Quality Manufacturing Today September/October 2016

QUALITY MANUFACTURING TODAY

www.qmtmag.com September/October 2016

3D Measurement

The Next Level of Remote Visual Inspection Four Times Larger Measurement Area

Accurate Measurement of Tip Gap Clearance

Measuring on Reflective Surfaces

Resolving Thin Features

www.olympus-ims.com

Providing world-class metrology products, services and solutions With over 80 years’ experience and representation in over 100 countries, Mitutoyo are recognised as the world’s foremost manufacturer of precision measuring equipment and a provider of related services.

Visit us online at www.mitutoyo.co.uk

DIMENSIONAL METROLOGY CITY & GUILDS AWARD (Level 2) Mitutoyo alongside City & Guilds exclusively offer the first National Qualification in Dimensional Metrology Find out more, or book your place at www.mitutoyo.co.uk/education

CONTENTS

September/October 2016 News and comment 4 Events 5 Remote inspection in 3D 6 How 3D stereo measurement is transforming the way videoscopes reveal crucial data

Pompeii: new secrets revealed

10

Getting a handle on performance

12

Driving down exhaust weight

15

How long is a piece of spring?

16

What has changed in quality auditing?

18

Magnetic performance

19

Check it twice

20

Quality in the round at Kawasaki

22

Accuracy focus on the power train

23

Doing their level best

24

Better wings quicker

26

Ancient world secrets unearthed with 3D scanning technology

Vehicle handling performance uncovered by Nissan Motor Company with assistance from Siemens Front cover: Olympus Web: www.olympus-ims.com Tel.: +49 40 23773 0

Editor Andy Sandford Email: editorial@qmtmag.com Director/Publisher Dawn Wisbey Email: dawn.wisbey@qmtmag.com Tel: +44 (0)20 8289 7011 Mob: +44 (0)7974 640371 Design and Production Manager Rob Tremain Email: studio@qmtmag.com IT Director Pat Coyne Email: pat.coyne@qmtmag.com Website: www.qmtmag.com Media enqiries media@qmtmag.com QMT Magazine is a multi-media business magazine for the quality, measurement, inspection and test industries, supported with a fully searchable interactive website www.qmtmag.com.

QMT Mobile: website is available in mobile-optimised form. Log on with your phone and you will be directed automatically to the mobile pages.

QMT App: download Quality Manufactory Today app for iPad and Android tablets

@QMTMAG Quality Manufacturing Today is published by Cranbrook Media Ltd. Registered company No. 06048241 Registered office: N.J. Ruse Associates, Eagle House, Cranleigh Close, Sanderstead, South Croydon, CR2 9LH Printers: Headley Brothers Ltd © Cranbrook Media Ltd

How metrology is the key to reduce the weight of exhaust systems for a luxury sports car

High accuracy video measurement free-form springs

Fascinating insight to how quality auditing changed over the years

High speed packaging system for ST Technologies

Automatic parts verification by weight

Mitutoyo equipment used to ensure roundness on pistons and cylinders

An Aberlink CMM is helping CPT make more efficient power train components

Use of digital inclinometers to ensure optimum performance

Aircraft wing shape research investment

If you can’t measure it, you can’t make it 27 The Inspex show is returning alongside TCT Show + Personalize 2016

Testing infotainment systems at VW

28

VISION 2016 in view

30

OCR technology used in VW’s Infotainment Systems

Ultra-versatile 3D machine technology

Products 33

QMT September/October 2016 www.qmtmag.com

3

NEWS

EDITOR’S COMMENT We always try and give you an eclectic mix of content – but I think we have taken that to a new level this issue.

Looking back two millennia, we have a story on how the historic sites at Pompeii were scanned and integrated with live action for the BBC and, at the cutting edge of modern computing technology, we look at how Siemens is applying simulated testing to give optimum performance to Nissan.

In another alternative take on the automotive industry we look at how VW tests its in-car infotainment systems using optical character recognition technology.

But don’t worry, we still have our usual mix of know-how, technical insights and application case studies looking at tried and trusted tools such as CMMs, roundness testers, inclinometers, micrometers weighing machines.

To give this all a bit of perspective, we also have the insights of Chris Eden on how requirements and attitudes to quality auditing have evolved over the course of his career.

Quite a mix – I hope you enjoy it.

cycle race, the UCI decided to significantly enhance the deterrence of technological fraud by hiring VJ Group’s VJ Technologies, a leader in innovative x-ray solutions, to develop and provide an in-field inspection solution that would absolutely identify any illegal components concealed within the frames or wheels of the bicycles.

The Innovative Solution comprised a VJ Technologies designed and manufactured portable x-ray source, large area digital detector, and VJ’s Vi3 image acquisition, processing and archival software, integrated within a small trailer that was towed by a car.

At the conclusion of the race, Mark Barfield, Director Technique of the UCI said, “It was great to work with VJ technologies and it certainly helped address the concerns felt by some [at the Tour de France]. They did an amazing job and I look forward to working with them again in the future.” www.vjt.com

CALIBRATION Trescal opens £2m facility Tresca has opened a new calibration and measurement centre that includes what it says is the UK’s only UKAS accredited facility for rotary table measurement testing.

Andy Sandford Editor QMT

SPORTS TESTING Thwarting cycle cheats X-ray specialist VJ Technologies was brought in by the organisers of the Tour de France to sniff out attempts at ‘mechanical doping’.

Just as athletes use illicit drugs to enhance performance, some cyclists have also been caught using a hidden motor which provides additional power to the wheels at critical times.

In January 2016, the governing body of world cycling, Union Cycliste Internationale (UCI), made the first discovery of technological fraud in elite cycle racing when a bicycle containing a concealed motor was found using small hand-held magnetic resonance instruments.

This year at the Tour de France, the world’s largest and most prestigious

4

Located at Pride Park, Derby, the 25,000 sq ft facility has cost over £2 million to build and offers measurement volumes of up to 2.1m by 4.4m by 1.6m on what is probably one of the UK’s largest CMMs. With the ability to measure component parts of up to 10 metric tonnes it offers new possibilities for industries such as aerospace and automotive.

The site features six laboratories in total, all operating under strict climatic conditions. The facility took around seven months to complete, and is now home to 46 employees. Technical capabilities include dimensional, electrical, temperature, pressure & vacuum and torque type calibrations, supported by Product Verification Measurements.

www.qmtmag.com

The measurement laboratory features two brand new CMMs, the first with rotary table measurement and the second, a high accuracy machine that offers a measurement performance capability (MPE) of 0.0009mm+L/650mm.

Commenting on the opening of the new laboratories, Steve Powell Branch Manager at Trescal Derby said: “The new Trescal Derby facility is a hub for extensive calibration expertise, strategically placed to support British manufacturing in the East Midlands and beyond.” www.trescal.com

CONFERENCE 3D event in Aachen Taking place from 22 to 24 November in Aachen, 3DMC is a new conference and exhibition dedicated to the application and development of 3D measurement technology for industrial, scientific and cultural purposes.

The committee organising the event aim to realise the aspiration of the European Portable Metrology Conference to bring an event to mainland Europe. The objective is to attract a wider audience and give the conference, year-on-year, a bigger presence.

To be held at the Laboratory for Machine Tools and Production Engineering (WZL) at the RWTH Aachen University, the event is aimed at end users of 3D metrology systems, equipment and software suppliers, service providers, researchers and procurement and quality managers.

The scope of the conference covers the technology and applications of portable coordinate metrology, 3D metrology for advanced manufacturing, automation and in-process metrology, future technologies, augmented reality, measurement uncertainty and traceability. www.3dmc.events/en/

ACQUISITION FARO buys LPT 3D measurement and imaging specialist FARO has acquired Laser Projection Technologies (LPT), which is focused on high-speed, long-range 3D laser projection and measurement systems designed for use in manufacturing applications requiring precise component alignment.

Located in Londonderry, New Hampshire, LPT’s laser projection and measurement systems are used throughout manufacturing environments around the globe to maximize

QMT September/October 2016

NEWS productivity and efficiency.

FARO President and CEO Dr Simon Raab said: “The acquisition of LPT enhances FARO’s robust portfolio of 3D measurement solutions.

“In addition to LPT’s leading laser projection solutions, we believe LPT’s proprietary imaging laser photogrammetry and imaging laser radar technologies have tremendous potential to disrupt the market by establishing a new class of high-speed laser measurement with advanced 3D imaging capabilities and we will focus our integration efforts on rapidly leveraging this potential. This technology is thousands of times faster than currently available Lidar products and has proprietary imaging features, which provide extraordinary qualitative and quantitative inspection capabilities in every area of manufacturing. In addition, this promising technology incorporates a well-developed laser projection capability to guide assembly, making it a fully robotic, high-speed collaborative tool for manual or automated assembly and verification. In this case, ‘seeing’ is truly measuring.” www.faro.com

SUBCONTRACT New facility boosts SMEs A new metrology subcontract inspection centre created by Hexagon Manufacturing Intelligence will bring advanced technology within the reach of tier two, three and four suppliers.

The purpose-built, state-of-the-art facility covers 3000 sq ft within the Innovation Centre of Silverstone Park next to the Silverstone Formula 1 circuit.

John Drover, Sales Manager for Hexagon Manufacturing Intelligence UK, said: “Our engineers and application metrology specialists are able to deliver inspection, validation, and quality control of components through the use of Hexagon systems which are capable of measuring to the sub-micron level, enabling our customers to achieve high performance and accuracy every time. But being able to verify and validate predefined standards for accuracy, reliability and precision is something that smaller businesses

are unable to achieve due to financial restraints and restrictions.

“Through this new facility, we are opening up exclusive access to both the equipment and the support to enable tier two, three and four suppliers across the UK to achieve first-rate provable standards. And by also offering dedicated training programmes, along with networking opportunities, this new facility will not only help facilitate growth and development across the SME sector, but it will help raise standards industry-wide.” www.HexagonMI.com

IMAGING Hyperspectral speakers Keynote speakers have been announced for the HSI 2016 | Hyperspectral Imaging & Applications Conference to be held on 13 and 14 October at the Ricoh Area, Coventry, UK. The conference is opened by Martin Whitworth from Campden BRI (UK), an organisation deeply involved in research and support to the food industry. His talk is entitled ‘Mapping composition in food samples by NIR hyperspectral imaging’.

Keynote speaker Dr Himar Fabelo from the Universidad de Las Palmas de Gran Canaria will be talking about the ‘The HELICoiD project: A comprehensive framework for real-time detection of human brain tumours using hyperspectral images’.

Visiting from the Center for Imaging Science, Rochester Institute of Technology in the USA, is Professor Vodacek a specialist in remote sensing.

