Quality Manufacturing Today Spring 2017

QUALITY MANUFACTURING TODAY

www.qmtmag.com Spring 2017

Automated CT Full control of your production process

NIKON METROLOGY I VISION BEYOND PRECISION

CONTENTS

Spring 2017 News and Comment 4 Events 5 Automated CT meets customers’ demands 6 Automation allows 100% inspection of complex parts

Focus on 3D

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A world of material testing on show

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The 3D Metrology Conference returns in October

Zwick Roell’s in house event draws thousands

Front cover: Nikon Web: www.nikonmetrology.com Email: sales.uk.nm@nikon.com Tel.: +44 (0)1332 811 349 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.

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@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: Buxton Press Ltd © Cranbrook Media Ltd

Shining a light on Large Volume Metrology 14 How to align a particle beam collider

Food for thought

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Faster and more accurate

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JLR panels faster for Meridian

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Shop floor success

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All set for accuracy

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Laser scanning speed plant installation

Shop floor measurement at a turned parts specialist

Measurement systems boost diecasting productivity

Xtreme in action at Holtex

Bespoke presetting at motorsport supplier

Virtual prototyping advances manufacturing 20 Simulation investment at Wall Colmonoy

Aluline forges a success story

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The height of accuracy

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A tasty beer requires a smooth finish

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Unlocking primeval mysteries

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Creating additive value

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Control preview

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Technology is key in a high wage economy

Tubular parts for the automotive industry

Surface roughness testing at Brewdog

Laser scanning characterises our fossil ancestors

Simulation success at Airbus

Control preview

Products 37

QMT Spring 2017 www.qmtmag.com

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NEWS

EDITOR’S COMMENT Welcome to the Spring Edition of Quality Manufacturing Today.

As the sap begins to rise and the birds take to the wing, a young man’s thoughts turn to metrology – and the festival of all things metrological that is the Control Trade Fair in Stuttgart.

In this issue, we take a look at some of the new equipment and technology that you will see on show there from 9 to 11 May. QMT is again a media partner of the show and we look forward to seeing you there.

There’s plenty more beside in this edition – from prehistoric fossils to craft beer, by way of the Large Hadron Collider and virtual prototypes, we’ve got it covered.

I hope you agree it is a good read.

Andy Sandford Editor QMT

VISION UKIVA machine vision keynotes Dr Mike Aldred from Dyson Ltd and Dr Graham Deacon from Ocado Technology have been announced as the keynote speakers for the UKIVA Machine Vision Conference and Exhibition to be held at Arena MK on 27th April 2017.

Both keynote addresses will illustrate how vision technology has relevance to everyday life such as household cleaning and shopping.

Dr. Aldred’s presentation will cover the design journey that brought the Dyson 360 Eye robot vacuum cleaner to market. Dr.Deacon will look at the challenges in developing a 3D vision guided robot capable of picking and placing fruit and vegetables for shopping orders.

Dr. Aldred’s presentation will open the morning session of the Machine Vision Conference at 10 AM, and Dr. Deacon will begin the afternoon session at 1.30 PM. The Conference itself will feature over 50 technical vision seminars across 6 separate presentation theatres covering the latest developments, technologies and applications as well as machine vision basics.

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The 6 theatres will cover 3D vision, camera technology, optics & illumination, systems and applications, software and embedded vision and Understanding vision technology.

The Conference is accompanied by a dedicated exhibition featuring 45 of the world’s leading companies in the field of vision. www.machinevisionconference. co.uk

TRAINING Free access to online courses Free access to a selection of online training courses is just one of the new benefits available to holders of Hexagon Manufacturing Intelligence’s PCDMIS software maintenance agreements.

Customers are now being offered the opportunity to study either metrology fundamentals or take a CMM operator course via Hexagon’s e-learning portal.

The leading measurement solutions provider is also giving away free membership to the metrology network at its Silverstone Park subcontract facility with the added bonus of preferential contract inspection rates for maintenance agreement customers.

Other new incentives include a special discount off Hexagon’s extensive range of classroom training courses, a six-month free trial of Q-DAS software and free delivery on orders of spares and accessories over £100. www.hexagonmi.com

NDT Call for papers The British Institute of Non-Destructive Testing has issued a call for papers for its 56th Annual Conference of, taking place from 5-7 September 2017 at The International Centre, Telford, UK. Anyone working on the NDT industry or with related technologies, or studying for an academic qualification relevant to NDT or associated industries is welcome to submit proposals.

The Institute says that if ou have developed an idea that you believe

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could help to shape the future of the industry you could share your findings with a readily engaged audience of NDT professionals at the conference.

Abstracts (of no more than 200 words) must be submitted online at: https://mc.manuscriptcentral.com/ ndt2017 by 21 April 2017. www.bindt.org

EQUIPMENT HIRE Investment at Manchester Metrology Manchester Metrology Ltd has made major investments in new equipment.

It has purchased £250,000 of equipment from Hexagon Manufacturing Intelligence that will allow it to offer the hire of the new Leica 403 laser tracker with B-probe, the New RS4 scan arm and the Absolute Romer arm.

All products are available with several software options including Spatial Analyzer, Polyworks and Verisurf plus many more.

The company has also purchased a new Aberlink Xtreme CMM which will be used for inspecting smaller accurate parts in house. www.manchester-metrology.co.uk

EVENT 3D print and scan FARO is co-hosting a Scan2Print event on Thursday 4th May 2017 with Canon and 3D Systems.

Taking place at the Canon Open Experience Centre, Uxbridge, the event will focus on the opportunities delivered by the latest 3D printing and scanning technologies to enhance the efficiency of the product design processes.

Real-life customer examples will illustrate how manufacturers, engineers, and product designers are combining 3D scanning and 3D printing to achieve record levels of productivity, efficiency, and cost-reductions. www.faro.com/lp/3d2print/

PUBLICATIONS Metrology Handbook out now A new and much enlarged edition of Mitutoyo UK’s Metrology Handbook is now on sale. Extensive revisions and additions have increased the page count by 50%, but the cover price has been held at £25.00 plus P&P. This book is primarily intended as reference material for those attending dimensional metrology training courses, especially the internationally recognized City & Guilds training award from the Mitutoyo Institute of Metrol-

QMT Spring 2017

NEWS ogy. The content is based on having taught tens of thousands of engineers from a variety of industries, an experience which highlighted the need for a wide-ranging source of information to provide answers to the many questions raised during metrology seminars.

Mitutoyo says it should also be useful to anyone who needs an overview of dimensional metrology in terms of its history, accepted practices and an appreciation of the wide choice of measuring equipment available today.

Mitutoyo’s Metrology Handbook is available via Amazon or direct from its Sales Office on +44 (0) 1264 353123 www.mitutoyo.co.uk

engineering and science companies can truly make a difference. The Super Science £10K Giveaway will help advance Southville Primary School’s teaching in science and technology.” www.renishaw.com

ROBOTICS Airbus contracts Tecnatom is supplying two new robotic inspection systems for the Airbus production site in Nantes. The first one is already operating at the customer premises and the second has just passed the pre-acceptance tests.

EVENTS 27 April UKIVA Machine Vision Conference and Exhibition Arena MK, UK www.machinevisionconference.co.uk 9 – 11 May Control • Messe Stuttgart

www.control-messe.de

5-7 September 2017 BINDT Annual Conference • Telford, UK 26 – 28 September TCT + Personalise • NEC, Birmingham, UK

EDUCATION Super Science £10K Giveaway winner

9 - 11 October 3DMC • Tivoli Stadium, Aachen, Germany

Renishaw has awarded £10,000 to Southville Primary School, Bristol, winner of its Super Science competition held in collaboration with the Bristol Post newspaper. The school will use the prize money to purchase a range of indoor and outdoor science equipment including circuits, magnets, microscopes and weather stations.

1 – 2 November Advanced Engineering • NEC, Birmingham

Southville Primary School was the winner of a random draw, which took place on December 16, 2016. Schools could increase their chances of winning by collecting as many Super Science tokens as possible and exchanging them for draw tickets.

“There are so many ways in which science and engineering companies can support schools and nurture pupils’ interest in STEM subjects,” explained Chris Pockett, Head of Communications at Renishaw. “Research

by King’s College London shows that children develop an interest in science very early on, before the age of 14. To encourage this interest, schools need resources and expertise they might not always have. This is where

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• QMT is a media partner The inspection systems are based on Tecnatom’s TAURUS robotic system, in this case on a base with turning table, in order to facilitate ultrasonic inspection of cylindrical carbon fibre acoustic panels for the A380, A350, A320neo and A330neo aircraft.

The systems use air transmission ultrasonic technology as the panels have a paper core that means it is not possible to use water for ultrasonic transmission.

The systems use Technatom’s GEOLID geometric recognition to identify the components and select the correct file trajectories for the inspection process. It also monitors the position of the workpiece in tooling, and the tooling’s position in the work space to prevent collisions. www.tecnatom-ndt.com

TESTING Saab signs with Exova Testing service provider Exova has signed a multi-million pound framework agreement with global Aerospace and Defence business, Saab, to deliver materials technology expertise and testing services over the next

five years (three years with a two-year extension option).

