spatial and temporal resolution.

Professor Cnudde said “Before we had the CT5000 system, we only performed standardized mechanical tests on large samples in the laboratory. Now, we can perform these tests in situ…allowing a direct relation with the compression values and the internal structural changes. Other mechanical testing devices we investigated, before we found the CT5000 system, were limited in the load which could be applied on the samples. Because we are mainly working on rock specimens, we really needed a load up to 5000 N to perform compressive and/or tensile tests.” www.deben.co.uk METROLOGY SOLUTIONS

TAKE CONTROL OVER QUALITY. SOLUTIONS FOR DIMENSIONAL INSPECTION ON SHOP FLOORS.

QMT Nov/Dec2015 www.qmtmag.com

EPMC

Setting the scene for EPMC Ben Hughes, chair of the EPMC organising committee, explains what is in store for delegates

Ben Hughes of NPL chairs the EPMC organising committee

Top right & below: EPMC builds on the success of LVMC

With initiatives like Factory of the Future and Industry 4.0, manufacturing industry is striving towards right-first-time production with increased production rates and tighter tolerances. Traditional fixed-base inspection is being replaced by more embedded in-process and on-machine metrology using portable optical measurement systems. The rapid pace of development of new metrology systems, software and practices has led to a need for greater dialog between systems manufacturers, endusers and the research community. To address this need Airbus founded the Large Volume Metrology Conference and Exhibition (LVMC) in 2005 to promote better understanding of current and future needs of the various parties within the metrology community. Since 2011 LVMC has been run by a committee of independent experts. In 2014 the

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committee initiated plans grow the event and bring it to a wider audience by taking it outside the UK to mainland Europe. We also felt the name of the event didn’t capture the actual scope of interest which is primarily portable coordinate metrology systems. So at the end of last year’s LVMC, we announced a change of the conference name to EPMC – the European Portable Metrology Conference. EPMC is built on the fundamentals of LVMC, namely the sharing and promotion of best practice, education and networking and adds some new content. Traditionally, technical presentations at LVMC have been application oriented case studies. More recently, the research community has increasingly sought an outlet at LVMC, with perhaps 25% of presentations being of a more research oriented nature. We strongly believe both aspects of the industry need to be represented. Furthermore, there is a need to foster better communication between these two parts of the community to ensure that current research is aimed at addressing real-world requirements and to keep industry informed of new developments so that it can plan for future capability. This year, to encourage these links, we are increasing the number of presentations and holding parallel presentation tracks for the first time, with research presentation in one track and application focussed presentations in another. We believe this arrangement will provide delegates with the greatest flexibility to choose the content they want. And, to ensure that all delegates are kept informed of the research content, all research presenters will be invited to give a two minute “sales pitch” to the entire conference audience, and to include a poster presentation that will be included in the poster presentation sessions during the networking receptions. Our trial last year of vendor workshops proved popular, so we will have more of them this year. Vendor workshops provide a platform for exhibitors to engage more formally with their customers and present practical solutions and case studies. We are also introducing the Metrology Stadium this year – an area dedicated to hands-on activities including competitions using the latest hardware and software. EPMC 2015 will be held between 9-11 November in the Mercure Hotel in Manchester – the same venue as the last two LVMC events. Next year we take the event to Dusseldorf in Germany. www.epmc.events

QMT Nov/Dec2015

SHIPBUILDING

Building in cruise ship quality Thorsten Störig and Ralph Zimmermann of Meyer Werft show how 3D laser scanning ensures quality in the cruise ship building industry Imagine putting together a jigsaw puzzle of more than 30 million pieces. The instructions say to group these pieces into about 80 individual blocks, which will weigh up to 800 tonnes. Those blocks must be precisely placed together, offering passengers a safe and pleasant journey aboard a tremendous cruise liner. Once planned, you have less than one year to construct, all the while meeting budget constraints and exceeding customer expectations in quality. Welcome to the world of cruise ship building. At Meyer Werft, we face these challenges on a daily basis. Building ships since 1795 in Papenburg, Germany, our company has seen the evolution of watercraft transportation from wooden ships to our latest release in April 2015 of the Royal Caribbean Anthem of the Seas.