He will be speaking on the HSI activities at the centre and giving insight into phenomenology, algorithms, modelling and simulation and applications for hyperspectral imaging.

The conference comprises 24 speakers and is free-of-charge for attendees thanks to sponsorship by Headwall Photonics, LOT QuantumDesign and Xmark Media. www.xmarkmedia.com

AWARDS Small business winner Physical Digital, the specialist 3D scanning and measurement service provider, has been named among the 100 small businesses in the UK to be celebrated by Small Business Saturday, a national campaign that culminates in the UK’s dedicated day for small businesses on December 3rd.

Physical Digital provides high-accu-

EVENTS 28 – 29 September 2016 TCT + Personalize Birmingham UK www.tctshow.com

•

2 – 3 November 2016 Advanced Engineering Birmingham UK www.easyfairs.com

•

8 to 11 November Vision 2016 Messe Stuttgart, Germany www.messe-stuttgart.de

•

22 to 24 November 3DMC Aachen, Germany www.3dmc.events/en

•

9 – 12 April 2017 Control Messe Stuttgart, Germany

•

www.control-messe.de

• QMT is a media partner racy 3D non-contact scanning and measurement services for a diverse range of clients. The company, which uses GOM 3D scanning systems to capture high-resolution images of objects and reverse engineer these images into 2D engineering drawings or 3D models, will be among the select number of businesses to be featured one per day for the 100 days leading up to Small Business Saturday itself.

Physical Digital’s MD Tim Rapley said: “We are really enthusiastic about the contribution of small businesses to the UK economy and believe that SMEs have a disproportionately positive impact on society, providing employment and supporting business development locally and nationally.

We love the idea of joining with other small businesses to showcase our wide range of 3D scanning and measurement capabilities and to demonstrate that the UK’s small businesses are not just shops and hairdressers.”

QMT September/October 2016 www.qmtmag.com

www.physicaldigital.com

5

VISUAL INSPECTION

Remote inspection in 3D

Figure 1: Using parallax to measure distance: the distance between the points at which the light from two different lenses hits the CCD camera can be used to measure the distance between the object and the CCD

Liam Hanna* of Olympus looks at how 3D stereo measurement is transforming the way videoscopes reveal crucial data *Liam Hanna is Product & Application Specialist RVI, EMEA at Olympus Europa SE & Co. KG.

R

emote visual inspection (RVI) is a valuable tool when inspecting complex equipment, reducing cost and time, avoiding the need to disassemble critical components such as gas turbines and piping infrastructure. Since videoscopes face the challenge of fitting complex optical and digital imaging equipment into the compact tip of the scope, inspection and measurement capabilities have traditionally been limited. However, in light of technological advances in miniaturisation, digital imaging quality and data processing power, the next generation of videoscope has progressed RVI to a new level.

Evolving the RVI workflow • Inspect - innovations such as wide angle measurement adaptors, better CCD cameras, laser diode illumination and intelligent processing allow a wider FoV, greater resolution and brighter, higher quality images.

• Check - multi-spot ranging systems provide instant confirmation of surface conditions (angle, curvature, etc.) and target distance.

• Measure - thanks to increased brightness and higher resolution, measurement tips can provide instant, repeatable, and high-precision results.

Equipped with sophisticated engineering and 3D stereo measurement capabilities, the latest videoscopes such as the Olympus IPLEX NX vastly enhance Probability of Detection (PoD) and flaw characterisation for extra confidence in decision-making. This article explores breakthrough inspection possibilities through direct real-world examples - illustrating how accurate measurements are guaranteed in conditions where standard videoscopes fail - and discuss the innovative technologies underpinning these capabilities.

Advanced 3D stereo measurement Our eyes use 3D stereo measurement to estimate sizes or distances. Industrial videoscopes work in a similar way, but instead use a measurement tip to focus and detect the image. When a point on an object is detected with a single measurement it is not possible to obtain accurate distance measurements. 3D stereo measurement can address this issue by measuring an object from two slightly different positions and determine the distance by parallax and triangulation (Figure 1).

The RVI workflow in 3 easy steps:

Inspect

6

Check

Measure

www.qmtmag.com

QMT September/October 2016

Unlimited CT possibilities

PRECISE • CT scanning with micron accuracy • Ultra-precise and stable manipulator

VERSATILE • Dual microfocus source capability from 160 kV to 450 kV • Dual imager capability with high resolution panel and linear detector

PRODUCTIVE • Fast CT results with high flux rotating target source • Advanced scanning strategies (panel scan, helical CT) for large parts • Automated scanning workflows

COST-EFFECTIVE • One system for small to large parts • Future-proof modular approach • Upgrade existing X-ray enclosures with modern CT technology

Configurable, microfocus CT systems Nikon Metrology’s configurable CT systems offer a large inspection envelope to scan small to huge samples. The modular systems support multiple sources, multiple detectors and can be custom-configured to fit a variety of applications. These versatile systems are also perfectly suited to upgrade existing X-ray bays or walk-in rooms with state-of-the-art microfocus X-ray&CT technology.

www.nikonmetrology.com/configurable_CT NIKON METROLOGY UK LTD +44 1332 811349 - sales.NM-UK@nikon.com

NIKON METROLOGY EUROPE NV +32 16 74 01 00 - sales.NM@nikon.com

NIKON METROLOGY GMBH +49 6023 91733-0 - sales.Germany.NM@nikon.com

NIKON METROLOGY SARL +33 1 60 86 09 76 - sales.France.NM@nikon.com

VISUAL INSPECTION Optimising the process of stereo measurement on a small diameter tip, videoscopes use a twolens setup to project the object onto a single CCD camera from two different angles. This setup makes it possible to obtain detailed information about the distance between the object and the measurement tip of the videoscope.

Various improvements in technology including image acquisition, processing and optics have enabled advances in 3D measurement, giving rise to the so-called ‘super wide field’ 3D stereo measurement. These improvements include better optics, laser diode illumination and improved CCD imaging sensors (cameras). Increasing PoD, the latest optics and a more sensitive CCD have given rise to significant increases in both the Field of View (FoV) and the Depth of Field (DoF); increasing FoV by 50%, and the DoF even further, 70% compared to conventional videoscopes, meaning that defects that are 4 x larger than conventional videoscopes can be measured.

Many of these targets may have surface areas that are too narrow perform measurements on...

Gaining access to those hard-to-reach areas, these improvements have also resulted in a considerable expansion of the range of ‘tip-to-target’ distances over which measurements can be performed.

Where, in standard models the tip-to-target distance range is limited to 5-30 mm, this range has more than doubled in the latest videoscopes. Combined

with advanced scope tip articulation this enables an unprecedented level of detail when measuring and imaging areas that are difficult to reach.

These features, as well as increased resolution twinned with enhanced laser illumination systems, have evolved the inspection workflow, making it easier than ever to inspect, check and measure in just three simple steps (callout box).

Increasing PoD where standard videoscopes fail As discussed, technological advances in RVI technology have resulted in several important benefits for the end-user, especially with respect to limitations associated with day-to-day use of RVI technology. The series of case studies below highlight the real-world value that the latest videoscope benefits afford when measuring, for example, thin features, reflective surfaces, dark compartments and objects under acute angles.

Measuring thin features Objects with small or narrow features are very common targets for videoscope inspections and measurements. Many of these targets may have surface areas that are too narrow perform measurements on. Using the latest super wide field 3D stereo measurement enables the distal end of a component to be measured with greater accuracy (figure 2).

Reflective surfaces Many of the targets that are measured with RVI have surfaces which are highly reflective; these include metals, glasses and oily surfaces.

Figure 2: Measurement made using a standard videoscope (left) and the IPLEX NX (right).

Red areas indicate areas that cannot be measured.

Figure 3: Reduced effect of reflection for measurements made by the IPLEX NX (right), resulting in improved contrast compared with conventional RVI methods (left).

8

www.qmtmag.com

QMT September/October 2016

VISUAL INSPECTION

Figure 4: Standard LED illumination (left) compared with bright laser diode illumination on the IPLEX NX (right).

Figure 5: Brightness control allows precise measurement of distance under highly acute angles.

Particularly in the aerospace and automotive industry, it is highly advantageous to be able to generate accurate measurements under these conditions, yet the bright reflections of these surfaces will often render the rest of the image too dark to measure (figure 3). Using cutting-edge image processing technology on the latest RVI technology, images of reflective surfaces can be modified to reduce this effect automatically and add more contrast to darker regions.

Bringing dark objects to light Another RVI innovation is an improved method for illuminating dark compartments and highabsorbance materials. Showing considerable improvement over conventional LED-based systems, laser diode illumination has the capacity to deliver light at a higher intensity resulting in brighter illumination and allowing measurements at a wider range of distances.

when inspecting the inside surfaces of pipelines.

Measuring hard-to-reach areas To achieve the best possible results with new RVI devices, a target distance of around 40 mm from the target object is recommended, compared to 20 mm required with standard videoscopes. In order to test measurement accuracy of the IPLEX NX against an extreme target distance and under adverse conditions, a measurement was conducted against a known distance of a calibrated rule of 100 mm (+/- 0.5 mm) length, from a target distance greater than 200 mm (192.8–204.8 mm). The surface of the rule was highly reflective, in order to place the system under the most adverse conditions possible and to understand the accuracy achievable in the worst case scenario. While a standard videoscope was unable to achieve any measurement data, this videoscope was able to take a measurement with 99.79% accuracy.

Summary

The latest image processing techniques can also act as a valuable tool in the analysis of angled surfaces Angled surfaces The latest image processing techniques can also act as a valuable tool in the analysis of angled surfaces. Often, surfaces that are hard to reach can only be illuminated from one angle causing non-uniform illumination. Using brightness control this problem can be corrected in real-time allowing measurements to be carried out over much greater distances. This is an important feature, for example

Advanced, Super Wide Field 3D stereo measurement is an invaluable tool for RVI as it helps to convert images into reliable, consistent, tangible data. The precision with which these measurements can be obtained, however, relies on using the very best optics and image processing software available.

All these elements have been brought together in the latest generation of industrial videoscopes for unprecedented quality and precision. www.olympus-ims.com

QMT September/October 2016 www.qmtmag.com

9

ARCHAEOLOGY

Pompeii: new secrets revealed Overturning previous stories and assumptions the CT provides new insights into the lives of those who lived at Pompeii

The Amphiteatre and Cast Exhibition was scanned using two scanners

Mapping the positions of fugitive figures

10

Mary Beard’s TV series used cutting edge 3D scanning technologies to unearth secrets of the ancient world

I

n the TV series ‘Pompeii New Secrets Revealed’ presenter Mary Beard, renowned classicist and TV historian, explored what life was like in one of the world’s most extraordinary and iconic archaeological sites.