Exova provides a wide range of consultancy services as well as mechanical, analytical and non-destructive testing in its laboratory in Linköping, Sweden. The work being undertaken as part of this agreement is performed according to the specialist requirements of Saab, requiring extensive approvals and high service levels.

Paul Barry, Group Managing Director, Industries, at Exova, said: “We are very excited to build on our long track record of providing technically demanding services to Saab by extending our current contractual relationship by up to a further five years. This contract will allow us to continuously improve our delivery programme and facilitate greater efficiency and value for one of our key clients. I very much look forward to serving Saab into the medium term future and beyond.” www.exova.com

QMT Spring 2017 www.qmtmag.com

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COVER STORY

Automated CT meets customers’ demands

Production line with automated CT inspection cell

By automating the CT scanning process manufacturers can achieve 100% inspection of complex parts

T

o meet the demands of ever more discerning customers, manufacturers are constantly striving to improve product quality. One way to achieve this is through 100% inspection of components, rather than taking samples from a production line for quality control. There is a problem if components are complex or already partly assembled, however, as they can take too long to inspect by probing or laser scanning.

In the case of additively manufactured components or plastic mouldings containing electronics, it may even be impossible to check them at all by conventional means.

...it was too slow to be used on a production line - until now.

Automated robot loading system

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Enter industrial computed tomography (CT). It is a valuable tool in the quality manager’s armoury, as X-rays allow the interior as well as the exterior of parts to be inspected non-destructively for material integrity (voids, porosity, inclusions etc) as well as dimensionally. Such equipment has traditionally been found mainly in research and prototyping departments, as it was too slow to be used on a production line - until now.

Recent advances by Nikon Metrology in developing high-flux rotating targets for X-ray sources, coupled with improved scanning concepts, algorithms and analysis techniques, allow samples to be inspected in 3D, reconstructed and evaluated in a matter of minutes to micron accuracy. Couple this with advanced computer control technology

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and a mature automated handling industry employing reliable robotic systems and one has access to viable in-line (or close to production line), 100% inspection possibilities.

They are compatible not only with short manufacturing takt times but also with the big data acquisition and connectivity requirements of Industry 4.0.

Nikon Metrology configures and supplies batch, semi-automatic and fully-automated CT scanning systems with handling peripherals to suit any application. Their capability can range from simple pass/fail inspection to comprehensive real-time quality analysis with feedback to the production process to keep parameters within tolerance.

From hospital to factory floor

The technology is analogous to CT scanning of a person’s head or body in the medical sector, which has been carried out for decades. Multiple X-rays of an industrial component are taken from various angles, although in this case it is the part that rotates, and the resulting grey scale images are converted into a three-dimensional voxel

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COVER STORY Automation ensures consistency

Robot positions sample on rotate table in CT system

Simplified control dash board with Pass/Fail analysis

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(3D pixel) grid. It is used to generate a CADto-part comparison map so that workpiece geometry can be checked for anomalies.

Actual part dimensions can also be recorded, inside and out, to extremely high accuracy.

The process not only avoids destroying a sample test part, which in any case may not be representative as it could be different from others in a batch, but also enables in-process inspection synchronised with a production cycle for total quality control. In the case of castings, further opportunities for savings in scrap rate derive from being able to see the size and position of any internal imperfection and determine whether subsequent machining steps will remove that portion of the component’s volume.

Weld inspection is another area where industrial CT is particularly useful, as checking visually for porosity and mechanical integrity is difficult without employing destructive methods. It is true that radiography techniques are available, but they are unable to cope with complex part geometries and do not give anywhere near the level of accuracy that CT offers.

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Nikon Metrology’s CT systems are designed with automation in mind. Its Inspect-X software allows users to save scan profiles and recall them later to review process data such as X-ray conditions, manipulator position and imaging settings along with reconstruction and volume analysis parameters. It ensures consistency and repeatability by eliminating the need for manual intervention, freeing the operator for other tasks such as preparation of samples. No programming skills are needed, as the software automatically loads appropriate analysis and reporting programs.

In some production environments, semiautomated CT inspection can be a solution and several such systems have been installed across Europe by Nikon Metrology, most recently in France. Guided by a simple, customised user interface, the operator loads parts individually, or a rack of multiple parts, to a position within the scanning station from where an automated system takes over to position them precisely for processing.

Communication with production databases allows automatic recognition of the part that is about to be inspected so parameters can be adjusted accordingly. Inspection results are written back to the manufacturing database for statistical process control, further analysis and storage to preserve data history.

In a batch production environment, instead of the operator only being involved in part handling with everything else happening automatically, a CT procedure involving additional manual duties may be more appropriate. Part identification, program selection, post-scanning interpretation of results and uploading of reports would then all typically be carried out by the operator.

...parts are automatically scanned, reconstructed, analysed and sentenced...

100% in-line inspection

Moving in the other direction, a fully automated, in-line solution suits flow-line production environments where critical parts with complex internal geometries or material structures have to be inspected. A CT facility for 100%, automatic inspection with feedback to control production has recently been supplied by Nikon Metrology to a manufacturing company in the UK. The complete inspection process is automatic, without any user input. Part identification codes are scanned and handled though the database and robots load parts from conveyors and position them in the CT system via an automated door, retrieving them after scanning. The program is loaded directly and parts are automatically scanned, reconstructed, analysed and sentenced according to the database recipe.

The entire procedure can be completed in under a minute and multiple parts can be

QMT Spring 2017

COVER STORY

Non-destructive CT technology allows both structural and dimensional analysis

automotive sector. Certain components would be extremely difficult to inspect quickly without CT, such as fuel injector nozzles, which have tolerances below 10 microns and are susceptible to blockages.

Penetration of dense materials

scanned simultaneously, if necessary, to keep within a short takt time.

This approach not only provides rapid detection and feedback of process variation but also eliminates the risk of the operator negatively influencing the metrology function.

A database with uploaded information on every manufactured part provides full traceability, crucial for aerospace and other safety-critical components. Efficiency is increased by being able to maintain a continuous flow of production and to optimise it in real-time, ideal for high-volume production environments such as in the

With its high power, 450kV micro-focus source, Nikon Metrology’s XT H 450 scanner is the ideal tool for inspecting parts of high density such as impellers, turbine blades and medical prostheses made from exotic alloys. The manufacturer has developed a proprietary curved linear diode array (CLDA) that optimises the detection of X-rays travelling through the part, without capturing undesired scattered X-rays, resulting in sharp, high contrast images with sufficient detail for comprehensive measurements and analysis.

The rotating target is liquid-cooled, allowing higher flux to be used consistent with shortening inspection times for production line use. 450 watts of continuous power is delivered without any restriction on measurement time, whilst a small microfocus spot size of 80 to 113 microns delivers a scatter-free CT volume down to 25-micron repeatability and accuracy. A flat panel detector is also built in for high speed or lower density applications such as 3D NDT defect detection in cast aluminium parts.

The complete inspection process is automated

In a semi-automated process parts are identified through a QR-code scanner

Conclusion

Automating 3D inspection using high power, real-time CT scanning brings huge benefits for the right applications. The investment can be amortised rapidly through reducing the need to employ skilled labour and increasing both productivity and yield. Quality is improved as a result of closed-loop manufacturing and better product insight, while feedback and storage of centralised data sits neatly with the requirements of Industry 4.0 and the smart factory of the future. www.nikonmetrology.com

QMT Spring 2017 www.qmtmag.com

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3DMC

Focus on The 3D Metrology Conference is a new event designed to bring applications and innovations in 3D metrology to a wide European audience

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This industry-focused event offers workshops, delivers talks and hosts an exhibition which appeal to a wide range of interests in what is increasingly seen as a critical and enabling technology.

End users represented by engineers, procurement and quality managers are a key target audience but service providers, metrology systems manufacturers and researchers cover the full audience spectrum.

The industry sectors which they represent are equally wide and include aerospace, automotive, power generation, marine, off-shore, built environment, cultural heritage and virtual reality.

Within these industries applications come in all scales, from the reverse engineering and inspection of small parts to the as-built 3D modelling of entire process plants.

If this scope seems too large for one event, remember that many 3D measurement tools such as imaging and scanning are applicable across a broad range of scales and manufactured objects.

Major systems manufacturers such as Hexagon MI, Nikon Metrology and Faro Technologies provide the tools for exactly this wide spectrum of industries and applications. Users themselves are increasingly comfortable crossing boundaries and a company offering reverse engineering of manufactured parts will also be happy to model ancient Egyptian artefacts for a local museum. A surveying company modelling bridge deformations with a total station might buy a laser tracker to do tooling jig inspection for a local car manufacturer. Drones developed for making maps can be used to inspect damage on aircraft, indoor GPS can be used to monitor an archaeological dig.

This is a fascinating, high-value technology area where cross connections produce new applications and solutions and an event which makes these connections meets an important need.

The conference is chaired by Ben Hughes from the UK’s National Physical Laboratory and has been set up by experts in portable and fixed 3D metrology from the WZL (Aachen University’s Machine Tool lab), PTB (Germany’s national standards lab), NPL (the UK’s national standards lab) and UCL (University College London). However, this is no academic conference. There are no scientific papers, only presentations. There are no formal social events, only good networking evenings where you can, for example, discuss the poster presentations over a drink with other measurement experts.