No room for errors

Construction costs incur multiples of 10 or even more during each subsequent step of the process

‘First time right’ is the target for all employees at the shipyard. Minor mistakes in one discipline can have a great effect on staff and material expenses and can even delay the entire building process resulting in additional costs. In the dock hall with its 500 meters long dry dock two vessels a year are built at six month intervals. While the hull of one ship is completed the construction of the engine room for the subsequent vessel is already underway. The roots for such a complex and diversified process lie in a risk-based approach by which the single vessel parts and work sequences are analysed and assessed for potential errors.

Actions coming from those studies, though, do not only focus on the so-called 5Rs (right piece, right time, right place, right quantity and right quality). The right information is a key factor in modern and expeditious shipbuilding. Structuring drawing details and the chapters of numerous standard documents in a way that subject areas only receive the exclusive content they need reduces the hazard of missing the forest for the trees The second pillar in effective quality management is short cycles for tests and inspections. At stages where the risk of an error is high, fast detection avoids having to dismantle, fix and restore completed hotel areas and mechanical spaces. More than 60,000 single checks during production, plus additional checks in the commissioning and delivery phase, ensure late stage problems are eliminated. The need for short-cycle quality assurance by well-trained inspectors is shown the exponential cost graph. As construction cost incur multiples of 10 or even more during each subsequent step of the process, mistakes not caught by early detection can result in millions of over-budget costs and jeopardise production schedules. To sum up results at dedicated process steps, quality gates are installed to review test progress and test results. The owner operating the ship and the classification society also take part in some of the inspections, so the follow-up of remarks and customer satisfaction contribute to a successful ship project completion. Measurement works cover the entire construction process. Alignment of the plasma torch cutting machines is just one of the first tasks, and absolute accuracy is a must when laying keels and fabricating the blocks. On top of this comes a host of other special jobs, such as determining the overall length of a ship and assisting in research projects. With more and more parts of a ship being prefabricated and attached in blocks, we need to be able to trust our measurements without doubt. Whether you’re measuring a complex sun shade composed of multiple concave shapes or a 260-metre-long waterslide with curves and loops, precise connection of the parts is critical. If we fail to identify potential mistakes or to provide the correct measurements, the entire ship could be scrapped. It is no wonder, then, why we take our responsibilities so seriously.

Versatile toolbox

To ensure we do not miss any critical details

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SHIPBUILDING that could contribute to significant additional costs, we rely on a diverse set of measurement instruments. In particular, 3D laser scanning plays a significant role in helping us ensure construction quality on an efficient cruise ship factory line. Since 2009, we have added Leica Geosystems laser scanners to our hardware equipment for documentation needs, depending on their high accuracy, speed and rugged design. Along with Leica TruView panoramic scan visualisation software, weâ&#x20AC;&#x2122;ve been able to overcome daily challenges with positioning and monitoring of special components and provide exact as-built verifications of complex constructions. Providing approximately 8,000 panoramic photos a year of critical ship elements to our internal clients, we can clearly show surface analysis, geometric controls and fit checks in our efforts to detect deviations at the occurrence stage before prefabrication installations. Weâ&#x20AC;&#x2122;ve also met more advanced standardisation requirements with 3D laser scanning, such as structure analysis, reverse engineering and volume determinations throughout the ship building process. In addition to geometric surveying for construction monitoring, the data provides documentation for warranty needs. Recently, by automating our 3D laser scanning, we have been able to even improve both our efficiency and our quality of measurements with around-the-clock capturing and monitoring of sections as they come together. Using multiple scans simultaneously day and night, we are gathering scan points to register, cut and fit

into CAD models. With automated scan data analysis of the sections, every building part is inspected and our KPIs are strictly reviewed. We have realised significant cost and time savings since automating our process and our quality has improved even further.

Advancing 3D laser scanning

With our latest purchase of the newest, ultra-high speed 3D laser scanner, the Leica ScanStation P40, we wanted to explore how this technology has advanced and if it could bring yet higher quality to our production. Under real-world conditions, we directly compared it side-by-side to our current Leica HDS7000 scanner by scanning steel beams in the prefabrication stages. To ensure a direct comparison between the scanners, they were both set with a scan density of 6.3 millimeters point spacing at 10 metres distance from the scanner and set for 3.5 minute scans. We scanned and analysed the edge of the deck plating. A main weakness in laser scanning in general is the noise at edges, known as mixed pixels. Mixed pixel noise was considerably lowered with the Leica ScanStation P40 over the Leica HDS7000. Far left top, Steel beams were scanned during the pre-fabrication process, far left bottom, For comparison the Leica ScanStation P40 and HDS7000 scanner were tested side by side, left top, The plate edge was scanned with both models, and left bottom, Comparison of scans obtained with the Leica ScanStation P40 (left) and HDS700 (right)