Undoubtedly one of the most tragic gems of the Roman world, Pompeii has laid deep beneath the volcanic ashes of the Mount Vesuvius since the eruption of 79 AD. Utilising the latest in CT, laser and photogrammetric 3D scanning techniques viewers were able to peer inside the casts of Pompeii, reveal the position of slaves’ quarters hidden underground and examine in unprecedented detail the recently restored frescoes.

With help from expert Estelle Lazer and her team from University of Sydney the CT data and x-rays have allowed forensic archaeologists to challenge previous assumptions about their lives and discover the real identities behind the people unable to escape the eruption.

Captured in forensic detail, the scans of Pompeii represent one of the most comprehensive digitisations of Pompeii to date. Covering the whole archaeological site, the scans allow it to be explored like never before. The CT data, terrestrial laser scanning and aerial photogrammetry was captured on location in Pompeii over 10 days in September 2015.

ScanLAB Projects completed all data processing and graphics for the 60-minute documentary which was shown on the BBC in March this year. Transitioning seamlessly between live action footage and scan data, the programme showed Mary Beard as she appeared to wander through the pointclouds.

The ScanLAB team & drone pilot travelled to Pompeii in September 2015 with a traditional film crew and presenter Mary Beard. A CT scanner and technicians were provided from Phillips and housed onsite for the duration of the shoot.

The Amphitheatre and Cast

www.qmtmag.com

Exhibition was scanned using two FARO Focus3D X 330. The limited amount access required both scanners to be present in the same room simultaneously.

Referencing was completed with 145mm spheres and the alignment of data was improved with additional scan to scan alignment in scene. Approaching the location from opposite ends, two scanners were used to capture this location. ½ Resolution scans from high vantage points were used to capture the location context, whilst the other team captured the fugitive figures and gardens. Referencing was completed with 145mm spheres.

To provide a graphic overview of the archaeological site, the team’s pilot flew a fixed wing survey drone over Pompeii.

The images captured were processed in photogrammetry software (agisoft) to create a pointcloud which was merged with the datasets from the Focus X 330. 1250 images were taken in 6 separate flight paths over Pompeii.

All locations were aligned using FARO Scene 5.4 (at the time the latest version of Scene available). Following filtering and automatic target detection and successful target based alignment was completed for all locations.

The locations were then globally aligned via csv to DGPS survey points. Colour processing was completed in PTGui before application to the scan data in FARO Scene. scanlabprojects.co.uk faro.com

QMT September/October 2016

METROLOGY SOLUTIONS

DISCOVER THE BEST MEASURING ARM. YOURS.

Engineered specifically to address dimensional inspection on shop floors, the HandyPROBE Next™ portable CMM offers impressive accuracy and the ultimate in versatility.

VISION EXPERTISE AT YOUR FINGERTIPS. The reference book for designing imaging and machine vision solutions is now updated for 2016 Over 450 pages of technical basics, expert knowledge and state-of-the-art technology all in one place.

PPM T O TA L S A H OW 27 ‒ 29/09/2

016 NEC, Birm ingh Stand A4 am 4

NEW

■ 2X more accurate ■ Free of any rigid measurement setup ■ Sturdy design for shop floor hardware

reliability

+33 4 57 38 31 50 | www.creaform3d.com

@QMTMAG

QUALITY MANUFACTURING TODAY

Magazine

The International Magazine for Quality in Manufacturing • Print •App •Web

Request your free copy of the printed version or download the electronic version directly! www.stemmer-imaging.co.uk/handbook

iTunes

Imaging is our passion. www.stemmer-imaging.co.uk

www.qmtmag.com

AUTOMOTIVE

Getting a handle on Siemens’ engineers and software are helping Nissan Motor Company uncover the complex interaction between body flexibility and vehicle handling performance

A

12

dding extra stiffness to a car body can improve vehicle handling performance and the subjective driving experience, but established measurement techniques or computeraided engineering (CAE) fail to explain this relationship.

When designing a next-generation lightweight platform, any additional mass from stiffening elements should be carefully considered, and the right balance between handling and noise, vibration and harshness (NVH) should be maintained.

Simply adding body reinforcements based on experience or by trial and error is very inefficient, and can lead to undesired and expensive body design changes late in the vehicle development process. Therefore, automotive original equipment manufacturers (OEMs) look for technologies which enable thoughtful decision-making. LMSTM Engineering services experts from Siemens PLM Software conceived an innovative testing methodology that helped Nissan Motor Company get the required understanding to do so.

“Body development for handling performance usually takes a lot of time and can be a substantial additional part of costs,” notes Hitoshi Kyogoku, manager of the Vehicle Dynamics CAE Group at Nissan. He belongs to an integrated CAE department

that optimises vehicle performance using computer simulation. The department evaluates vehicle characteristics such as crashworthiness, strength, NVH and handling before testing them on actual cars, and is constantly looking for new technologies to improve accuracy and increase its application range.

When investigating the effect of body reinforcements on the driver, the engineers joined forces with their colleagues from the design and testing departments, and decided to involve experts from Siemens’ LMS Engineering business unit, to learn about new high-end testing methodologies.

Together, they conducted a detailed study involving different body variants, hoping to fully understand the relationship between body stiffness changes and their effect on handling performance.

www.qmtmag.com

QMT September/October 2016

A unique test approach on the track “LMS Engineering employs unique and highlevel measurement technologies, especially in operational conditions,” explains Mr Kyogoku. “That is very important for us.”

Approaches like static stiffness tests on the bench can quantify the effect of body reinforcements into a single static stiffness value, but when evaluating on the track, objective global vehicle performance quantities like yaw-rate, lateral acceleration or

at: See us EC how, N TCT S , stand Hall 3A F20 F18 &

RenAM 500M, for a new era of metal additive manufacturing Renishaw’s new metal powder bed fusion additive manufacturing system for industrial production, RenAM 500M, features increased emphasis on automation and reduced operator intervention. The system is the first to be designed and manufactured in-house by Renishaw, applying over 40 years of cross-sector engineering excellence that spans electrical, mechanical and optical technologies. Highlights include: • Renishaw designed and engineered optical system with 500 W laser • Automated powder sieving and recirculation with SafeChange™ dual filter system • RESOLUTE™ linear position encoder on Z-axis for high accuracy operation

For more information visit www.renishaw.com/additive

Renishaw plc Brooms Road, Stone Business Park, Stone, Staffordshire, ST15 0SH, United Kingdom T +44 (0)1785 285000 F +44 (0)1785 285001 E additive@renishaw.com

www.renishaw.com

AUTOMOTIVE roll angle are typically difficult to directly relate to body stiffness changes.

“The solution LMS Engineering experts presented could reveal the underlying mechanism,” says Mr Kyogoku. “LMS Engineering helped us identify forces and visualize body deformation in time domain, and that was very valuable information for us.”

Identifying operational forces Global vehicle handling performance quantities result from the combined effect of all forces between the suspension and body.

Understanding the underlying mechanisms starts by studying those individual contributors on the track, but accurate load identification is complex. Vehicle handling studies cover transient phenomena, usually dominated by lower frequencies.

Classic, acceleration-based matrix inversion often fails because of the bad numerical condition of the inversion matrix. At low frequencies, only a few independent body modes are involved, leading to a significant coupling between the transfer functions in the inversion matrix. LMS Engineering proposes an alternative matrix inversion method using strain responses. These are much more sensitive to local structural phenomena, enabling a better matrix decoupling, which allows accurate load identification in time domain.

LMS Engineering experts have vast experience with strain measurements. Being experts in both testing and simulation, they employ CAE to explore the proximity of the suspension to body interface points for strain hotspots, and the optimal sensor locations for matrix inversion. These significantly outnumber the forces to be identified, and represent sufficient diversity of body dynamics for a wellconditioned equation system. By combining operationally measured strains with laboratory force-to-strain transfer functions, the forces could reliably be estimated for the different body variants.

“We were very impressed with the results,” confirms Hitoshi Kyogoku. “The differences in the contributing forces due to the body reinforcements we tested could be well observed, with good repeatability. Accurate time domain body load identification was crucial to investigating what happened.”

Assumptions align with subjective feelings LMS Engineering experts and Nissan engineers collaborated on estimating the effect of the modified measured force distribution in the connection points on vehicle handling characteristics.

“LMS Engineering masters very high-level technical methods,” says Mr Kyogoku, “but the permanent and open communication between our engineers and the people from Siemens PLM Software was one of the most important factors that made this study a success.” This collaboration resulted in a clear indication of what an expert driver could experience on the track.

14

www.qmtmag.com

Both the force amplitudes and their time-delays with respect to the steering angle input (also called the ‘phase’ or the ‘body force build-up’) were important in these discussions. Studying the force interactions in detail, it was found that for evaluated modifications to a base model, a set of fast-acting lateral forces increased in level, while the vertical forces were redistributed over a fast and a slow load path.

As the lateral forces excite the body roll motion and the vertical loads counteract, a moderate change of transient body roll motion was assumed.

At the same time, the engineers expected limited effect on lateral acceleration because of mutual cancellation between the lateral forces. These objectively observed assumptions exactly matched the subjective feeling of the expert driver on the track.

Targeted design decisions For further in-depth investigation, the identified time domain forces were combined with a modal model of the trimmed body, made from transfer functions, measured in free-free boundary conditions. The resulting total body deformation could be animated, and decomposed into individual modal contributions. This allowed the study of the relative importance of global torsional and bending modes, as well as local flexibilities to the force mechanism, at each stage of the handling maneuver.

This was very informative when comparing the dynamic behavior of different body variants.

Compared to traditional static stiffness tests on the bench, which typically only provides one single stiffness value for the entire body, this method allowed attributing stiffness modifications to body modes. In the future, this knowledge can be used to investigate where structural reinforcements can be more effective, and will enable a more targeted approach to optimising body flexibility for vehicle handling.

Nissan engineers are looking forward to the next step. “We will try to reproduce the observed phenomena in CAE,” confirms Hitoshi Kyogoku.

Leveraging this knowledge for simulation purposes will lift this application to earlier stages of the design cycle.” www.siemens.com/plm/lms-engineering

QMT September/October 2016

AUTOMOTIVE

Driving down exhaust weight Metrology is at the heart of a project to halve the weight of exhaust systems for a luxury sports car An innovative project to develop a lightweight exhaust system for a luxury sports car has relied on Hexagon Manufacturing Intelligence equipment for quality control checks.