The first event was held last year in Aachen in November 2016 and the second event will be held this year between 9th and 11th October, at the Tivoli Stadium in Aachen, Germany. However, future events will take place in other European locations with the intention of attracting a wider audience and giving the conference, year-on-year, a bigger presence.

The first event was developed as short notice but still attracted 13 exhibitors and 120 members of the audience in the presentation sessions. The audience itself was approximately 63% from industry and 37% from research, and had representatives from 20 countries. This year the event is aiming to be 30% 50% bigger and prospects look promising.

There were 25 very diverse presentations. For example, German service company Sigma3D talked about the alignment of radio telescopes, PTB presented an advanced interferometric measurement system, Airbus Toulouse outlined a new procedure for measuring brackets on the A350, Tata Steel in the Netherlands used a 3D camera to measure flatness on strips from a steel rolling mill, Rolls-Royce Germany applied optical methods to control the shape of turbine blades, Zeiss compared CMMs with photogrammetric systems and Milan Polytechnic optimized the analysis of computed tomography images.

There was excellent participant feedback with positive suggestions which the organizers will feed into the second event of the series in October. This event is now open for presentation proposals on any subject which promotes the application and development of 3D metrology. www.3dmc.events

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QMT Spring 2017

MATERIAL TESTING

A world of material testing on show

Zwick´s new laboratory has over 50 static and dynamic testing machines

Zwick Roell’s International Forum for Materials Testing, testXpo, is a company open house taken to a whole new level Now in its 25th year, the event takes over the whole company’s headquarters campus in Ulm, Germany, with displays of equipment and live demonstrations from Zwick Roell and partner companies. To give an idea of the scale, on each day of the five-day event 1400 people from around the world sit down together for lunch.

The event gave visitors the chance to see the new testing laboratory at Ulm site, understand how it develops its product range in response to global megatrends, and see the latest version of its testXpert software.

The new lab is equipped with 50 static and dynamic testing machines and is available for pre-testing customers‘ specimens and for contract testing. It also acts as a showroom by providing a comprehensive overview of a large part of Zwick‘s product range.

As well as static testing machines from 200 N to 1,200 kN, the new laboratory possesses a wide range of fatigue testing machines designed to handle large components such as goods vehicle axles. The modular portal-type test bench employs hydrostaticbearing single testing actuators for dynamic contract tests and features a test area height of 2,340 mm and a clear test area width of 2,000 x 4,000 mm.

The laboratory is also equipped with hardness testing, impact testing and melt index testing machines. The extensive pool of accessories, including specimen grips and test fixtures, allows special testing requirements to be implemented without delay. The new laboratory will allow Zwick to cater for the increasing demand from the medical, electronics and composites fields, as well as tests for customers in the metals, automotive and plastics industries.

Zwick’s latest testXpert III software aim to offer an intuitive and workflow-oriented approach for materials testing machines, enabling efficient testing from simple standardized tests to demanding

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research and development requirements. This latest development is the result of close collaboration with users in materials testing and over 30,000 testXpert installations.

Global megatrends are driving materials applications to new extremes. To make turbines for jet engines and power generation more efficient they have to operate at higher temperatures and incorporate new high strength materials, while the trend towards lightweighting for carbon footprint reduction is leading to the use of more and more complex composite materials and new multi-phase and hot forming alloys that allow a variety of materials properties within a single component.

With materials used in automotive, aerospace and power generation now having to withstand a wide range of temperatures, Zwick has focused on a modular approach to materials testing that allows a wide variety of tests covering, for example, heat resistance and thermo-elastic behaviour, to be carried out on a single piece of equipment.

The company therefore now offers a versatile testing machine equipped with a temperature chamber and high-temperature furnace and capable of tensile, compression and flexure tests between -150°C and +1,200°C. New lightweight composite materials require a variety of testing regimes – including tensile, compression and various types of shear testing for both research and development and quality control.

Where a large number of different tests have to be carried out at a relatively low throughput, it makes no sense to have a number of different machines, so again Zwick offers a modular concept whereby a single electro-mechanical or servo-hydraulic testing machine is equipped to perform as many test methods as possible with the least amount of rebuilding. www.zwick.com

QMT Spring 2017

The international exhibition for all concerned with NDT, testing for quality, materials testing, condition monitoring and diagnostic engineering.

The Institute’s Annual Conference, NDT 2017, is to run alongside the Materials Testing Exhibition, giving delegates many opportunities to visit the show.

Cost-effective participation packages are available.

Materials Testing 2017 will present companies with a major forum for promoting their products and services and interfacing with their markets; a unique opportunity to: l Review the latest technologies l Source new contacts l Meet industry colleagues l Keep up-to-date l Get new business l Participate in the development of the industry.

Organised by the British Institute of Non-Destructive Testing Midsummer House, Riverside Way, Bedford Road, Northampton NN1 5NX, UK. Tel: +44 (0)1604 438300; Fax: +44 (0)1604 438301; Email: mt2017@bindt.org

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LARGE VOLUME METROLOGY

Figure 1 - the CNAM telemeter (lower left, aluminium) and the PTB absolute 3D laser meter (lower right, blue) being tested on the 50 m tape bench facility at GUM, Poland.

(Photo courtesy CNAM).

* LUMINAR – Large volume Unified Metrology for Industry, Novel Applications and Research: www.emrp-luminar.eu Project partners were: The National Physical Laboratory (NPL, UK), Conservatoire national des arts et métiers (CNAM, FR), Główny Urzad Miar (GUM, PL), Istituto Nazionale di Ricerca Metrologica (INRiM, IT), Physikalish Technische Bundesanstalt (PTB, DE), Airbus Operations, Filton (UK), Advanced Manufacturing Research Centre and Nuclear Advanced Manufacturing Research Centre (UK), Sios Messtechnik (DE), The University of Bath (UK), University College London (UK) and Karlsruhe Institute of Technology (DE).

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Shining a light on Large Volume Metrology Andrew Lewis, LUMINAR* Project Coordinator, NPL, reports on recent outputs from a major European research project

H

ow do you align a particle accelerator as big as the planned successor to the Large Hadron Collider or accurately measure large, next generation aircraft components during manufacture and assembly? Such questions in Large Volume Metrology (LVM) have triggered research by a collaboration of scientists across Europe to deliver a range of new ideas and prototype measuring systems for use in LVM. The three-year collaborative research project (LUMINAR*) reached its conclusion in summer 2016 with simultaneous demonstration of the new systems and research outputs in a live industrial environment at Airbus, Filton, followed by a two-day workshop.

Large Volume Metrology plays a critical role in quality assurance and manufacturing control in many areas of advanced manufacturing, civil engineering and scientific research. Recently, several issues had been identified requiring further research: a need for measurements (often in harsh environments) of multiple targets simultaneously with accuracy better than photogrammetry; how to guarantee traceability in absolute distance meters (ADMs); achieving better compensation

for refractive index and refraction (beam bending) effects; better compensation for thermal expansion at non-standard temperatures; and new issues associated with using LVM tools dynamically (i.e. with moving targets).

The project developed several new tools, techniques and facilities, in parallel which were then tested, inter-compared and then demonstrated at Airbus, Filton, in a live factory environment, before being discussed at a two-day end of project workshop. (Full details available at the project website – see footnote).

The issues of ADM traceability and refractive index compensation were addressed by CNAM and PTB which developed two new absolute distance measuring systems, both incorporating along-the-beam refractive index measurement and traceability to international references. CNAM developed a long-range telemeter operating at 1.55 µm (infra-red) using relatively cheap off-the-shelf optical components (see figure 1). Traceability to the SI is assured through a simple frequency measurement. The absolute distance capability was demonstrated over ranges up to 50 m with

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QMT Spring 2017

LARGE VOLUME METROLOGY

Figure 2 – a 2D version of the INRIM InPlanT system being tested at the Airbus facilities as two measuring axes (sliders, diagonal on left and right).

The two axes are angularly linked by an orthogonal pair of autocollimators (rectangular table supporting the optical components, higher central).

A two (target) ball bar rotated by a precision rotary table was used as a reference for this short distance test (bottom).

resolution and accuracy around 2 µm. Refractive index compensation was achieved using a second wavelength at 785 nm and delivered 500 µm accuracy at 50 m range - this will be improved in future work to closer match the ADM accuracy.

This instrument is highly portable and designed for measuring and monitoring of long path lengths such as large aerospace assembly jigs and accelerator components’ positioning. Variations on the instrument can operate up to ~1 km range.

PTB, in collaboration with SIOS Meßtechnik, developed a next generation of 3D laser meter, based on existing laser tracer mechanics with a new design of optics and laser sources. Rather than a single red laser, the PTB device uses two high power lasers and modulation techniques to generate four wavelengths in both the visible (green) and infrared parts of the spectrum. Combinations

of these four wavelengths generate signals which can either determine the absolute distance to the target or to compensate for the refractive index of the air along the beam path. Traceability to the SI metre comes through the use of an iodine-stabilised laser. The system is more complex than that of CNAM but offers higher accuracy (refractive index compensated length accuracy 1 µm + 0.1 parts per million; ADM accuracy 0.5 parts per million) and the ability to track moving targets. The PTB device is also shown in figure 1 which shows the CNAM and PTB devices being compared against a reference laser interferometer in the underground 50 m testing bench at GUM. This bench was upgraded during the project with variable temperature control (for simulation of industrial environments) and improved sensors for temperature, humidity and pressure monitoring.