There was also a better representation in geometry and contrast of the deckbeam, webplate beam and the deployed HDS targets with the new Leica ScanStation P40. At Meyer Werft, where measurement quality and efficiency are critically important for cruise ship building, 3D laser scanning has proven to be increasingly beneficial in our daily activities. Our test results on the new Leica ScanStation P40 point to an even better future for this technology. hds.leica-geosystems.com www.meyerwerft.de

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CMMS

No compromise on quality

Safety critical ejector seats call for modern CMM technology

Headquartered in Higher Denham, some 30 miles north-west of London, Martin- Baker is the world’s longest established and most experienced manufacturer of aircraft ejection seats and related survival equipment. Given the safety critical nature of Martin-Baker’s products, they are manufactured to the highest standards of quality and reliability. Although numerous modern inspection and testing aids are used to ensure ‘as-designed’ performance, the mainstay of Martin-Baker’s inspection functions is its collection of Mitutoyo CNC Coordinate Measuring Machines (CMMs). Since the first machines were installed almost twenty years ago they have benefited from both Mitutoyo hardware and software updates. Although these CMMs still perform well, mindful of technological advancements, the company’s oldest CMMs have now been replaced with Mitutoyo’s advanced Crysta Apex S9206 CMMs complete with scanning probe systems. Darren Smith, Martin-Baker Quality Manager explained. “All Martin-Baker staff fully appreciate that the ejection seat may represent a crew member’s last chance to survive and that there can be no compromise on quality. Every facet of the safety system from initiation, escape path clearance, ejection sequencing, stabilisation, life support and parachute descent to final rescue, must work perfectly to safeguard a life. To help guarantee the quality of our products, we make regular purchases of the best available inspection equipment and also invest in technical updates for our existing inspection aids. “As our production levels continue to rise, component throughput in our busy inspection and goods inward departments has grown

accordingly. Therefore it helps that, when compared to our older machines, besides having an enhanced accuracy specification, our new Crysta Apex S9206 CMMs perform quicker measuring routines. This is due to the employment of high accuracy scanning systems that enable rapid data collection. “To allow our operators to take full advantage of our efficient new Mitutoyo CMMs, prior to installation we radically reorganised our environmentally controlled inspection and goods inward departments.” Martin Baker also uses Mitutoyo’s MCosmos CMM offline programming software in order to maximise measuring time by generating measuring programs away from the CMM by using CAD models rather than physical parts. This means programs are ready for execution prior to the arrival of parts thus improving workflow through the inspection department. “Whenever possible we use our new Crysta Apex S9206 CMMs, as their CNC operation automates measuring routines and provides both accuracy and speed. In addition, removing the human element ensures repeatability and eliminates variables. On completion of an inspection batch, a fully detailed and traceable inspection report is generated for each individual component. Then any deviation from nominal conditions on component’s features can be quickly communicated back to production before an out of tolerance situation occurs.” Mitutoyo Coordinate Measuring Machines are available in a wide range of sizes and accuracy classes to cover practically all precision 3D measuring applications. The advanced Crysta Apex S9206 CMM has an x,y,z capacity of 905mm x 2005mm x 605mm. It is built using lightweight materials and features an innovative moving-bridge type machine structure. This provides high motion stability to take advantage of the increased scanning speed and high accuracy of the CMM. www.mitutoyo.co.uk

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Making the cut Sheffield Industrial Saws rely on a portable hardness tester to ensure blade quality The UK’s only producer of hotsaw blades, Sheffield Industrial Saws, relies on a Bowers TH174 portable hardness tester to accurately measure circular saw blades. Sheffield Industrial Saws uses the handheld device to measure the hardness of the tooth tips of its hot and friction saw blades, which are made from carbon steel. The Bowers metal hardness tester is one of the only products on the market that can fulfil these hardness testing requirements and still be portable.

FARO ® EDGE SCANARM ® HD HIGH SPEED SCANNING PERFORMANCE MEETS HD DATA CLARITY! Seamlessly scan across diverse surface materials regardless of contrast, reflectivity or part complexity without any special coatings or target placement. The extra wide scan stripe and fast frame rate boosts productivity by increasing coverage and reducing scanning time.