Coventry University’s metrology department used the ROMER Absolute portable measuring arm and G-Tube software to perform measurement and inspection tasks on a variety of parts and subassemblies.

The project, undertaken at the Institute for Advanced Manufacturing and Engineering (AME), initially examined ways of halving the weight of the complete cold end of the exhaust system.

A second phase, supported by Innovate UK, involved developing a production ready solution that delivered the product technology to market.

As part of these investigations, the metrology team also employed the ROMER Absolute arm to inspect parts in a robotic welding cell on the AME shop floor.

“Through the successful completion of the project, the consortium has proven the ‘art of the possible’ in exhaust light-weighting; namely the removal of almost 50 per cent of the weight from the cold end assembly,” explained Trevor

Toman, AME’s head of metrology.

The project had also effectively demonstrated how pre-market prototypes could be manufactured in a production representative environment, he added.

“AME enjoys a good working relationship with Hexagon whether it’s through the purchase and ongoing support for measuring arms, scanners, laser trackers and equipment access for small projects or the mutual delivery of continuing professional development to customers.”

The Institute for Advanced Manufacturing and Engineering, a collaboration between Unipart Manufacturing and Coventry University, currently has 60 budding engineers studying on its ‘live manufacturing’ degree courses. www.hexagonmi.com

BLAZE 600M BROADEN YOUR HORIZONS Combining high-resolution digital imaging with LED illumination, the BLAZE 600M portable blue light measurement system provides rapid data acquisition on the shop floor. With adjustable measurement fields and multiple data acquisition modes, BLAZE 600M is the versatile option for fast inspection and 3D meshing tasks.

HexagonMI.com

QMT September/October 2016 www.qmtmag.com

15

OPTICAL MEASUREMENT

Paul Thomas, development engineer at Clifford Springs, measuring the circumference of an irregularly shaped seal energising spring to an accuracy within single-figure microns on the Nikon Metrology iNEXIV VMA-4540 video measuring machine.

How long is a piece of spring?

A novel method uses video to measure the length of freeform springs to within single-figure microns

H

16

ow do you determine the diameter of a seal-energising spring after manufacture, while it is still an irregular loop of coil with its ends welded together and not yet formed into a circle by the seal it will eventually strengthen? The standard options are traditional circular go / no-go gauges for a specific size of large spring or a conical step gauge rising in one millimeter increments for a family of smaller sizes. However, Redditch-based Clifford Springs has established a more accurate process using a Nikon Metrology iNEXIV VMA-4540 CNC video measuring machine.

To a repeatability measured in single-figure microns, the optical measuring equipment automatically determines the length of a freeform loop of coiled spring to determine what its circumference will be when it is circular, after which dividing by pi produces a precise result for the diameter.

Clifford Springs now plans to use the iNEXIV VMA-4540 to count automatically the number of coils per unit length of spring, looped or unwelded, which predicts its load deflection characteristics in use. Compared with the present method of manually counting the number of coils in a given length and using a formula to extrapolate the total number for the whole spring, the optical method will be more precise.

Furthermore, measuring the angle between successive coils in a spring and their distance apart will be more accurate, as well as much faster,

than current manual procedures using an optical profile projector. Another important benefit is that an automated system eliminates the risk of human error.

Managing director John Clifford commented: “Customers are increasingly asking for reports with proof of the numerical values from our inspection of the springs we manufacture, but only transcription of manually measured results was previously possible. “Since May this year, the Nikon optical measuring machine has allowed us to print off actual readouts of spring diameter and soon coil count and geometry will be included. It has enhanced the perception of our metrology expertise amongst our customers and increased the confidence they have in our products and reports.�

Clifford Springs is one of only a handful of companies in the world that produces such a wide range of canted, helical, garter and meander springs for energising seals. Springs range in diameter from a few millimeters to around 300 mm and are mainly of stainless steel, although carbon steel, phosphor bronze and PEEK are also used in the manufacture of some varieties. Half of production output from the Redditch factory is supplied as coil for the customer to process, the remainder being cut and welded into individual springs. Addition of a spring to a seal provides extra resistance to outward radial forces imparted by a fluid or gas being conveyed under pressure.

www.qmtmag.com

QMT September/October 2016

OPTICAL MEASUREMENT

With 60% of turnover coming from selling springs into the global oil and gas sector, which is currently suffering a downturn, one would suppose that the company is currently going through a difficult period. This is not the case, however, as market share has been won due to the adoption of industryleading production processes, from coil winding to welding and now to product inspection. Other industries in which energising seals are widely used include the aerospace and automotive sectors.

Different inspection systems investigated Paul Thomas, development engineer at Clifford Springs said: “We considered several alternative systems for automating the inspection of our springs. They included blue and white light scanners, but they are better for comparative rather than absolute measurements, and traditional optical profile projectors, which are too reliant on manual intervention.

“Tactile metrology on a coordinate measuring machine (CMM) was discounted, as touch-probing would move the spring during inspection. Trials were carried out using a laser scanner on a CMM, but the resulting point cloud gave profile data that was difficult to translate into a length measurement.

“So an optical video measuring system was really the only option and we looked at three or four potential suppliers. The Nikon Metrology iNEXIV solution was the only one that worked successfully and has since proved very satisfactory in operation.”

He went on to explain that Nikon Metrology helped Clifford Springs to co-develop a novel method for measuring a spring’s length. The iNEXIV’s AutoMeasure software instructs the 2D measuring head to follow the contour of the loop automatically, repeatedly re-orientating itself and taking coordinates of points at the same height at intervals around the outside (or inside) of the spring.

The operator simply has to enter the start point, end point and measurement pitch.

Every measurement is taken at the peak of an individual coil of wire, which is automatically recognised, rather than in the adjacent troughs, so that the true outside or inside diameter of the spring is obtained. Between 500 and 1,000 sets of coordinates are captured, depending on the size of the spring.

Successive points are linked around the entire loop to create a series of very small, straight lines which are added together to determine the length, ie circumference of the spring. To allow for the fact that it is the arcs between the points that should really be totalled, AutoMeasure introduces a small correction factor that increases the measured length to arrive at the true circumference.

Each result is not only very accurate but also highly repeatable. If the shape of the same loop is altered on the iNEXIV table and the measurements are taken again, the lengths recorded have consistently been shown to be within a few microns of each other.

Nikon Metrology’s AutoMeasure software drives the iNEXIV VMA-4540. The software automatically calculates the circumference after individual measurement of a coil spring.

Above left, close-up views of spring measuring in progress, below left, a traditional go/nogo gauge for establishing the ID and OD of a specific size of seal energising spring is shown in the foreground. Pictured behind is a conical step gauge rising in one millimeter increments for measuring the diameters of a range of smaller spring sizes. Such hard gauging has been supplanted by the Nikon Metrology iNEXIV VMA-4540 video measuring machine at Redditch-based Clifford Springs.

Versatile platform The iNEXIV VMA-4540 at Clifford Springs is currently employed exclusively for two-dimensional inspection. The instrument does, however, have optical auto focus (AF) using the instrument’s generous 73.5 mm working distance, allowing measurement of depth. The facility is not used at the moment, as coil width is easily determined manually using a vernier caliper, but it remains a possibility if the manufacturer decides to increase the level of automation in the inspection of its products.

It is possible to fit a touch probe for capturing point data if, for example, sloping faces or undercuts need to be inspected. The probe is offset from the optical axis but works in the same 450 x 400 x 200 mm coordinate space, with only slightly reduced operating range. A stylus changer is provided, so it is feasible to mix optical and tactile measurements in the same cycle. The instrument’s versatility is further enhanced by a variety of illumination options based on episcopic, diascopic and eight-segment ring LEDs. Combining these enables accurate detection of low-contrast edges. www.nikonmetrology.com

QMT September/October 2016 www.qmtmag.com

17

AUDITING

What has changed in quality auditing? *Chris Eden is a Director of Quality Matters Limited, a management consultancy specialising in Management Standards and the systems needed to ensure certification by a UKAS accredited certification body.

Experienced consultant Chris Eden* looks at how quality auditing has been subject to a seismic shift during his career

My own experience goes back to the Defence Standards through BS 5750 and then on to ISO 9001. This is the route whereby Quality Assurance standards have evolved over the years into the latest version which uses the ISO annex SL format (10 Sections). It is instructive to note that Quality Assurance has become Quality Management.

Quality Auditing has also changed to keep pace with the development in Standards.

Auditors covering the Defence Standards, AQAP and BS 5750 often set themselves a target number of non-conformities (NCRs) to report, and would continue auditing until they found the requisite number of NCRs. Their Figure 1 – the evolution of prime objective was to find areas of nonquality assurance standards conformity.

DEF STAN Many 05-21 Defence Standards (Military Standards) auditors 05-24 05-29 prided themselves BS 5750 British Standard Quality Assurance AQAP on the 1979 number of NCRs they BS 5750 ISO 9001/2 could report.

Allied Quality Assurance Publications (Military) 1987 Of course, once the IS0 9001/2 auditor’s 1994 Quality Management Systems requirements were known IS0 9001 It became 2000 common Quality Management Systems practice IS0 9001 to leave 2000 a number of readily Quality Management Systems IS0 9001 identifiable 2008 errors for the auditor IS0 9001 Latest Quality Management Systems to find.

2008 An audit

18

www.qmtmag.com

became a battle of wits rather than an audit of the system. Audits were often unannounced and this resulted in NCRs being raised because personnel were not available; this was also very disruptive.

Training for auditors was a bit sketchy and it was quite normal for an organisation to send one auditor on a recognised auditor training course and then to expect that person to pass on the information to others; the message tended to get diluted and skewed after a while; think of ‘Chinese whispers’.

Other auditors became Registered with IRCA (International Register of Certificated Auditors) who require auditors to undertake auditor training and conform to a set of rules. Registered auditors have to undertake continual professional development to be able to renew their qualification on an annual basis.

The fear that organisations would correct any problems just before the audit were unfounded The 1994 version of ISO 9001 made some changes in the way audits were carried out and these relied on the auditor checking each clause of the Standard against the quality manual in use by the organisation. It also introduced the requirement for auditors to be adequately trained and competent.

External auditors would expect to see evidence/certificates of training for auditors.

When the 2000 version and its minor updates in 2008, was issued there was a change to the audit requirements; auditors were required to audit the processes, rather than the clauses of the Standard within the organisation; the

QMT September/October 2016

AUDITING prime requirement was to confirm that the processes were working correctly rather than just looking for non-conformities.

It was fine to have zero non-conformities and the practice of target numbers of NCRs was no longer used. Unannounced audits were discouraged as it became clear that prior notice would allow the organisation to have critical people present. The fear that organisations would correct any problems just before the audit were unfounded as any good auditor will see any attempt to fix problems and then hide all evidence that this has been done.