Figure 3 - NPL’s four prototype FSI measuring heads.

The infrared measurement beams exit from the wide angle optics (cone shaped apertures).

QMT Spring 2017 www.qmtmag.com

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LARGE VOLUME METROLOGY

Figure 4 - the hybrid modelling approach adopted by the University of Bath delivers better compensation accuracy for thermal effects compared with conventional linear methods

Figure 5 – the UCL work builds in compensation for beam bending effects into their photogrammetry analysis software – beam bending through refraction makes targets appear to move.

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The development of new systems for multiple target metrology (including those in difficult environments) was tackled by INRIM and NPL. INRIM have developed a system called InPlanT – an in-plane measuring technique designed for operation in harsh environments where the precision metrology has to be separated from the target being tracked yet still has to make coordinate measurements inside the compromised volume.

Three linear axes mounted outside the measurement volume carry moving carriages which track an optical target (a glass sphere) within the volume using a projected laser beam. Each measuring head makes a measurement within a single plane (hence the name InPlanT) which is insensitive to thermal or refractive index gradients in the same plane. Combining the three axial positions of the measuring heads gives the 3D coordinate of the target. Within the limited project funding, the INRIM system simulated a large 3D volume during testing at Airbus and achieved accuracies of around 50 µm. The InPlanT system is ideally suited to operation in harsh environments (e.g. radioactive, flammable) as the only items within the hazardous environment are small glass target spheres.

NPL developed a novel coordinate measuring system based on frequency scanning interferometry called OPTIMUM (OPtically Tracked Interferometric Measurement with Uncertainty using Multilateration). The system is analogous to

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well-known outdoor GNSS except that it operates indoors using infrared laser beams to simultaneously measure the distance to multiple targets from multiple measuring heads. When there are enough targets and measuring heads, the system equations can be solved mathematically to calculate the 3D coordinates of all targets and measuring heads together with uncertainties of those coordinates. The system can track multiple targets simultaneously in 3D – the system has been tested with up to 15 targets so far. The distance measurements are compensated for target vibration using a second laser source and an in-built quantum standard provides traceability to the SI. The University of Bath, developed a new hybrid modelling approach which uses a synthesis between live data (thermal and dimensional) measured at a carefully selected sub-set of locations on a 3D structure, and simulated thermal modelling, to achieve a significant improvement on conventional thermal expansion correction for large parts in industrial environments. The live data is used to iteratively correct a finite element model – measurements at a few critical locations are used to determine better corrections across the entirety of the assembly (see figure 4).

University College London developed several systems for detecting and quantifying refraction effects (see figure 5) in large volumes, especially regarding their effect on photogrammetry (a common LVM technique). These include a multispectral photogrammetry target system for detecting refraction effects over long ranges, a digital axicon camera for high precision photogrammetric target measurement and volumetric refraction-enabled photogrammetry analysis software which can take refraction effects into account when performing conventional photogrammetric measurements.

...the LUMINAR project has advanced the state of the art...

Research at KIT has focused on improving the ability of LVM to make real-time determination of reliable spatiotemporal uncertainties of arbitrarily moving objects, namely position and orientation, both with respect to time. This has required the development of real-time model of laser tracker kinematics with Bayes filtering as well as fluctuating refractive index model. Testing of the research was performed using a laser tracker with a constellation of four high-accuracy laser tracers used as a reference. The research showed that, in certain situations, an industrial robot’s motion control can be, at times, more accurate that a laser-tracker derived measurement of the robot position.

In summary, the LUMINAR project has advanced the state of the art in high accuracy LVM and generated much interest from a range of potential end users of the new technologies, some of which we expect to be developed into commercial products or services.

For further information, in the first instance please contact the project coordinator, Andrew Lewis, at NPL (andrew.lewis@npl.co.uk) www.npl.co.uk

QMT Spring 2017

FOOD & DRINK

Food for thought

The scanner allows OAL to create a complete 3D ‘walkthrough’ model of the factory with full point measurement to an accuracy of 2mm

Laser scanning helps food equipment supplier speed installation OAL has been involved in designing, implementing and automating innovative engineering solutions for the world’s food industry for more than 20 years. The company boasts a range of competencies that include automation, design, mechanical capabilities and product development In order to speed-up the laborious measurement and drawing process that takes place prior to embarking on a plant installation, or system modification, it recently purchased a Focus3D X 30 laser scanner from FARO UK. Jake Norman, OAL Innovation and Marketing Manager explained “In an ideal world every factory would have accurate, fully dimensioned 2D/3D drawings of every aspect of each facility, so that proposed plant modifications could be easily assessed and defined. In reality, the first steps when considering remodelling a plant to meet the demands of new products, often involves an extremely time-consuming measurement and drawing process.

“We believed that for complex plants these crucial procedures were taking too long and that at times it was difficult to achieve the desired levels of dimensional accuracy. This lack of visual dimensional information often meant that initial discussions related to new layouts, at a senior level, were delayed or made more difficult by relying on inaccurate layouts.

“We have since transformed our measurement and drawing processes with the purchase of a FARO Focus3D X 30 laser scanner.

“The use of our FARO Focus3D purchased from FARO UK for 3D factory scanning, now provides us with fast, precise 2D/3D drawings and layouts. We can now quickly and deliver

a complete 3D ‘walk-through’ model of the factory with full point measurement to an accuracy of 2mm. Our specialist team can visit a facility and rapidly and precisely scan a single area or the entire site.

“Depending on facilities’ equipment complexity and size, sometimes we need to make multiple scans. At each position the scanner captures an impressive 976,000 measurement points per second in a full 360° data capture. Once multiple scans for a single area have been finished the team completes a post processing routine to register millions of data elements, enabling the creation of a scanned ‘point cloud.’ At this stage a full ‘3D walk through’ of that area is available.

We then repeat the process for other areas of the factory under measurement with post processing, including joining individual ‘point clouds’ together, creating a ‘project point cloud’ of the entire site.

“The key benefits of using the Focus3D X 30 include the creation of 3D layouts to the required accuracy, the ability to dimension and annotate any 3D element and to create an accurate, realistic 3D ‘walk through’ of the ‘as installed’ plant.

“Now, all plant remodelling is based on accurate data so the entire design process is much quicker, whilst accurate information is available for optimal reverse engineering.

Finally, at the project installation stage, the availability of accurate data ensures that our new parts fit first time.”

Paul Woolner, OAL Lead Designer added.

“Given the size and complexity of many of the plants that we need to measure, our ability to now remotely scan them, rather than access them physically, is proving much safer.” www.faro.com

QMT Spring 2017 www.qmtmag.com

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SHOP FLOOR METROLOGY

Faster and more accurate

Shop floor measurement speeds production at Technoset The Sylvac Scan 52 is fast and accurate and eliminates the possibility of human error in manual measurement

A Sylvac Scan 52 from the Bowers Group enables precision engineering company Technoset to automate measurement processes and save data electronically. The result is a quicker turnaround time and more accurate results.

Technoset specialises in the precision machining of components from high performance materials using multi axis turning and milling machining centres.

Kevan Kane, managing director, Technoset, said: “The machine allows us to measure parts in the same location as they are machined for convenience and accuracy, therefore measurements can be taken on the shop floor.

“The Sylvac Scan 52 is fast and accurate, and eliminates the possibility of human error in manual measurement.”

Previously, every time a manual measurement was made, members of staff were required to record the results on a process check sheet, which was time consuming and carried the risk of errors.

Unlike the manual method of recording, both the inaccurate and accurate measurements are recorded, which is useful for route-cause analysis reviews and the optimisation of components as they are developed.

Around 60 - 70% of the components manufactured at Technoset can be measured using the Scan 52 in some format, and in most cases, approximately 70% of features and characteristics of those components can be measured using the machine.

Periodic tool measurement enables Technoset to optimise the life of its tools, allowing operators to change the tip of the tool before the wear affects the finished component, therefore reducing waste and producing less scrap. www.bowers.co.uk

JLR panels faster for Meridian

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Measuring systems boost die casting productivity

A global die casting company has seen a big boost in productivity thanks to a series of measuring systems supplied by Hexagon Manufacturing Intelligence.

Meridian Lightweight Technologies turned to Hexagon for help with its inspection operations after winning new contracts to produce a range of inner and outer body panels for Ford and Jaguar Land Rover.

The Nottinghamshire-based manufacturer initially chose a Hexagon WLS white light scanner and fixturing system for checking the quality of magnesium castings that not only feature complex geometries, but also vary in size from 1m - 1.8m.

“The system is ideal as it scans large areas in a matter of seconds. Previously, a coordinate measuring machine was used which took hours to acquire the results that the WLS performs in minutes,” explained Emile Jatta, Meridian’s programme manager.

The company was so impressed with the advice received from Hexagon’s sales and technical support team that it decided to further expand its quality control capabilities

at the Sutton-in-Ashfield facility.

Meridian has recently purchased several Hexagon attribute gauges equipped with measurement probes and Go/No-Go target gauges, which check parts and report failings either with variable data or pass/fail reports.