The tips of the hot and friction saw blades are flame hardened and water quenched using Sheffield Saw’s own in-house designed machine. The tips need to be hardened in the region of 42-54 HRC to a varying depth depending on the pitch of the tooth, with tooth pitches varying from approximately 6mm up to 25mm. Hot saws are used in steel section mills for cutting red hot carbon and alloy steels over 750°C, while friction Saws are used for friction cutting cold carbon and alloy steels. Blade materials for the saws include carbon, manganese and steel with a normalised body 22 HRC with flame hardened teeth 42 to 54 HRC. The Bowers TH174 Portable Hardness Tester used by Sheffield Industrial Saws is a handheld dynamic metal hardness tester with an integrated impact device DL featuring testing in confined spaces. With a wide measuring range, it can be used for steel and cast steel, and provides highly accurate testing at any angle. www.bowersgroup.co.uk

Choose the FARO solution to simplify and speed-up your whole workflow! Call us at 00 800 3276 7253 for a free demo today! www.faro.com/scanarm

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COMPOSITES

GTR accelerates inspection

Laser scanning gives an F1 composites manufacturer speed and accuracy

The extraordinary strength to weight ratio of composite materials has enabled F1 and other series engineers to design cars that use semi-monocoque chassis, wings, spoilers, and other parts, made from these materials that are significantly lighter and stronger. This results in cars that are both faster and safer. Motorsport’s transition to the use of composites as a preferred material has been aided by a small number of highly specialised companies that have the required levels of composite design and production expertise. One such concern is GTR. The company’s founders, John Biddlecombe and Simon KingdonButcher, have built a business that is now firmly established as a leading composite part supplier to the demanding motorsport market. As many composite parts are manufactured to demanding dimensional tolerances to ensure engineering reliability and best possible aerodynamic characteristics, they present a range of problems to the metrology industry. Not only must measuring equipment exhibit the required levels of accuracy and repeatability, the dynamic nature and the continuous evolution of designs within F1 demands speed of inspection and instant data capture Troy Hull, GTR Quality Manager explained. “Our knowledge of the use of composite within motorsport is second to none. We manufacture everything from chassis, suspension, wing assemblies and bodywork to the smallest of fairings. Now, the vast experience we have gained in this most demanding of areas has enabled GTR to acquire contracts for the manufacture of composite components, mouldings and assemblies for other challenging sectors, such as the defence, aerospace,

automotive and gas and oil industries. “In addition to the quality of our work, a major factor in GTR’s success is our ability to react quickly to our customers’ needs. Having invested in the best available design systems including Catia V5 and Siemens NX CAD, we are able to rapidly take all projects from concept to fully designed products and on to manufacture. Our first-class production facilities, such as our 3.0m diameter autoclave, one of the five we have on site, and state-of-the-art clean rooms also add to the speed of our service. “We use the FARO Edge ScanArm HD to perform a range of non-contact 3D inspection routines and to accurately capture complex and free-form surface data as a detailed 3D point cloud. We scan a wide variety of components, including items such as 5 meter aerospace wings and F1 gearbox components, down to the smallest of parts. Through the use of our ScanArm we are able to undertake first article inspection and to precisely digitise previously difficult to inspect features such as flush and gap. In addition to being quick and accurate, as FARO laser scanning is so easy to perform, we are able to verifying the most awkward of features and to include their dimensions in 3D documentation and comprehensive, easy to understand inspection reports. “We also use the FARO Edge ScanArm HD to check components’ complex geometries against design or CAD comparison to ensure that their surface forms remain within tolerance. Additionally, on the rare occasion that no CAD files or drawings exist, we sometimes need to reverse engineer parts. The ScanArm allows us to perform a rapid scanning routine and to digitise a part and create a fully surfaced accurate CAD model for future use.” www.faro.com

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LIGHTWEIGHT SYSTEMS

A light touch

ASDEC has the capability to measure vibration where others fear to tread Vibration measurement and analysis of extremely small and lightweight systems that would be impossible with traditional accelerometer based techniques is handled well by non-contact Laser Doppler Vibrometers, according to ASDEC. The Advanced Structural Dynamics Evaluation Centre (ASDEC) is the UK’s first commercial robotised 3D scanning laser vibration measurement and modal analysis centre Working with the Space Research Centre at the University of Leicester, ASDEC tested Glass Microchannel Plates (MCPs) used as X-ray optics used by in space science instrumentation. These are typically 40mm by 40mm by 1.2mm glass plates with 20 micron square pores with an Iridium coating to increase reflectivity. The front faces of the plates are covered with a thin layer of aluminium foil (60nm) spanning the pores to reduce the thermal load and to block visible light. Testing MCPs is critical in development of satellite systems. Engineers need to understand the structural characteristics to ensure durability through launch and into the expected life of the system. However even the