ISO 19011:2002 (Guidelines for Management Systems Auditors) was published. All auditors were required to undergo training to ensure that their knowledge of the revised ISO 9001 was up to date.

This Auditing Standard was updated in 2011; It was recognised that first/second party audits were quite different from third party audits. First party audits are those carried out on their own organisation (internal audits) and second party audits (typically audits of suppliers). Third party audits are carried out by Certification Bodies for awards of compliance certificates). Third part audits are now covered under a separate Standard ISO 17021 and are not discussed here further.

The ISO 19011:2011 Auditing Standard allowed audits to be carried out remotely

by telephone or video conference, where this did not compromise the audit. Travelling for six hours to spend one hour auditing was always counter-productive. The Standard also requires that the selection and competence of auditors had to be evaluated.

The latest version of ISO 9001:2015 was a major change in the way the Standard was being operated, not only did it use a new format (Annex SL) but it made ‘risk thinking’ a major part. The requirement for procedures was no longer mandatory.

Auditors would be required to confirm that the requirements have been met by interview with top management. In some instances, audits will need to be longer as It may take time to gain information and evidence that actions have been taken and are effective.

It became obvious that auditors would need to undertake transition training to the requirements of the new Standard in order to understand the changes and then apply this to auditing.

All auditors are required to transition to the new systems or lose the qualification. IRCA mandated that registered auditors had to attend a two-day transition course and pass the course elements before the deadline of September 2018 or the qualification would be withdrawn. www.quality-matters.com

AUTOMOTIVE

Magnetic performance Innomech has developed a high speed packaging system for ST Technologies A new system incorporating a laser micrometer will help SG Technologies, which produces high performance magnetic components, to more than double the production capacity for one of its highest volume products.

Innomech has designed the new system to automate a particularly labour-intensive and repetitive product packaging process for a series of components that are used within automotive fuel injectors. The new fully customised system gives SG Technologies the option to increase production throughput for this product line by 150%, while also improving its manufacturing process efficiency and reducing work in progress.

The automated system eliminates all manual handling of finished magnetic components as they are being transferred from work in progress trays into specially-designed packaging trays ready for shipment. It has also been configured to handle two distinct product families, each containing multiple variants and without requiring any manual adjustment.

The system works by gently sweeping the components onto a conveyor belt, a high speed laser micrometer verifies the height of each part to within a few microns, and then a Codian ‘pick and place’ robot transfers five components at a time into a packaging tray.

“Innomech has developed the ideal system to automate a potentially rate-limiting product packaging process and to provide us with increased flexibility and capacity to meet fast-growing and changing customer demands. The system also removes any risk of potential damage to products through manual handling which is critical in our drive towards zero defect manufacturing and even greater process efficiencies,” said Stuart Hutcheon, commercial director at SG Technologies. www.innomech.co.uk

QMT September/October 2016 www.qmtmag.com

19

AUTOMOTIVE

Check it twice A US automotive supplier uses weighing to automatically verify parts

Fig 1 – The display shows green if the part count is right

20

Mistakes happen—especially when workers complete repetitive manual tasks, such as parts counting. In an effort to meet customer requirements and ensure its boxes contain the exact number of pieces, a top engine valve supplier to the automotive industry added an automatic second check for each shipment.

US Engine Valve ran into a problem when an important automotive manufacturing customer required the company to upgrade its verification system for counting engine valves.

Although the company has supplied top-notch engine valves to the automotive industry since 1987, its verification process had room for improvement. To meet this important customer’s demands, it had to incorporate a two-step automated check of counts for each shipment. Previously, US Engine Valve operators visually checked the number of engine valves in each box and recorded it manually. As with any manual process using hand-written record-keeping, mistakes can easily be made.

US Engine Valve Manufacturing Engineer Joshua Robinson contacted Mettler Toledo distributor Everest Scale to find a solution. The solution was a combination of the ICS685 Weighing Terminal and the PBD655 Bench Scale Platform. This intelligent combination paved the way to improve record verification, efficiency and accuracy – all while dramatically reducing human errors.

With this new system implemented, electronic verification has reduced the

www.qmtmag.com

Fig 2 – If the part count is wrong the light shows red or yellow

errors that could have cost the company reputational damage and affected the bottom line. The ICS685’s colorWeight feature clearly indicates if the target weight range has been reached. The colour indicator allows operators to quickly determine whether the package weight is correct with a quick flash of a green light. Errors are shown with a red or yellow screen, meaning the count is off and the box either has too few or too many parts inside. In addition, the ICS685 stores accurate weight records of each box shipped.

The terminal’s memory allows the data to be stored and transferred to another device for a third check, if needed. With memory enabled, the scale records all transactions internally and these can be extracted into a CSV file via a USB drive or by connecting to DatabICS software. The memory cannot be edited or tampered with, which helps operators ensure that the results shown are the actual transactions that occurred over the scale. The credible results can be compared to the manually written records to locate discrepancies.

Besides enhancing its accountability, US Engine Valve’s production line has become more efficient and it takes less time to move products through the production line.

Mr Robinson says: “Saving time has been a big benefit and improved record accuracy have been extremely helpful.”

His company has been able to catch errors before shipments get to customers, which has increased overall customer satisfaction.

He says this was the first time he had heard of using scales for counting validation.

In the future, US Engine Valve plans to use weighing equipment for complete inventory tracking.

Mr Robinson adds: “Our inventory records have increased significantly, allowing us to look at discrepancies between when we have downtime and when we’re operating.” www.mt.com

QMT September/October 2016

The UK’s largest meeting place for advanced engineering professionals

Join us where the familiar and the unfamiliar collide to provide“Fantastic…I new opportunities thinkacross this the engineering “…the corridors ha is the best year yet” and they are our de supply chain.

Dave Withey,

“Fantastic…I think this is the best year yet” Dave Withey, Senior Project Engineer, Research, Jaguar Land Rover

Graham Mulholland,

AdvancedSenior Engineering the industry eventManaging whereDirector, Project Engineer,is Research, Jaguar Land Rover epm: technology group high-technology manufacturing sectors converge under one roof to meet and do business. “…the corridors have been full all the time, and they are our decision makers” Graham Mulholland,

Managing Director, “Fantastic show…lots of interest, not just from epm: technology group aerospace but from automotive and other sectors” Robert Richards, BDM, Metrology Software Products

“Fantastic show…lots of interest, not just from aerospace but from automotive and other sectors” Supported by: Robert Richards, BDM, Metrology Software Products

“It wa minde sport got so

LCL Elect

“It was fantastic to meet with likeminded people…especially in motor sports and hybrid power…We’ve got some great leads to follow up” LCL Electronics

Contact us about exhibiting today gg +44 (0)20 8843 8800 or visit www.advancedengineeringuk.com

ROUNDNESS

Quality in the round at Kawasaki A leading hydraulic technology manufacturer is using Mitutoyo equipment to ensure roundness on pistons and cylinders

KPM’s Mitutoyo’s Roundtest is capable of both form and surface finish measuring

22

Located in Plymouth, Kawasaki Precision Machinery UK Ltd (KPM UK) is the centre for Sales, Engineering and Manufacturing for Kawasaki hydraulic components and systems, including the world famous Staffa radial piston motor, for Europe, the Middle East and Africa.

As the pistons and cylinders and other ‘round’ parts of Staffa products have extremely challenging dimensional tolerances, KPM UK recently searched for a roundform system that could enable attributes, including roundness, straightness, flatness, concentricity, coaxiality, perpendicularity and runout to be measured to extremely demanding levels of accuracy. It decided on a top of the range Mitutoyo Roundtest Extreme RA-H5200CNC, CNC Roundness/Cylindricity Measuring System.

KPM UK Measurement Technician David Surcombe explained: “Although our existing roundness and form checker remained in good working order, we were aware of the progress made in roundness checking technology in terms of usability, speed and accuracy. Also as a larger, heavier product was about to be added to our Staffa range we needed a machine that could not only accommodate these new bulkier parts, but also remain future-proof if further even larger products were introduced.

“The Roundtest Extreme from Mitutoyo proved to be the ideal machine for our needs. Although our decision was based on specification and not price, the Mitutoyo machine also proved to be the least expensive of the options.

“Following a trouble free installation of the Mitutoyo Roundtest Extreme RA-H5200CNC and on-site training, we were soon able to master the system and to perform complex component checks. It helped that Mitutoyo’s Roundpak software is very intuitive and simple.

As the vast majority of our inspection routines are carried out on the same families of parts.

We have already written many part programs with the help of Roundpak’s easy to use offline programming function.

“We are now able to load a component on to the Roundtest Extreme and make use

of the machines advanced self-centring ability, this considerably speeds-up the part loading process. We then recall the relevant program and instigate a fully automatic, fast CNC measuring routine. On completion, in addition to presenting all of the relevant accurate dimensional, geometric and surface finish information, Roundpak’s clear graphics provide an instant visual indication of the status of all of the features being inspected.

We are then able to download and archive this information.

“When compared to our older machine, in addition to enhanced precision and additional functions provided by our new Mitutoyo Roundtest Extreme, its impressive speed has increased the throughput of roundness and surface finish work in our busy inspection department.

“As our new Roundtest Extreme has a maximum workpiece diameter of 680 mm and a weight capacity of 80 kg, not only is it capable of inspecting our new, larger parts, it should also be able to accommodate all future anticipated parts.”

Mitutoyo’s Roundtest is capable of both form and surface finish measuring. A linear scale incorporated into Roundtest machines’ X-axis, enables measurement to be taken while tracking the workpiece surface. This capability is most effective when measuring a diameter difference involving a displacement that exceeds the detection range of the probe, or a taper that can only be measured with a slider/column movement.

Roundness and surface roughness measurements are both available from a single measuring system therefore workpiece resetting for roughness measurement is not required. In addition, roughness measurement is possible in the axial and circumferential directions. www.mitutoyo.co.uk

www.qmtmag.com

QMT September/October 2016

CMMS

Accuracy focus on the power train

The CO2 reduction capability of CPT’s products relies on accurate components

An Aberlink CMM is helping CPT make more efficient power train components Controlled Power Technologies (CPT) specialises in the development of cost-effective CO2 reduction measures for the global automotive industry that avoid major redesign of the powertrain or vehicle electrical system.

Core competencies include low voltage power electronics, advanced control software and the application of low voltage switched-reluctance machines (SRMs) to gasoline and diesel powertrains - providing innovative mild hybrid vehicle solutions.