In addition, Hexagon has supplied a series of interchangeable, highly-flexible fixtures which have improved efficiency. They have transformed Meridian’s CMM by enabling different components to be changed over without the need to remove the fixture base.

“These fixtures are one of the department’s most valuable assets to date as they not only offer exceptional accuracy, but also use only a third of the floorspace taken up by the previous systems,” said Emile.

He is full of praise for the service provided

by Hexagon and expects to continue the successful working relationship on future metrology projects.

“The team’s attention to detail and orderliness of even the smallest elements cannot be underestimated. Every detail matters seems to be Hexagon’s policy which entices Meridian to keep them as a supplier,” he added. www.HexagonMI.com

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QMT Spring 2017

SHOP FLOOR METROLOGY

Shop floor success Holtex Engineering Solutions has been an early user of Aberlink’s Xtreme shop floor coordinate measuring machine Holmfirth-based precision engineering firm Holtex manufactures a large variety of high-end, highprecision complex components, as one-offs and in small batches.

Director Ben Robinson says: “Previously we have used manual metrology equipment, although a growing order book and rising pressure on our quality control facilities meant that we needed to automate as many of our inspection tasks as possible. In addition, the demanding nature of our work meant that we needed a CMM that would provide the required levels of precision.

“The Xtreme CMM has proven very easy to use, extremely accurate, and due to its CNC nature, extremely fast. As our machine operators have responsibility for the quality of their own output, they have quickly mastered the use of the Xtreme and make regular use of the new CMM. Typically our personnel will use the Xtreme to measure fistoffs before commencing on production runs, and to make occasional in-process checks.

“Our new Aberlink CMM is also used for final inspection tasks by our quality personnel. As we have written programs for repeat work, we are now able to load multiple parts on to the machine, recall the applicable program and to perform fully automated final inspection routines.

“The use of our new Aberlink Xtreme has increased our inspection precision capability and speeded-up both our production and inspection routines. Our new CMM can be seen as a commitment to help preserve our reputation for the quality of our work.” www.aberlink. co.uk

All set for accuracy Bespoke pre-setting helps maximise precision Brake and clutch manufacturer ALCON uses a ZOLLER venturion 450 universal tool presetting and measurement system ensure accuracy for its motorsport customers These include World Rally Championship teams, Formula teams and NASCAR. Brian Cutler, Production Engineering Manager at ALCON, said: “We chose the ZOLLER venturion 450 tool presetter because we manufacture a multitude of complex products in a wide range of materials, often using tools weighing an average of 15 kilograms each. ZOLLER offered us the tailormade solution we needed, and with fully automatic operation.

“ZOLLER UK were able to offer us a bespoke adapter which was modified and fitted to the machine. Alongside intuitive software that is able to interpret the 90 degree turn-through of our right angle headed tools.

“We are now able to programme our vast library of tools, and monitor drill and insert changes, ensuring the operator uses the correct tool for the job.”

The venturion 450 gives each operator with an individual log-on so that ALCON have full traceability of who has manned the machine – which can be extremely important to its customers.

“Training prior to the delivery of the machine

meant that our team had a deep understanding of how to operate the system and software from day one. We were especially impressed by ZOLLER UK’s ability to deliver exactly what we asked for swiftly and within the agreed amount of time. www.zoller-uk.com

ALCON produces brake and clutch systems for elite motorsport customers

QMT Spring 2017 www.qmtmag.com

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PROTOTYPING

Virtual prototyping advances manufacturing Metals specialist Wall Colmonoy is using advanced simulation tools speed turnaround and enter new markets.

Simulation Tools are having a significant impact in the manufacturing industry and virtual prototyping is playing an increasing role in today’s advanced engineering.

One company making the most of this technology is Wall Colmonoy. Based in Pontardawe, South Wales, Wall Colmonoy’s European Headquarters began using ESI ProCAST virtual prototyping software earlier this year, to assist in the design and manufacture of precision cast components – focusing predominately on investment and sand castings. The software aids in rapid prototyping, design and manufacture of precisely engineered castings such as valve seats for oil & gas, valves for homogenisers in the food industry, seaming chucks and rolls for canning industry, neck rings for glass container, and roll end bushes for the steel industry.

Wall Colmonoy’s engineers use ESI ProCAST in conjunction with computer-aided design (CAD) software to streamline the casting process by virtually designing and prototyping before moving into physical manufacturing. This allows for more efficient designs as engineers can try multiple iterations by virtually simulating shop floor realities – eliminating the need for trial melts and predicting potential manufacturing defects in the cast design to manufacture parts right the first time.

ESI ProCAST is an advanced tool which is the result of more than 25 years of collaboration with major industrial partners and academic institutions around the world.

ESI engineer Les Fletcher, said: “ProCAST is specifically designed to improve casting yield and quality and it’s been hugely successful in streamlining casting process design for companies such as Wall Colmonoy and Rolls-Royce. More than a thousand companies have adopted ProCAST since it was first developed and every day more and more manufacturers are realising the benefits virtual prototyping can bring to the casting process, be it high-pressure die casting, investment casting, shell casting, low pressure die casting, sand casting, gravity die casting, tilt pouring or the lost foam

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process.”

“We did a lot of research into the different virtual prototyping software companies out there, but for us, ESI came out top as they could provide the best software that met our requirements,” explains Michael Shreeve, Wall Colmonoy’s Process Improvement Engineer.

He says ProCAST helps Wall Colmonoy proactively perfect its designs and optimise and improve its manufacturing process by allowing for a full coupling of thermal-flow-stress analyses and evaluations of all casting processes including defect detection, residual stresses, part distortion, microstructure and mechanical properties prediction.

Wall Colmonoy’s engineering expertise used together with ESI ProCAST software enables flexibility, process control, speed to manufacture and ultimately optimal product quality for customers.

ProCAST simulation software will benefit Wall Colmonoy in exploring other markets including automotive and aerospace as they typically require more intricate components.

Wall Colmonoy looks to add ProCAST to other Wall Colmonoy divisions, including Franklin Bronze Precision Components, located in Franklin, Pennsylvania, USA. Franklin Bronze manufactures investment castings for glass container and many other industrial sectors including food, automotive, drilling & mining, marine, steel, and valve & pump.

With increasingly complex part shapes, challenging performance requirements, and the shorter turnaround needed, Virtual prototyping is proving to be especially effective in casting. More and more metal casting companies, like Wall Colmonoy, are using ProCAST to optimise and more efficiently manufacture metal castings. Moreover, virtual prototyping is allowing Wall Colmonoy to broaden their offerings into other sectors not previously explored. www.wallcolmonoy.co.uk

QMT Spring 2017

Renishaw Solutions Centres... lowering the barriers to additive manufacturing UK

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Equipped with the latest AM, machining and metrology systems staffed with knowledgeable engineers, a Solutions Centre offers you a fast and accessible way to rapidly deploy this exciting technology in your business.

Renishaw will support you throughout your investigation and business case development process, helping you to optimise your design, build your confidence in the process, and gain the evidence you need to make investment decisions.

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www.renishaw.com

CMMS

Aluline forges a success story

High precision is vital to Aluline ensuring the functionality and aesthetics of the products.

A Danish company relies on investment in the latest technology to succeed in a high wage economy

A Managing Director René Schow Jørgensen (left) and Quality Manager Lars Andresen (right) value the latest technology

lways use the latest production technology – that’s the principal that a Aluline A/S, Danish manufacturer of aluminum components and solutions, relies on to excel in the global market.

In order to stay competitive and up to date, the family-run company is intensely focused on process innovation and also updates its measuring technology on a regular basis: the Danish enterprise recently introduced two ZEISS ACCURA coordinate measuring machines with a new scanning probe.

This made the company not only the first in Scandinavia to rely on this technology, but also allowed it to reduce measuring times by up to 70%.

“The competition has always been tough, even back in the 1960s,” says René Schow Jørgensen, Head of Aluline. “Today, it’s a different type of competition. What used to be a regional competition has become global.” Together with his brother Morton Schow, he runs the company founded by his father in 1965. The 110 employees manufacture aluminum components for various industries from the small town of Tølløse. The company covers the entire manufacturing process – from design to all processing steps to the finished part.

Precision for high-end loudspeakers, prosthetics and locking cylinders Many components will be visible to end customers

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A total of 11-12 million items comprised of around 300 different parts for various applications leave Aluline every year for destinations around the globe. The company’s customers hail from the medical technology, telecommunications, consumer electronics, defense, automotive and aerospace industries. “Most of our customers have one thing in common: they demand the utmost precision, particularly because many parts will be visible to end customers,” explains Schow Jørgensen. For example, flawlessly machined aluminum rings for

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loudspeakers featuring a carefully engraved brand logo help a high-end product stand out from a mass-produced article. Precision has a direct effect on the functionality of products such as prosthetics or for doors. For example, if the production tolerance for the diameter of a locking cylinder of just 0.1 mm or the roundness is not met, there is a risk of oil leaking or the door not opening and closing properly.

To achieve maximum accuracy and meet the rising demands of the market, the company regularly replaces its machines.

Schow Jørgensen says: “We have been using CNC machines since 1975, and yet the average age of our CNC machines is less than five years.”