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slightest touch can ruin the device, damaging the structure or removing the film. It is also a requirement of all space hardware that the behaviour under structure borne vibration and acoustic excitation must be characterised. Jon Sykes, Senior Mechanical Engineer at the Space Research Centre says, “The facilities at ASDEC provided the perfect solution to conducting necessary vibration testing on parts that are so light and delicate at any other testing method was impossible.“ ASDEC is able to deploy its portable system in any test location, even clean room environments, to undertake detailed vibration measurements of systems and instruments. asdec.co

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INSPECTION/MEDICAL

First article inspection An optical measurement system underpins quality at Pentagon Plastics Every new moulding produced at West Sussexbased Pentagon Plastics needs a First Article Inspection Report, which involves measuring the dimensions of the component against drawings provided by the customer. This report is then sent to the customer for verification and approval. Pentagon uses a Baty Venture 3030 optical measurement unit for this and to monitor specific components throughout production runs. The unit is also used by in-house toolmakers to carry out fine detail checks. “The Baty unit has enabled us to carry out far more precise measurements on the components that we produce” says James Penny, Quality Inspector at Pentagon Plastics. “It helps us to ensure that the quality of components is maintained throughout the production runs, and makes it easy to identify any areas for concern. Small detail such as a very small radius or a small angle are easy to measure thanks to the powerful zoom on the machine.” Pentagon Plastics previously used a shadowgraph for the measurement process, but the Baty Venture 3030 has made the process much easier. It also allows Pentagon to measure additional features and give true positioning tolerances with other

geometric dimensions. “Our processes have been significantly improved following our investment in the Baty unit” says Mr Penny. “The Venture with Fusion software creates drawings as components are measured, and this visual representation makes the task of building a report far more efficient and accurate than we could have achieved previously.” The Baty Venture 3030 allows measurements to be taken and saved to the hard drive, which keeps a record for statistical purposes over many runs. This information can then be exported directly into an Excel spreadsheet, which significantly speeds up the reporting process. www.bowersgroup.co.uk

Right, Auto-injectors are designed for maximum easeof-use and to help patients or non-medical staff to administer a single dose of a particular (typically life-saving) drug, below, The Innomech system integrates five tests

An automated test system for Owen Mumford helps speed up product release Innomech has designed and developed a new fully automated test system to help Owen Mumford, a global leader in medical device design and manufacturing, to carry out more efficient batch testing as a final verification of quality for one of its leading auto-injector products. The new system will help significantly speed up product release for shipment and is more than 5 times faster than a previously semi-automated process that needed five different pieces of test equipment, each with its own specially-trained operator. In the new system Innomech has integrated all five tests with a total cycle time of less than one minute. The automated system requires just one operator, eliminates the need for any manual handling of auto-injectors between different tests and ensures all test results are fully recorded into a secure electronic record to comply with FDA 21 CFR part 11 regulations for medical device manufacturing. The operator starts the test cycle by inserting a complete auto-injector pre-loaded with its cartridge of active drug into the Innomech

machine. The system then measures the forces required to remove the autoinjector’s safety cap and to fire the trigger, the dose time, volume of dose delivered and the distance the needle protrudes from the body of the device. The cycle ends with the fired device being automatically ejected from the machine into a sharps bin to protect the operator from the risk of any accidental scratches or puncture wounds. If an auto-injector fails one of the five tests then the machine retains it, a red warning light is displayed and the operator receives an on-screen explanation allowing them to remove the product and to take further action as required. www.innomech.co.uk