CPT is focused on bringing its liquid-cooled Cobra, SpeedStart, SpeedTorq and Tigers technology to mass market readiness. Based on the same core SRM architecture, Cobra is a high speed (70,000rpm) motor for electric supercharger applications which shares the same platform as the Tigers high speed (70,000rpm) high temperature tolerant generator for the recovery of thermal and kinetic energy from fast flowing exhaust gases.

SpeedTorq is a 20,000rpm SRM designed for low voltage (<60V) mild hybrid applications in the driveline, thereby complementing the SpeedStart engine mounted starter generator. While Cobra is focused on trucks and buses, SpeedStart, Tigers, and SpeedTorq applications are aimed at a wide variety of cars and commercial vehicles.

The advanced nature of CPT’s products and the high rpm speeds they operate at dictates that all critical components have extremely demanding dimensional tolerances. To help ensure that the required levels of manufacturing precision are adhered to the company administers a stringent quality control system. As the demand for CPT’s products is rapidly growing, to allow the company’s inspection function to keep pace with increased

QMT September/October 2016

production investigations were recently made into the availability of high precision, rapid acting advanced measuring systems. The solution to CPT’s quest for both accuracy and speed of inspection was found in the Axiom Too Coordinate Measuring Machine from Aberlink.

CPT Manufacturing Engineer, Remie Hayter said: “In addition to their designs, the CO2 reduction ability and the reliability of our products is based on the accuracy of their component parts. Although we have a range of precise measuring equipment, when the need occurred to inspect certain geometrical features we have been using external inspection resources. As our production levels have now ramped-up the need for a more efficient, universal component inspection method became more urgent.

“Our Aberlink CMM is able to precisely measure each of the geometric features on all of our components and to provide rapid feed-back to production. In addition we use the Axiom Too to verify the accuracy of received components in our Goods Inward Department; we also use the Axiom Too as an invaluable aid for our R&D department.”

Available in manual and CNC variants, the Axiom Too is Aberlink’s best-selling CMM It has an aluminium bridge with a very low thermal mass, rendering it ideal for use either in controlled environments or within less than perfect shop-floor conditions. Advanced materials give reduced inertia for fast operation and air bearings are used on all axes for optimised stiffness. A granite Y Beam allows preloading of bridge bearings in both directions. www.aberlink.co.uk

www.qmtmag.com

23

MOTORSPORT

Doing their level best Carlin Motorsport uses digital inclinometers to ensure optimum performance Bowers Group has supplied Carlin, a professional motor racing team, with several Wyler Clinotronic PLUS digital inclinometers.

The inclinometers are used in the workshop, garage, and at the track, making them a key tool in the set up and maintenance of Carlin’s motorsport cars.

Based in Surrey, Carlin is one of the largest teams outside Formula 1, with race experience in a variety of championships including British F3, Porsche Supercup, World Series by Nissan, Formula Renault 3.5, A1GP, FIA Formula 3 European Championship, GP3 Series and GP2 Series. Some of today’s most successful drivers have passed through the doors of Carlin, with famous names including F1 drivers Sebastian Vettel, Daniel Ricciardo, Kevin Magnussen and Daniil Kvyat.

The Wyler Clinotronic PLUS is a robust shop-floor proof digital inclinometer with 4 machined faces, permitting the measurement of angles through 360o. The inclinometers are used in the workshop on a daily basis to set up surface tables. Here the inclinometer is used in its absolute function to check that the surface table is level before work on the car commences. It is then used on various parts of the vehicle whist the car is mounted on the surface table.

Several important criteria are measured using the inclinometer. Machined areas on the chassis are used as a reference point, where the inclinometer is set to its relative function in order to act as a guide for relative measurements. The relative function is also used to set the angles of the wings in relation to the chassis. The steering is checked; Carlin engineers set the inclinometer relative

24

www.qmtmag.com

to the chassis and then place it on top of the steering wheel to set the angle to zero.

The camber and caster of the wheels are also checked, ensuring the correct wheel alignment of the vehicles.

Carlin engineers use the inclinometer at the race track to establish a level patch for any adjustments and maintenance to vehicles as required. It is used in its absolute function to ensure that the patch is completely flat. If a car crashes, or if a driver is struggling with a set up issue and the car needs to be adjusted, the patch can be used as a level base to ensure all measurements are accurate.

Carlin also uses a Clinotronic inclinometer to set up scale versions of cars in their offsite wind tunnel, allowing engineers to measure the downforce and drag of the car in a controlled environment.

F3 Chief Mechanic Ian Grant said: “The Clinotronic is very versatile; we use it in a variety of ways both in the set up garage and out on the circuit. For such a small piece of kit it is actually very important.

“The WYLER is used a bit more on F3 vehicles than other teams. This is because a lot of the other teams have a fixed wing angle requirement, as well as various standard measurements that need to be met. F3, on the other hand, is a championship where we have the flexibility to make more of our own components. For example, we are allowed to set our own angles for the front wheel blanks and the rear wings. Over a race weekend, the inclinometer is used to check that these have remained at a consistent level.” bowersgroup.co.uk

QMT September/October 2016

NEW FEATURE FOR 2016

CAD/CAE SOFTWARE 3D PRINTING ADDITIVE MANUFACTURING MOULDING & TOOLING MACHINE TOOLS METROLOGY INSPECTION

28 SEPT - 29 SEPT 2016

REGISTER NOW

ADDITIVE MANUFACTURING

Better wings quicker

Clive Martell, Renishaw’s Head of Global Additive Manufacturing says this is a fantastic opportunity to test the capabilities of AM

26

New research investment will shape the aircraft of the future

Renishaw is contributing its additive manufacturing expertise to a new £17.7 million project, being led by Airbus in the UK, to develop an innovative way of designing and manufacturing aircraft wings, which will encourage a “right first time approach” and reduce development time.

More than 30,000 new aircraft are expected to be required in the next 15-20 years, replacing existing in-service models and also to expand airlines’ fleets as the number of air travellers increases.

The project, called Wing Design Methodology Validation – or WINDY - has been made possible thanks to joint industry and UK government investment from the Department for Business, Energy and Industrial Strategy (BEIS), supported by the Aerospace Technology Institute (ATI). It was one of a number of projects announced by BEIS during the Farnborough International Airshow.

“Aircraft wing design is a hugely complicated process and this project will look at ways we can increase the robustness of the design and test process while also reducing the time this takes,” said Airbus Chief Operating Officer Tom Williams. “Developing state-of-the-art technology will be at the heart of achieving these improvements and this investment is vital for that.”

The project will be led by a team from Airbus in Filton, Bristol, which is a global centre of excellence for wing design, development and testing. As a key partner, Renishaw will provide its expertise in metal additive manufacturing (3D printing) and precision measurement.

“This is a fantastic opportunity to work with Airbus and other project partners to develop processes that will fully test the capabilities of additive manufacturing,” said Clive Martell, Renishaw’s Head of Global Additive Manufacturing. “If we can highlight the design and production benefits of this technology in one of the most demanding industry sectors,

then it paves the way for greater of adoption of AM for serialised production in many other applications.”

WINDY will look at aerodynamic modelling of wings, the potential for use of complex 3D-printed components in wing structures and the possibility of innovative loads control on aircraft for better efficiency in flight.

“One of the key aims of the ATI’s UK national aerospace strategy is to sustain and grow the UK’s global leadership in aircraft wings,” said Simon Weeks, Chief Technology Officer of the Aerospace Technology Institute. “The WINDY project is a key element of this aim, securing essential wing design and integration capabilities in the UK and opening the way to innovative 3D-printed wing components.

These will lead to lighter and more efficient wings, which will be needed for future generations of greener airliners.”

The Aerospace Technology Institute (ATI) was established in 2013 to develop a technology strategy for UK aerospace and to ensure that industry and Government get the best economic return for the UK economy from their joint investment in aerospace R&D. The UK aerospace industry is the No1 in Europe and second globally only to the United States, with particular strengths in wings, engines and advanced systems and helicopters. The sector supports more than 3,000 companies distributed across the UK, directly employing 116,000 people, 4,100 of which are apprentices and trainees and supporting many thousands more in adjacent sectors. Since 2010, the sector has grown by 5% each year, spurred on by the Aerospace Growth Partnership (AGP), which brings industry and Government together to tackle barriers to growth, boost exports and grow high-value jobs. www.renishaw.com

www.qmtmag.com

QMT September/October 2016

TCT PREVIEW

If you can’t measure it, you can’t make it

The Inspex show is returning alongside TCT Show + Personalize 2016 At this year’s TCT Show + Personalize the organisers, Rapid News Publications Ltd, will reintroduce the Inspex brand to the UK market, throwing the spotlight on the challenges and opportunities for metrology and inspection within the 3D manufacturing industry.

Rapid News acquired the Inspex brand when executing the purchase of the Interplas trade show in 2014 and has since been developing the best way to bring the brand back to market in a way that would enhance the focus on metrology and inspection technologies on the show floor at TCT. For the 2016 show all providers of metrology and inspection hardware, software and services will be given enhanced visibility through a specific Inspex marketing program, including the show planner, show preview and on-site guide — as well as being highly visible on the show floor and in locators and show maps.

Inspex exhibitors include Nikon, Renishaw, Europac, Olympus, Central Scanning, FARO. Measurement Solutions, Volume Graphics and, making its TCT show UK debut, North Star Imaging.

Also featuring for the first time will be the Polish manufacturer SMARTTECH, now represented in the UK by Croft Additive Manufacturing. The company offers a full range of contactless 3D measuring systems, capable of mapping objects to the highest levels of accuracy. Smarttech3D scanners are used by some of the world’s leading companies including Volvo, Volkswagen, General Electric, Bosch and Whirlpool.

Alongside the show floor focus will be a dedicated Inspex seminar session highlighting the latest technology available along with real-world applications designed to pose the

QMT September/October 2016

FARO live at TCT 2016 FARO UK will present many of the company’s cutting-edge metrology products at TCT Live 2016, including the recently launched Design ScanArm. The Design ScanArm is a portable 3D scanning solution tailored for 3D modeling, reverse engineering, and CAD-based design applications across the product lifecycle management (PLM) process.