The mid-sized company, which counts several global market leaders as its customers, also sets the standard when it comes to measuring technology: “With our measuring equipment, we want to be better than our customers, or at least at the same level of technology,” states Jørgensen. Therefore, he and his colleagues decided in 2013 to replace their two 12-year-old ZEISS PRISMO measuring machines with newer models despite being fully satisfied with the systems.

QMT Spring 2017

CMMS

From design to all processing steps to the finished aluminum part, the company covers the entire manufacturing process at its headquarters in Tølløse, Denmark

They chose the ZEISS ACCURA bridgetype measuring machine because its measuring accuracy of 1.9 μm provides the desired precision as well as the possibility of scanning workpieces continuously instead of capturing single points.

Furthermore, employees were already familiar with ZEISS CALYPSO measuring software. Management and the measuring technicians also expected the new contact XTR scanning probe to simplify and accelerate the quality assurance of geometrically complex parts without sacrificing accuracy. Because a rotary axis is integrated into the probe, the stylus system can turn as far as possible in 15 degree increments and thus always be positioned at the right angle to the part.

Measuring time cut by more than 2/3 The two coordinate measuring machines will enable the Schow brothers to meet their ambition of having the same or better measuring technology than their customers: “There are simply no questions asked when we show new customers

our measuring lab. They know that we measure accurately and manufacture precisely.” But that is not enough: thanks to the new contact probe, Aluline now measures geometrically challenging parts without having to change the sensors. In the past, employees needed 35 minutes per workpiece to measure the 128 defined features of a valve housing. The part had to be turned manually three times for the sensor to capture the boreholes from all angles. The XTR probe, as well as a fixture specially developed by ZEISS for this workpiece, enabled Aluline to considerably reduce the measuring time without sacrificing precision. Schow Jørgensen: “We can now measure the workpiece in just 11 minutes instead of 35 – and that in a single run.” Because the part no longer has to be turned, employees can use the time between the start of the program and measurement report review for other tasks while the machine independently completes the entire measurement. With some 30,000 items annually for this product alone, this improvement has had quite an impact.

Another benefit for Aluline is that the workpieces can now be scanned continuously. As a result, measuring technicians receive a lot more information about the geometry of the parts than they did with single-point measurements. They are therefore able to provide valuable feedback to CNC technicians and engineers.

A tricky operation In general, both measuring machines now run 24 hours a day: the measuring technicians use them to monitor the production startup of all aluminum components. Furthermore, the machine operators take random samples every two hours. Following the measurements, the results are automatically transferred to the measurement documentation.

According to Schow Jørgensen, the introduction of new measuring technology was well worth the investment for the family-run company. However, the switch to the new measuring machines caused him a few headaches in the beginning. This was not

Left, the new probe and a special fixture enabled Aluline to reduce the measuring time for the valve housing from 35 to 11 minutes without sacrificing precision, below, Aluline

About Aluline Aluminum is light, recyclable and noncorrosive. For this reason, aluminum components are used in numerous industries – including the automotive, medical technology and consumer electronics sectors.

Family-run Aluline A/S has specialized in this versatile material since its founding in 1965 by Leif Schow Jørgensen.

Today, the company’s 110 employees develop and manufacture aluminum parts. At its site in Tølløse about 60 kilometers from Copenhagen, the Danish company covers the entire manufacturing process from design to finished part.

QMT Spring 2017 www.qmtmag.com

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CMMS

The new probe and a special fixture enabled Aluline to reduce the measuring time for a valve housing from 35 to 11 minutes without sacrificing precision, inset, Quality Manager Lars Andresen (left) and Managing Director René Schow Jørgensen (right) want to have the same or better equipment in their measuring lab than customers

Quality Manager Lars Andresen and his colleagues monitor the production startup of all aluminum parts with the two ZEISS ACCURA measuring machines. Furthermore, random samples are taken every two hours

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the result of the new technology, but the timing of the change-out: because the measuring machines were essential to production, the switch had to be completed during a three-week plant shutdown.

“Switching out the machines in such a short time was a tricky operation,” says Schow Jørgensen.

During these three weeks, the old machines had to be picked up and the new ones set up in their place. However, this was not the only hurdle: at the end of the three weeks, the measuring programs for the most important workpieces had to work on the new machines. The measuring technicians specially trained by ZEISS were able to use the same

measuring software that they were familiar with.

However, in order to utilize the potential of the new measuring machines and the probe, it was not possible to transfer the programs one to one. “But even this process went off without a hitch,” reports Schow Jørgensen. By the end of the plant shutdown, the new machines and the measuring programs were up and running for the most vital parts.

Production started as scheduled. And management once again determined that “Our drive and courage to renew our technology was worth the investment.” www.zeiss.com/metrology

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QMT Spring 2017

FARO Laser Tracker – The New Standard in Value/Performance and Workflow Productivity

Visit us at Control, Stuttgart, 9-12 May

Large-scale, 3D metrology is now faster and easier than ever before The new FARO VantageS and VantageE Laser Trackers offer the next generation of portability with battery operation capability & industrial-grad Wi-Fi. Speed up your productivity with continuous operation thanks to a hot-swappable battery pack. With the new RemoteControlTM workflow you can easily control the tracker from anywhere in the measurement area. More about the Laser Tracker series at www.faro.com/lasertracker

METROLOGY SOLUTIONS

@QMTMAG

QUALITY MANUFACTURING TODAY

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AUTOMOTIVE

The height of accuracy A Trimos height gauge ensures accurate measurement of tubular automotive parts

The Trimos height gauge has helped voestalpine Rotec improve capacity and save time

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Bowers Group has supplied voestalpine Rotec Ltd with a Trimos V5 Height Gauge to ensure the accurate measurement of machined tubular components for the automotive industry.

Based in Hinckley, Leicestershire, voestalpine Rotec Ltd manufactures products ranging from simple bush tubes to complex assembled parts and has extensive knowledge of tube processing and manipulation. voestalpine Rotec Ltd Kaizen Manager Keith Wileman said: “The Trimos has enabled us to make huge improvements to processes with regard to both capacity and time. For example, a measurement that may have taken 30 minutes to complete previously can now be completed in approximately 3 minutes.

The Trimos is easy to use and has enabled us to train operators to use which is a huge benefit. Also it allows us alternative methods of measurement.” voestalpine Rotec supplies a variety of global automotive OEMs, Tier One and Tier Two suppliers and works closely with customers to develop product solutions.

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Some of the automotive parts that voestalpine manufactures include formed press work, welded assemblies, brace works, and suspension brackets.

The company manufactures parts for leading off highway vehicles, global automotive companies, and titanium bicycle frames for Brompton bicycles.

Due to the complexity of components manufactured at voestalpine, measurements may be required for a variety of dimensions including; height, diameter, hole centres, pitch, flatness, and squareness.

Components are typically manufactured using a laser, with complex dimensions that are notoriously difficult to measure. It is important to maximise the laser for cutting during manufacture and lengthy measurement processes required for each component impact on machine efficiencies.

Before the Trimos V5 Height Gauge, operators at voestalpine would have to move away from the machines use the linear gauge and shadowgraph instruments then back to their workstations.

First-off measurements would be taken, and then adjustments would be made to the component as needed, which then require further measurement.

Understandably, the company wanted a multi-use piece of measuring equipment to fully maximise machine efficiencies.

Particularly intricate components manufactured

by Voestalpine may have over 20 individual holes and slots, which could take operators a considerable amount of time to measure. In addition of line processes such as layout inspection it is incredibly time consuming. Quality Engineers typically recorded measurements manually, which involved writing down several measurements and then typing it all up later, this all added to the possibilities of human error.

Keith Wileman continued: “The automatic recording of measurement data has been a major impact in reducing time spent by quality engineers filling out results and has removed the possibility of human error. Also its ease of use were important considerations in the purchasing of the Trimos V5.

The data acquired from the Trimos V5 has also enabled us to generate automatic spreadsheets as supporting documents that satisfy customer requirements on the part approval process.”

Bowers Group also supplied Voestalpine with Bluetooth equipped hand tools; the Sylvac S_Mic Pro Bluetooth Micrometer set (0 -102mm) and Sylvac S Cal Digital Callipers (200mm) to fulfil its other measurement needs. www.bowers.co.uk

QMT Spring 2017

The Bowers Group of Companies

Telephone: 08708 50 90 50 www.bowersgroup.co.uk sales@bowersgroup.co.uk The Bowers Group offers organisations across the globe a range of quality metrology instruments to assist them in the creation and development of exceptional products designed to meet the exacting needs of today’s markets.

BORE GAUGING HEIGHT GAUGE

HARDNESS TESTER CALIBRATION

NON-CONTACT MEASUREMENT

SURFACE, ROUNDNESS

TURNED PARTS

WHATEVER YOUR MEASUREMENT NEED BOWERS IS YOUR PARTNER IN PRECISION

FOOD & DRINK

A tasty beer requires a smooth finish

Surprisingly enough, a surface roughness tester is a key ingredient in a good pint

Even the smallest traces of microbiological contaminants can multiply during the brewing process, so it is vital to maintain highest levels of hygiene to produce consistently high quality beer.

To help ensure adequate levels of cleanliness, stainless steel remains the material of choice for brewing-plant. The specific alloys that are most often used are AISI 304 and 316, which are very corrosion resistant and are essentially inert to beer.