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Photo: Owen Mumford

Test solution for injection device

PRODUCTS

Vision measurement from Renishaw At EMO Milano 2015 Renishaw launched a vision measurement probe (RVP) for use with the REVO 5-axis measurement system on co-ordinate measuring machines. RVP increases the multi-sensor capability of REVO by adding noncontact inspection to the exisiting touch-trigger, high-speed tactile scanning and surface finish measurement capability of the system. For certain applications, noncontact inspection provides clear advantages over traditional tactile probing techniques. Thin sheet metal parts or components with large numbers of holes as small as 0.5 mm, and parts which are not suited to tactile measurement, can be fully inspected with the RVP system. RVP also gives exceptional improvements in throughput and CMM capability by utilising the 5-axis motion and infinite positioning provided by the REVO head. EMO Milano 2015 also saw the launch of REVO-2, a new improved version of the multi-sensor 5-axis measuring head. REVO-2 and its new CMM controller UCC S5, build upon the successful REVO multi-sensor system with enhanced power and communications capability to carry the latest REVO sensors such as the RVP vision measurement probe. The head also has an increased range of movement in the negative A-axis which can improve part access and reduce the complexity of stylus setups. REVO-2 incorporates Renishaw’s own ATOM™ optical incremental encoder system that combines miniaturisation with ruggedness and metrology performance. ATOM is the world’s smallest read-head using filtering optics. It offers speeds up to 20 m/s (29,000 RPM on a 17 mm disc) and resolutions to 1 nm (0.004 arc second on a 108 mm disc) with a range of linear and rotary (angle) scales available in stainless steel and glass. Renishaw also launched a new

free software suite for Renishaw calibration systems. It includes Capture and Explore, which provide data capture and analysis for the XL-80 laser interferometer system. CARTO release 1.1 supports linear, angular and straightness measurement with a choice of keypress, position and remote (TPin) triggering. CARTO features a new database system which automatically stores and organises data for the user, simplifying operation and allowing users to quickly and easily compare data with historical results. The CARTO user interface allows new users to begin capturing and analysing data quickly, without the need for training or reading lengthy manuals. The capacity for customisation throughout the suite means that both Capture and Explore can be tailored to suit an individual user’s requirements. Further development on CARTO will follow to add more features, including rotary, flatness and dynamic measurement. CARTO release 1.1 will be available to download free of charge from www.renishaw.com

with standards an the accuracy of the total system. The useful life of a standardised test block is determined by the density of indentations on the surface and once the recommended densities are reached the standardised test block must be replaced. Verification testing with standardised test blocks should be performed throughout the total working range of the hardness test machine using multiple standardised test blocks with appropriate hardness values certified at relevant load forces. It should be noted that standardised test blocks should only employ the top surface of the block. In additional to an extensive range of commonly used blocks, Zwick Roell Indentec can also supply Brinell test blocks with scales 250kgf to 3000kgf, complete with UKAS accreditation to ISO 6506-3: 2014 & ASTM E10. All hardness test blocks supplied by Zwick Roell Indentec are supplied in a hardwearing plastic storage case with foam inlay, to provide adequate protection for the block. www.zwick.co.uk

Hardness test blocks

HD thermal inspection camera

Zwick Roell Indentec offers a wide range of hardness test blocks for all standard test methods, available in various materials including steel and carbide, and are supplied complete

FLIR Systems has launched a new series of uncooled HD thermal inspection cameras. It says that the T1K series represents a premium product that sets a new industry standard, delivering outstanding image clarity, exceptional measurement performance, and an intuitive yet simple hybrid-touch user interface. The new cameras allow users to find problem areas quickly, measure them precisely, and document and report findings for corrective action. T1K series cameras feature hardware, software, and optical designs tailored to take advantage of the new 1024 X 768 HD-IR detector. High fidelity images are created utilizing FLIR’s new OSXTM Precision HDIR optics which feature a precision ultrasonic autofocus capability. The combination of the higher resolution detector and the variety of OSX lenses available allow users to view problems from longer distances and with greater accuracy, promoting better safety and more efficient workflow. Advanced real-time image processing uses the integrated on-

with UKAS accredited certification. Standardised test blocks as reference materials are an integral part of hardness testing. They ensure accuracy, integrity and traceability of the hardness testing process. Typically they are used to both verify hardness test machine performance and to provide a means for performing indirect calibrations. Zwick Roell Indentec says daily verifications via test blocks will quickly validate hardness testing equipment performance, compliance

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PRODUCTS

board FLIR Vision Processor, which combines FLIR’s patented MSX multi-spectral dynamic imaging with a series of other proprietary image enhancement algorithms to deliver highly detailed thermal and visual images to users while in the field. Additionally, built-in audio and onscreen text/sketch annotation features support infield documentation while the included FLIR Tools reporting software allows users to generate instant reports on a variety of mobile and desktop platforms. www.flir.com