The FARO Design ScanArm features optically-superior blue laser technology with fast scanning speed to deliver highresolution point cloud data and the ability to seamlessly scan challenging materials without the need for spray or targets. The device is lightweight and maneuverable for convenient desktop mounting in the design studio or engineering lab and features a simplified user interface that makes it easy to operate regardless of skill level or 3D scanning experience. www.faro.com right questions and deliver the right answers Head of Content at TCT Show + Personalize, Jim Woodcock, said: “The re-introduction of the Inspex brand signposts our intent to bring metrology and inspection to the fore as advances in manufacturing technology continue. TCT’s core focus has been on additive technologies since we started covering rapid prototyping in the 1990s and as these technologies mature the role of supporting and enabling technologies becomes more prominent. 3D design, manufacture and metrology must work together as part of a chain to get the most out of today’s technologies.” www.tctshow.com

www.qmtmag.com

27

INFOTAINMENT

Testing infotainment systems at VW

Volkswagen’s Interactive Electronics Test Facility ensures that Infotainment Systems in every car function accurately and reliably

The Volkswagen Corporation tests its Infotainment Systems by optical character recognition technology

A

t Volkswagen Corporation, the testing department, and specifically the Interactive Electronics Test Facility, makes an important contribution to the usability of the increasingly complex interactive electronics found in their vehicles. The team of engineers ensure that Infotainment Systems in every car function accurately and reliably. To improve their automated testing processes, engineers from Volkswagen introduced ABBYY FineReader OCR technology to verify the content of the Infotainment Screens.

More exact, more efficient

The main communication between driver and vehicle takes place through the Volkswagen Infotainment System. Due to the variety of Volkswagen models and different corresponding equipment options, the testing engineers face great challenges: because of the large amount of software and many new features and functions in the systems, it is not possible to prevent errors from occurring. The logics between features are, in practical terms, very complex and the degree of networking between functions is also very high.

Moreover, software updates for various models and display variants in different languages are issued every two weeks. All of this necessitates a thorough testing system to be employed.

In order to pre-test the information that the driver obtains from the Infotainment Systems while driving, the test engineers set up optical inspection systems. The testing department develops its own verification methods for fully automated tests of individual infotainment components. First, the display contents are captured as an image and then converted into plain text using OCR (text recognition technology). The results are then

In the past Volkswagen used other text recognition systems but they had some disadvantages: “In order to differentiate between real errors, and alleged error messages which were based on incorrectly recognised text, we had to continuously optimise and train the text recognition, which was a very time-consuming process,” says Rolf Nissen of the Volkswagen Interactive Electronics Department.

The next problem was that display contents with coloured text caused many problems in the past, because it was too difficult to differentiate between graphics or actual text.

Finally, since the Interactive Electronics Test Facility also verifies all Infotainment Systems for Volkswagen markets worldwide, any problems with the system must also be detected in different languages. “For example, Dubai is a very interesting market for Volkswagen. However, the menu navigation for the cars which have been manufactured for this region is only available in English at the moment,” says Nissen. “This will soon change, so that Arabic will also become a part of the testing process.” After looking at the challenges Volkswagen knew it needed to find a more robust OCR technology in order to better carry out testing. In the search for a suitable solution, the Volkswagen employees came across the ABBYY FineReader Engine software development kit.

The decision-makers at Volkswagen were quickly convinced about its advantages – high OCR quality

www.qmtmag.com

QMT September/October 2016

Reliable Driver-Car Communication

28

compared with the existing database and the metadata stored there. If the text does not match the information stored in the verification database, the discrepancies and errors are automatically entered into the logbook.

INFOTAINMENT

and accuracy; up to 198 recognition languages, including Arabic; special functions for pattern training and compiling dictionaries. ABBYY FineReader Engine impressed the testing engineers so much that Volkswagen quickly decided to adopt the solution for its testing process.

Success story: from evaluation to application As a first step, ABBYY FineReader Engine OCR technology was initially evaluated on a set of sample images. The purpose was to determine to what extent the solution could be integrated within Volkswagen’s existing processes. This phase, spaced over many months, was conducted without problems and to the full satisfaction of the client. Volkswagen could then incorporate ABBYY technology into further practical testing at other facilities.

After six weeks of implementation the system was fully operational. As a result, Volkswagen could read and process up to 600,000 characters per day using ABBYY FineReader Engine technology. This vastly increased the quantity of Infotainment Systems that the department could test each day. Following this success, the new solution was implemented at the remaining 60 testing facilities, so that even more Infotainment Systems for different makes and models produced by Volkswagen could be tested.

The test department put high demands on the performance of ABBYY FineReader Engine in its testing system. “The results were extremely good.

Although we did not measurably tweak the OCR technology, ABBYY FineReader Engine recognised text within complex images straightaway” explained Serap Askar, manager of Image Processing Department at the Volkswagen Test Facility. “The API was so well documented that we could quickly implement the technology at five of our test facilities. The test points, which are furnished with the ABBYY FineReader Engine, can respond flexibly – even to short-term changes – such as updates to the menu navigation. The results were comprehensible, reproducible, and applicable to other environments.”

The optical inspection system based on ABBYY FineReader Engine significantly shortened testing times and also contributed to a major increase in testing accuracy. Finally, the improved quality assurance of the Infotainment Systems also resulted in Volkswagen customer satisfaction. Considering that there were more than 200,000 cars registered

by Volkswagen Corporation customers in Germany in Q1/2011 alone, the increase in customer satisfaction has produced a significant reduction in costs for Volkswagen. www.abbyy.com

Above, Volkswagen could read and process up to 600,000 characters per day using ABBYY FineReader Engine technology, above left, the optical inspection system based on ABBYY FineReader Engine significantly shortened testing times

NDT

SOLUTIONS CODE-COMPLIAN

T

EXPERIENCE UNPRECEDENTED SPEED, ACCURACY AND TRACEABILITY FOR PIPELINE INTEGRITY. ▬ Pipecheck is the simplest solution on the market. In just 3 steps (Scan-Analyze-Report), get sophisticated results that cannot be generated from any other technique. This is a unique solution designed to provide instant results and maximum efficiency. +33 4 57 38 31 50 | www.creaform3d.com

QMT September/October 2016 www.qmtmag.com

29

SHOW PREVIEW

VISION 2016 in view 3D machine vision turns out to be an ultra-versatile technology

Jana Bartels, Product Manager at Basler AG, in Ahrensburg, Germany: “The trend towards Industry 4.0 is already a significant factor in the field of 3D machine vision and will continue to increase in importance.”

Images of the data cloud: Thanks to 3D point cloud generation, mvBlueSIRIUS can capture 3D data for moving objects in real time and with a sufficiently high resolution.

30

Industry 4.0 perspective: In Stuttgart, Basler, ODOS, LMI and Matrix Vision will all be demonstrating the transformation from traditional machine vision to production optimisation.

According to the organisers of VISION 2016, which takes place in Stuttgart from 8 to 10 November, traditional machine vision is morphing into an intelligent tool for production optimisation – taking on far more than pure inspection tasks.

For example, the show will feature 3D technology with which users can improve logistics handling and which they can use in conjunction with data glasses for ‘augmented reality’.

There is an increasing tendency among users to view such 3D systems as multi-functional devices to which they can entrust a plethora of tasks says Jana Bartels, Product Manager for 3D/ToF at Basler AG. She says: “There is growing interest in 3D cameras, for example for process automation and monitoring, to simplify the control of robotic systems, and to optimise, and increase the security of, man-machine interfaces.”

Among the highlights she cites is a collaborative project between Jungheinrich AG and the Hanover Institute for Integrated Production (IPH) with Basler AG, and Götting KG as well as the Institute for Technical Computer Sciences (ITI) at the University of Lübeck (Universität zu Lübeck). This project resulted in the creation of a high-reach fork-lift truck that understands human language and uses 3D machine vision to interpret gestures. This project points the way to future communications between man and machine.

Ms Bartels comments on a number of emerging trends: less complex 3D systems are in the pipeline incorporating faster sensors with higher resolutions, which will be easier to operate. Rather than focusing on the initial capital acquisition costs, users will be more concerned with the Total Cost of Ownership. Among other things, Basler will present cameras with an LVDS-based

www.qmtmag.com

BCON interface for embedded vision systems and the new time-of-flight camera at the VISION trade fair. As she explains: “It is the first industrial VGA camera available in the mainstream price segment that works on the ToF principal.

Discuss trends before they become established Ritchie Logan, Vice President of Business Development at odos imaging limited, Edinburgh, views Industry 4.0 as an important driver for innovation in the vision sector. “Industry 4.0”, he explains, “and the new 3D Time-of-Flight technology meet a wide range of user desiderata.

That helps us to develop new solutions in connection with Industry 4.0 and Logistics 4.0.”

As the world’s largest trade fair for machine vision, VISION is extremely important to odos imaging, because, as it reports: “we get the opportunity here to hear about new trends for the first time and to discuss them with customers and potential users before they become established.”

In addition, the VISION trade show offers good opportunities for networking with other companies within the sector. “We return home with all of these impressions and data in our luggage to get on with doing what we do best as a hardware company; developing new solutions for current challenges.”

The Scottish company will be presenting new developments such as StarForm, a high-resolution 3D ToF camera, and the StarStop event recording camera with freeze motion function.

The customers of the Berlin-based LMI Technologies GmbH are particularly concerned with three significant factors: reliability, rapid and precise measurements and easy operability.

“Our products are used in 100% in-line control scenarios”, LMI’s Managing Director, Terry Arden explains. “Our customers often use our technology in harsh environments.” For that reason, the devices need to be sufficiently robust to ensure that they still perform extremely well in spite of vibrations or dust. In addition, there is a requirement for precise measurements even in the face of high production speeds. As Arden goes on to say: “Our sensors deliver a high resolution thanks to which, crucial quality features of a given component can

QMT September/October 2016

Zero rejects with machine vision

Machine vision systems recognise the smallest defects in large quantities and at maximum speeds. 100 percent monitoring, uninterrupted documentation and the ability to track each stage of production minimise rejects and maximise profit.

For newcomers and professionals: find out all about machine vision at VISION.

8 â&#x20AC;&#x201C; 10 November 2016 Messe Stuttgart, Germany www.vision-fair.de

SHOW PREVIEW At the VISION trade fair, LMI will be presenting their most recent CMOS technology (Gocator 2410 smart 3D laser line profiler, Gocator 3506 smart 3D snapshot sensor), which, according to the company’s literature offers the highest resolution within the entire sector at 2 and 5 mega pixels respectively

Right, odos imaging will be presenting the high-resolution StarForm 3D-ToF-camera, far right, thanks to the BCON interface, the LVDS-based Vision technology can be realised as a board-level camera,

be precisely identified and verified with a high repeatability rate.” The user-friendly operation is equally important, he goes on to say. Among other things, the customers expect a simple set-up process, effective 3D visualisation of a scanned component, and drag-and-drop mensuration tools.