However, if the surface finish is not up to scratch problems can, and will arise. So, when ordering new plant, brewers need to make sure that the surface is polished and finished to specification.

Craft beer maker Brewdog, for example, is scrupulous in ensuring the quality of its plant.

Located on a 5.5-acre site in Ellon, North of Aberdeen, Brewdog’s plant is a state-of-the-art eco brewery and is one of the most technologically advanced and environmentally friendly breweries in the world.

Although there are a relatively small number of micro-organisms that can affect the quality of beer, they can have a massive negative effect on the end product – radically altering the taste of the beer and potentially resulting in expensive losses for the brewer.

Plant Engineer Niall Murphie explains: “As Brewdog is constantly increasing our capacity we regularly source new processing equipment. To help prevent hygiene problems - all stainless steel vessels, fabricated pipework and equipment we purchase has its surface finish check to ensure it conforms to our stated hygiene standards.

“As our previously used surface finish checking methods were somewhat subjective and could lead to differences of opinion with our suppliers, we recently searched for a more objective means of measuring this important parameter. Having

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considered several options, we purchased a Surftest SJ-210, Portable Surface Roughness Tester from Mitutoyo. As our new surface tester is calibrated and its results are traceable to national standards, our suppliers see its findings as being unbiased and factual.”

He continues: “Now, in addition to using the new, Mitutoyo instrument throughout our brewing plant, its light weight and portability allows us to bring it to our fabrication suppliers and to check that all stainless steels fabrications conform to our specifications. In addition to setting the instrument to a nominal surface finish figure of, for instance 0.8 μm Ra, we also apply acceptable upper and lower tolerance limits. This ensures that pass/fail results are displayed immediately after completion of a measuring routine. As we use the Surftest SJ-210 in some difficult to access areas it helps that its results are displayed on an easy to read back-lit LCD. As well as improving our accuracy capability in this critical area, our new Mitutoyo instrument has also increased our speed of stainless steel surface inspection.”

The Surftest SJ-210 Portable Surface Roughness Tester, as purchased by Brewdog is a portable surface roughness tester that is able to operate independently of mains power and to make accurate measurements on almost any part of a workpiece of practically any size. www.mitutoyo.com

QMT Spring 2017

9 – 11 October TIVOLI Stadium Aachen, Germany www.3dmc.events

ANNOUNCING THE 2nd 3D METROLOGY CONFERENCE 3DMC 2017 Following the highly successful inaugural 3D metrology conference and exhibition last year, the organising committee is pleased to announce 3DMC 2017, which will be held in the Tivoli sports stadium at 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.

The event is aimed at end users of 3D metrology systems, equipment and software suppliers, service providers, researchers and procurement and quality managers. These target audiences operate in sectors such as aerospace, automotive, power generation, marine, off-shore, built environment, cultural heritage and virtual reality.

By bringing people together from these diverse fields, the conference aims to encourage attendees to share experiences and knowledge, values and requirements and develop the 3D metrology industry. The scope of the conference has been extended due to attendee demand, and now includes:

• • • • • • •

The technology and applications of portable coordinate metrology systems from mid to large scale Fixed 3D metrology on the micro to mid scales 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

CALL FOR ABSTRACTS NOW OPEN www.3dmc.events

The conference also looks beyond its immediate technology boundaries and welcomes guest lectures on diverse subjects. The call for abstracts is now open. For more details, or to register or submit an abstract, please visit www.3dmc.events

OUR MEDIA PARTNER

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FIELD RESEARCH

Unlocking primeval mysteries

A laser scanner supplied by Manchester Metrology is solving the fossil mysteries of Little Catalina Emily Mitchel, a researcher from the University of Cambridge is on the Bonavista Peninsula to get a better understanding of what’s left of some of the oldest organisms in the history of life on earth, far right, Emily Mitchell, as well as other researchers, are mapping fossils along the coastline in Little Catalina

This fossil scan from Little Catalina contains some Ivesheadiomorphs, fronds and holdfast discs

Scan of fossils

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Emily Mitchell a palaeontologist from the University of Cambridge, is using a hand-held laser from Manchester Metrology LTD to map thousands of large, complex fossils — dating from about 560 million years ago — along the Bonavista Peninsula coastline in Little Catalina in Newfoundland, Canada.

“They’re very complicated and they’re very large, they can be up to a metre long and they’re really, really weird-looking,” Emily told CBC Radio’s Central Morning Show.

“They don’t look like animals, and they don’t look like plants, and they don’t look like fungi or mushrooms and as a result it’s very hard to work out what they actually were.”

Emily says the fossils are incredibly important.

“This is the first time that we see large things that probably are the precursors to animals actually appearing. It records the fossil surface to very, very small detail, we can get .05 of a millimetre so that’s very, very small. That detail is important because the fossils are incredibly difficult to photograph.

They’re not very deep into rock so photographs have to wait for the exact perfect light to capture them so it’s quite difficult and that perfect light can only last for half an hour an hour on some surfaces.”

Ms Mitchell shipped 150 kilograms of equipment from the UK in order to record the fossil surface, including a generator and the FARO laser scanner, supplied

by Manchester Metrology, which is mounted on a tripod with a mechanical arm. This is an extremely accurate, portable coordinate measuring machine that measures quickly, simply and precisely The equipment

records the fossils, which are not allowed to be moved, exactly where they are on the rock face.

The laser can also capture the entire surface of the rock, and pick up details researchers wouldn’t necessarily be able to see at the site.

Emily’s speciality involves looking at the spatial positions of fossils. “These creatures didn’t move around, so the place where they are on the rock face encapsulates their entire life history, so how they reproduced, how they interacted with neighbours and local environment,” she said.

By combining the scans and statistical analysis, researchers can compare the spatial positions of the fossils on the rock-face to modern organisms to work out biological facts, such as how they reproduced.

During the three weeks spent in Newfoundland, Mitchell and colleagues from Memorial University and the British Geological Survey mapped about 4000 fossils.

Emily said the combination of very large surfaces, unique species, and the oldest complex organisms in the fossil record make the area a “brilliant” place to do research.

She plans to return next year to continue her research in Port Union, where a rare fossil discovery, Haootia quadriformis, was made in 2009. www.manchester-metrology.co.uk

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QMT Spring 2017

ADDITIVE MANUFACTURING

Creating additive value

Stephen Chadwick, Managing Director, Dassault Systèmes EuroNorth, looks at recent advances and application of Additive Manufacturing in the aerospace industry Additive Manufacturing (AM) goes beyond 3D printing. It has evolved into a production and manufacturing technology that displaces or complements conventional processes in an increasing number of applications in aerospace and defence (A&D) as well as other industries.

In many industries 3D simulation applications are deployed to accelerate structural analysis and virtual testing to bring better products to market faster. Dassault Systèmes SIMULIA for example delivers realistic simulation applications for the analysis of finite elements, multi physics models, fluid mechanics, mechanical and multiscale systems, noise and vibration. These enable users to explore realworld behavior of products, nature and life.

As an integral part of the Dassault Systèmes 3DEXPERIENCE Platform, SIMULIA applications accelerate the process of evaluating the performance, reliability and safety of materials and products before committing to physical prototypes. The multiphysics modeling & simulation portfolio provides access to Abaqus within the Platform environment allowing not only solving, but also knowledge capture, tool integration, design space exploration, best-practice development, methods re-use, and collaboration. This maximizes the value of users’ investment in simulation by allowing simulation results and IP to become corporate assets that powers innovation.

AM is used extensively by aerospace OEMs including Airbus Group which after a twoyear comprehensive benchmarking process, is extending its use of Dassault Systèmes’ 3DEXPERIENCE platform to its AM programs integrating design, simulation and production.

Airbus Group will deploy collaborative design and simulation applications as part of the “Co-Design to Target” industry solution experience, for the additive manufacturing of tooling, prototyping and parts for test

Applying additive manufacturing (right) rather than conventional machining (left) can refine components to reduce weight and costs while adding performance

flights and for production use on commercial aircraft. This provides Airbus Group with digital continuity to optimize its conceptual designs by virtually validating each phase of the AM process. Using this approach Airbus Group can explore design and manufacturing possibilities to meet engineering and manufacturing requirements for the additive manufacturing of tools and parts.

Robert Nardini, Senior Vice President Engineering Airframe, Airbus recently said. “Numerous projects across Airbus are accelerating the use of additive manufacturing to produce prototypes as well as production components potentially delivering lighter and less expensive parts that meet technological, performance, safety and cost standards.” He added, “Airbus has long used 3D simulation applications to accelerate the structural analysis and virtual testing of aircraft and now we can define a new way of designing parts by leveraging simulationbased design to better answer aviation market needs.”

AM creates new opportunities in many different areas such as remote fabrication for support and maintenance, rapid prototyping for realizing new concepts and experiences and, perhaps most importantly, developing designs that were previously impossible to fabricate. Airbus Group will be able to take advantage of the 3DEXPERIENCE platform’s automated design assistant for parts, whether they are 3D printed or not, thus accelerating a new wave of transformation in the aerospace industry. Using this platform Airbus will have an end-to-end solution, including all engineering parameters, for the additive manufacture of parts inclusive of material science, functional specification, generative design, 3D printing optimization, production and certification. www.3ds.com

QMT Spring 2017 www.qmtmag.com

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SHOW PREVIEW

More exhibitors, more floor space The 2017 edition of the Control International Trade Fair for Quality Assurance has more exhibitors than ever before The 31st edition of the Control trade show, which runs from 9 to 13 May at the Stuttgart Exhibition Centre will have over 900 exhibitors from 30 countries – more than ever before as well as a 10% growth in exhibition floor space, a new hall layout, improved infrastructure and a technically led supplementary programme.