Technology led CMM Hexagon Metrology says its new technology-driven GLOBAL EVO CMM promises better scanning performance, throughput and productivity. Designed in collaboration with internationallyrenowned design house Pininfarina, this new machine is tailored specifically to offer process speed and efficiency to manufacturers requiring accurate tactile scanning and high throughput. Built on the foundations of the successful GLOBAL range, GLOBAL EVO features a number of new technologies to improve speed without compromising on performance. Central to the design is Compass, a combined hardware/ firmware vibration reduction technology which acts like a suspension system for the CMM. With Compass, the machine can effectively compensate for vibrations caused by its own movements, enabling higher-speed scanning with no loss of accuracy. Accompanied by the Scan Pilot firmware feature, which ensures robust and rapid measurements even

when scanning complex unknown profiles, Hexagon says Compass gives GLOBAL EVO outstanding scanning performance. GLOBAL EVO is also the first CMM to include Fly2 Mode, the nextgeneration of Hexagon Metrology’s trajectory-optimising technology. Automatically generating and implementing the most efficient path between points, Fly2 Mode ensures smooth movements and reduces program execution times. The GLOBAL EVO made its debut at the EMO machine tool show in Milan in October and is now available to order. www.hexagonmetrology.com.

and saturation can be set using IC Measure and saved for future use. www.theimagingsource.com

Robotised scanning solution

On-screen measurement

Smarttech3D has launched a fully automated 3D scanning solution comprising a 3D optical scanning head mounted on robotic arm and in a fully enclosed safety envelope. The SMARTTECH3D Robotized system is aimed at large industrial customers who would like to minimise human intervention in the inspection process and hence reduce possible errors. The operator simply has to place the object to be inspected on the rotary stage and turn the robotic arm on.

Machine vision system manufacturer, The Imaging Source, has introduced IC Measure, its new software for on-screen measurement and image capture. IC Measure allows the measurement of lengths, surfaces and angles in a simple user interface that also provides image capture and image enhancement functions. The IC Measure calibration tool makes it possible to define image scale (µm – km); the software is quickly calibrated using an ocular micrometer (microscope) or an object of known size (e.g. a ruler). The measurement tools are designed for macroscopic as well as microscopic applications. The complete integration of image capture and image enhancement makes the manual measurement of lengths, angles, circles and polygons especially efficient. The seamless zoom function allows for pixelperfect measurement. IC Measure also offers a variety of annotation tools, which allow the user to add texts, graphics and arrow mark-ups. The lens distortion filter corrects barrel, pincushion, and vignetting distortions. Image processing and optimisation routines, such as histogram comparison, allow for optimal enhancement of relevant image details. IC Measure saves single images and image sequences to BMP, TIFF, JPEG and PNG, and video data streams to AVI files. All annotation data can be exported to CSV files. Camera settings, such as exposure time, image refresh rate, focus, noise reduction, contrast, brightness

The robotic arm then uses 3D scanning to locate the exact position of the object on the rotary stage and from this data recognises the relevant CAD program for the part. Once the CAD program has been located the user can choose which precise area of scanned surface he would like to inspect. Quality control is provided automatically by the robot. Once the inspection in complete, the operator is given a full inspection report, with any deviations noted in the report and visualised in PDF3D. A specially developed plugin allows 3D scanning as well as inspection to be carried out directly in GEOMAGIC Control software. The user-friendly interface makes the job simply and intuitive. The robot arm can also capture the shape of the object which can then be used for CAD modelling. The 3D scanning head is certified according to the VDI/VDE 2634 standard, so the end-user can be sure that surface is measured with the described accuracy of 0.03mm for a 300mm by 400mm measurement volume. The SMARTTECH3D Robotized system does not require a special air-conditioned or darkened room, it features a shock-absorbing system and the whole system is on wheels and can be moved wherever it is required. www.smarttech3dscanner.com

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GREAT STORIES CONTINUE AT HxGN LIVE 201 2015 JOIN US ON LOCATION IN HONG KONG Join Hexagon Metrology for the Metrology track at HxGN LIVE, as we bring the event to Hong Kong for the first time. HxGN LIVE is Hexagonâ&#x20AC;&#x2122;s international event dedicated to helping customers harness the power of Hexagon technologies.

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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