To withstand these challenges, LMI incorporates CMOS chips and embedded technology into the chips. At the VISION trade show, LMI will be presenting their most recent CMOS technology (Gocator 2410 smart 3D laser line profiler, Gocator 3506 smart 3D snapshot sensor), which, according to the company’s literature offers the highest resolution within the entire sector at 2 and 5 mega pixels respectively.

Rapid Capture of Moving Objects For the customers of Matrix Vision GmbH from Oppenweiler, the rapid acquisition of 3D data from moving objects is crucial. According to Technical Director Uwe Furtner (MEng.): “Our solution, which involves real-time 3D point cloud generation with a sufficiently high resolution level fully meets this requirement.” He goes on to explain that rapid 3D data capture is also desirable because it represents a valuable addition to Industry 4.0, because of its outstanding ability to be integrated into networked environments. For quality checking purposes, he says, users can compare the CAD data directly

32

www.qmtmag.com

online with the results of the calculated point clouds.

Rather than representing a pure 3D solution, the company’s mvBlueSIRIUS product, which will be on display at VISION 2016, consists of a 6D camera which provides movement vectors and RGB colour data in addition to 3D point clouds. According to the Managing Director: “In addition to a pure data calculation, our camera is able to recognise objects, which can be described in terms of data relating to shape, colour, size and velocity.” The special thing about this 6D recognition is that it makes it easier for people to use who have no experience with algorithmic output analysis.

“User exectations of the machine vision industry are increasing steadily”, says Thomas Walter, Divisional Head of Industry & Technology at Messe Stuttgart explains: “Whether the machine vision customers are active in the automotive, pharmaceutical, food and drinks, packaging, transport or logistics sectors, what the industry requires for production processes and logistics is increasing precision, speed, and data processing power. How this demand is being met can be seen at VISION”.

Over 400 exhibitors from 28 countries are expected in Stuttgart this November. www.messe-stuttgart.de

QMT September/October 2016

PRODUCTS

Wire crimp tester Mecmesin has launched the CrimpTest-1 kN, a rugged and rapidthroughput tester for quality testing wire terminal strength. It features simple controls combined with accuracy and ease of use to give a reliable everyday tester, requiring minimal training and maintenance.

Motorised pull testers improve accuracy and reduce operator strain and injury. For added safety, this ergonomically-designed horizontal tester pulls samples away from the user. A single button press runs a test, and just 4 multi-function buttons provide for all settings, operation and output to an RS232 statistical printer.

Peak force at break is displayed along with clear pass and fail indication. Four speed settings are available: 25, 50, 100 and 200 mm/min. to comply with all regular test standards. Units of force can be displayed in N, kgf or lbf.

This bench tester is competitivelypriced and designed for continuous use within the production environment. It is IP52 rated against ingress from dust, wire fragments and water. www.mecmesin.com

Shopfloor surface gauge The 4D Technology 4D InSpec Surface Gauge is a handheld, noncontact instrument that measures precision machined surface defects with micrometre-level resolution.

TD’s patented technology allows rapid measurements that are unaffected by the vibration present

in most manufacturing environments, so repeatable precision surface measurement can be made in factory floor, machine shop and field service environments.

In the past, QA/QC personnel have often relied on visual comparison techniques to determine the severity of surface defects. Nanoscale surface metrology systems can provide more reliable data, but can be expensive, slow and susceptible to environmental factors.

The 4D says the InSpec fundamentally changes how precision surface measurement is accomplished by enabling direct inspection of large and small components, right on the shop floor.

Rugged and lightweight, the handheld gauge has a single cable tether to its computer and is designed to handle the rigors of daily use.

The system measures surface defects between 0.1 and 100mm deep on a wide variety of part geometries. Its design makes it easy to access tight corners or reach across large surfaces and a ‘fold mirror’ attachment enables borescope-like access to features without direct line of sight.

inspections with film, can now be deployed in digital radioscopy for defect evaluation of aluminum and magnesium alloys in die castings via a second review monitor.

Digital reference images ASTM E2422 (Aluminum), ASTM E2660 (Steel), ASTM E2699 (Titanium) and ASTM E2869 (Magnesium) have been available with YXLON X-ray system since 2012.

Although digital X-ray inspection is faster, more reliable, less expensive and more environmentally acceptable due to the elimination of chemicals compared with film, some industries still hesitate to embrace it. The digital ASTM reference images are an effective basis for film replacement, and users quickly appreciate the benefits of the easy and safe image storage as well as the simple digital data exchange. www.yxlon.com

Quick-swap fixtures for portable CMMs A complete 4D InSpec system includes the handheld gauge, computer, touchscreen display and software. www.4dtechnology.com

X-ray reference images As a new option, YXLON now provides ASTM E2973 digital reference images for aluminum and magnesium die castings in the Image2500 and Image3500 imaging software of its X-ray inspection systems.

The reference images, which were previously only been available as an image catalogue for radiographic

Phillips Precision has announced new fixture systems for gauge arms, laser trackers, and all portable 3D CMMs. To further enhance the value and productivity of these tools, Inspection Arsenal now offers quick-swap, highly repeatable fixturing designed for all portable devices.

New for portable CMMs, is a universal Loc-N-Load base plate/dock designed with 4 locations to accept all sizes of interlocking quick-swap plates. The base is manufactured with the same 1x1” hole pattern (¼20 thread) as the plates to create a seamless work holding area. Clamps are included that are designed to affix any style or brand device to the base plate.

By fixturing on quick-swap plates, operators can change parts in and out without building and breaking

QMT September/October 2016 www.qmtmag.com

33

PRODUCTS down setups. Several unique parts can be setup or multiples of the same part fixtured and programs repeated.

Affordable plates can be dedicated and kept with the job box for fast, repeatable setups.

Customers can buy items individually or choose a preconfigured bundle that includes a 24 by 12” base, two 6 by 6” and 6 by 12” plates, a 12x12” plate, a specially designed removable qualifying ball plate, and a versatile angle plate. Also included is a work holding kit versatile enough to hold most any part. www.fixture-up.com

Rugged XRF analyser With its new Vanta range of handheld XRF analysers Olympus aims to offer increased productivity in materials analysis tasks. The rugged design allows elemental analysis and quantification for a wide variety of materials in any setting, and, says Olympus, results are now faster, more accurate and reliable than ever.

Applications include alloy recycling, positive material identification (PMI), and geochemistry.

For protection in the harshest environments, the Vanta range has a mesh and shutter to protect the detector from sharp objects and costly repair. The analysers are IP 65 rated for protection against dust and water, and drop tested to military standards.

An operating temperature range of -10 °C to +50 °C makes the range suitable for geochemistry and mining discovery programmes in extreme climates.

Elemental analysis and quantification are achieved in just 1-2 seconds, thanks to Olympus’ new Axon XRF processing technology. This increases throughput and ensures analytical confidence, for example streamlining the QC of alloy and material identification. Alongside an internal library of over 700 alloys for comparison, alloy recycling, PMI and precious metal identification can be performed quickly and confidently.

The customisable user interface

34

is easy to use, allowing new operators to perform useful analysis with minimal training. The Vanta instruments also feature embedded GPS for XRF data spatial tracking, removing the need for costly external GPS accessories. www.olympus-ims.com.

Automated measurement technology To meet the needs of Industry 4.0 and Smart Manufacturing, Alicona has developed collaborative systems allowing intelligent interaction between humans, optical metrology technology and universal robots.

These measurement solutions can be used either manually or automatically for inspection of features on large objects. Systems can be built for quality assurance of round heavy components with a weight up to 120Kg or horizontal systems for large flat objects on which detailed features need to be measured Applications for this productionintegrated measurement solution include the control of sharp edges/ break out on aircraft engine turbine disks and to detect chipping along the edge and to verify minimum radii, essential for safety and reliability in the engine.

The wheeled design makes the robot portable and flexible to use in a variety of places. Manufacturers have the option of taking the measurement to the product or taking the product to the measurement.

The handling of the new robot measuring systems is very easy and user friendly either automatically or manually. The Automatic modes can be preprogrammed and the

www.qmtmag.com

measurements made unattended.

In manual mode the operator manipulates the robot arm and measuring sensor to the required position for measurement. www.alicona.com

Entry-level 3D profile sensor The new LMI Gocator 2100 Series of self-contained 3D profile sensors aims to bring advanced 3D smart imaging capabilities to a wider market.

Laser line measurements of crosssectional shapes of parts and materials surfaces can be collected to create 3D point clouds representing whole parts for performing volumetric measurements. The same sensor can also generate highly detailed laser intensity images for use with common 2D image processing software.

Improvements in the new models include a smaller footprint for easier integration into tight spaces and existing control systems; standardized connectors and cables for reduced system complexity; low latency communication with Gigabit Ethernet communication; and Gocator Firmware 4.x support offering the latest measurement tools such as Part Matching.

This easy-to-use scanning and inspection solution is pre-calibrated and delivers advanced capabilities to handle even the most complicated inspection tasks. It features the same growing set of 2D and 3D measurement tools and real-time visualization found in LMI’s highperformance sensors.

Available in 5 models offering a measurement range from 80 to 800 mm, the series is fully scalable, allowing multiple sensors to seamlessly link together to handle wider targets. With no additional software to install, out-of-the-box setup and configuration is fast and easy.

Gocator profile sensors offer the flexibility for easy integration into production facilities for inspection and control. www.stemmer-imaging.co.uk

QMT September/October 2016

WHERE INNOVATION MEETS APPLICATION

1st 3D metrology Conference - 3DMC november 22 -24, 2016 aachen, germany

3DMC is a new conference and exhibition dedicated to the application and development of 3D measurement technology for industrial, scientific and cultural purposes. After working on the development of the UK-based European Portable Metrology Conference, the 3DMC committee is aiming to widen the audience for a 3D metrology conference by hosting this new event on mainland Europe.

Experts from NPL, UCL, PTB and WZL have created an event aimed at end users of 3D metrology systems, equipment and software suppliers, service providers, researchers and procurement and quality managers. The scope of the conference includes: • • • • • •

The technology and applications of portable coordinate metrology 3D metrology for advanced manufacturing Automation and in-process metrology Industrial requirements and the future technologies driving 3D metrology development Augmented reality Measurement uncertainty and traceability

Register at WWW.3DMC.EVENTS

THE ONE STOP METROLOGY SHOP FARO ARM, GAGE, LLP AND LASER TRACKER HIRE

PROBES, PROBE KITS & ACCESSORIES

Training on all Faro software, Delcam, Aberlink, Geomagic, onsite inspection services using arms and laser trackers www.manchester-metrology.co.uk Manchester Metrology Ltd Unit 12,Greenside Trading Centre, Greenside Lane, Droylsden, Manchester. M43 7AJ Tel:-01616378744 Fax:-01614250944