The new hall layout for Control, which follows the construction a new hall 10 and the renovation and expansion of the West entrance foyer, has allowed the show organisers, P.E. Schall GmbH & Co. KG to arrange the exhibits in a block format. This makes it more compact and reduces the amount of legwork needed to get around all the exhibits.

New online tools also aid the visitor, including a mobile website and the ‘My Trade Fair’ tool for optimised planning of their time at the show.

The portfolio of exhibits will reflect the growth sectors such as industrial image processing and vision systems, robot-aided subsystems and complete systems as well as optoelectronic sensor technology.

The consistent trend towards the digital means that more and more components, modules and systems for industrial quality assurance are optimised for Industry 4.0 compatibility and form the essential building blocks for implementing smart manufacturing in the real world.

Quality Manufacturing Today is a key media partner of the Control Trade Fair. www.control-messe.de

More Xtreme CMM Due to the global sales success of its Xtreme CNC CMM, Aberlink will be demonstrating a new, larger volume version of the machine on Stand 7207 at Control.

To help satisfy the growing demands for automated inspection, an Xtreme CMM fitted with a new 16 Digital Input / Output Interface, will be shown being robot loaded.

The easy to use I/O Interface will work with any Aberlink CNC CMM and can be quickly configured by the CMM user.

The Xtreme’s configuration ensures that it maintains its accuracy at very fast measurement rates and does not suffer from the accumulative inaccuracies that can occur in conventional 3-axis Cartesian designs.

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Also being put through their paces, will be several versions of Aberlink’s bestselling Axiom Too CMMs featuring a new temperature compensation facility. Now, in addition to multiple part temperature sensors, each of the CMMs’ X-Y-Z axis will include temperature sensors. These CMMs will be running the latest version of Aberlink’s MK4 Vision software featuring a wider range of new non-contact measurement functions.

An Axiom Too HS, fitted with a PH10TTP20 probe, will be demonstrated running Aberlink’s latest CAD software modules.

The HS is the high-specification variant of Aberlink’s Axiom Too CMM. In addition to boasting an enhanced accuracy specification, the impressive speed of the HS variant enables it to perform a remarkable number of inspection tasks in a fraction of the time normally taken.

Finally, Aberlink’s large Zenith 3 1500, CNC CMM, fitted with a PH10M-SP25M, will illustrate the latest Aberlink 2D and 3D scanning capabilities that are designed for applications such as reverse-engineering CAD models. www.aberlink.co.uk

Wireless laser tracker On Stand 3506, Automated Precision Inc (API) will show its new OT2 Core wireless laser tracker – completely wireless & controller-free laser tracker technology.

API says that the OT2 Core offers a highperformance laser tracker that delivers essential laser tracking measurement capability at an affordable price. Its compact size and wireless operation offers high accuracy measurement with the convenience of portability and ease of use.

Based on the Omnitrac 2, OT2 Core offers many of the same features including an Autolock sensor that can recapture a lost beam. The OT2 Core operates using the same high precision ADM (Absolute Distance Measurement) technology as the Omnitrac 2 With no external controller, there is no cable needed to connect the tracker to its operating system. The entire system is integrated, with all data capable of being transferred via WiFi. The controller operates up to six hours on a rechargeable battery with an optional AC/ DC direct power adapter. This allows the OT2 Core to take measurements outdoors and in remote areas where there is no easy access to a power supply.

Even with an integrated controller, the OT2 Core is lighter than most competing trackers.

The total system weight, including controllers, is just 10.9 kg.

QMT Spring 2017

SHOW PREVIEW This portability makes it the ideal measurement tool for many applications in a range of industries with its 50m operating range. It can be taken into tight spaces where other systems cannot measure due to their size.

Its rugged design and stable construction allow it to be used in rough environments at industry plants. In addition, the OT2 Core can operate in a range of mounting positions: sideways, upside down, underneath or directly on a part. API says that as a small, more portable system, the OT2 Core promises to bring the accuracy and reliability of laser metrology to shipyards, construction sites and other new sectors. Its competitive price allows smaller manufacturers and operators to take advantage of these benefits. www.apisensor.com

Vision systems and more Bowers Group will be exhibiting a variety of existing and recently launched products, including the new range of Bowers Universal Gauge Sets and Setting Devices, along with the New Version 4 Fusion Software on the Baty Venture Vision system, and the R400 with the FT2E Touch Screen Display.

Visitors will have the opportunity to meet members of Bowers Group’s Special Applications Team, who devote their time to the development of measurement solutions for non-standard applications. An extensive selection of bespoke equipment aimed at special measurement challenges will be on display, including solutions for the measurement of grooves, threads, splines and sphericals, which are fully compatible with Bowers XT range of digital bore gauges and include optional Bluetooth.

See Bowers Group on stand 7105. www.bowers.co.uk

Modular workpiece clamping The Pintec modular clamping system from Christian Brewer (Stand 5411) allows users to quickly and simply fixture difficult shaped workpieces in the metrology room. The company says it is ideal for companies that work with low volumes, small batches and prototypes.

Very often it is not profitable to build a special fixture for small series, but nevertheless the workpiece must be fixed for coordinate or optical metrology and must be presented in a secure and special position. And easy, fast, professional and effective solution is Pintec.

Pintec is easy to assemble and handle so it is not a problem to fixture difficult and complex workpieces. Pintec can also be used in the fields of laser-and needle-engraving. www.pintec.de

Koenigsegg partnership Exhibiting on Stand 5108, Creaform has announced that Koenigsegg, the Swedish manufacturer of high-end, high performance sports cars, has used its metrology products to bring its product development and quality to unprecedented levels.

Thanks to Creaform’s MetraSCAN 3D scanners, HandySCAN 3D scanners, and HandyPROBE portable coordinate measuring machine, Koenigsegg could scan on its automotive parts’ dark and highly reflective surfaces—and virtually eliminate noise during its product development and quality control analyses.

With over 300 hand-formed carbon parts in every Koenigsegg car, Creaform’s inspection solutions provided the accuracy and reliability required by the engineering team, even under rugged shop-floor conditions, to inspect production parts and adjust jigs.

“Koenigsegg’s outstanding vision in the automotive industry has upped the game for all car manufacturers. Koenigsegg is synonymous with quality and innovation— and the entire Creaform team is proud to have contributed to this amazing project,” sawid David Gagné, Creaform’s Division Vice-President, Engineering and Metrology Services.

At Control, all of Creaform’s metrology solutions for improving quality control and manufacturing processes will be on show. These include 3D scanning, reverse engineering, quality control, non-destructive testing, product development, and numerical simulation (FEA/CFD). www.creaform3d.com

QMT Spring 2017 www.qmtmag.com

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SHOW PREVIEW

Layer thickness measurement DEPraTechnik (Stand 6118) will be showing the new Bowman series of high-performance X-ray fluorescence spectrometers for layer thickness measurement and element analysis.

Developed by K ALPHA the modular Bowman series offers devices optimised for a range of different measurement tasks, and can be individually adapted to suit various requirements.

Key Features are precise analyses and layer thickness measurements for elements between aluminum and uranium. Variants cover SiPIN detector or SDD, motorized Z axis with fixed or programmable XY stage, high-precision or extended travel range, single or multicollimator.

With a 50-watt x-ray tube, the Germanmade systems fearure an optimized measuring geometry and short measurement times with high measuring quality. They are especially suited for ENIG, ENEPIG and electroless nickel meaurement, including the determination of phosporous content.

Focus laser and fixed or multivariable focus are available as are different magnifications.

Bowman also offers innovative x-ray fluorescence with capillary optics for small measuring spots with high intensity. www.depratechnik.de

Inspection and analysis software

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a particular inspection process or analysis.

Avizo also provides dimensional metrology with advanced measurements, reporting & traceability, actual/nominal comparison by integrating CAD models, and a fully automated in-line inspection solution.

It includes advanced traceability and reporting features for tracking data workflow from acquisition time to actual quantification results, allowing efficient delivery, sharing, and archival of documented results. www.amira-avizo.com

Scanning in a Capsule On Stand 3304, GOM will show the ATOS Capsule, a new sensor for full-field digitizing and inspection of contoured part geometries.

This fringe projection system is designed for production quality assurance of small to medium-sized parts and excels by its high precision for fine details.

Applications include first article inspection of gears, turbine blades and wheels as well as medical parts. In addition to surface deviations from CAD, GD & T data and detailed information are derived automatically.

ATOS Capsule combines proven GOM technologies, such as Blue Light Technology and the triple scan principle, with a housing design that provides optimum protection against dust and splashing water for industrial use. Due to the maximum stiffness of the unibody housing, the sensor achieves the required process stability for automated applications and precise measuring results.

The ATOS Capsule system is used for automated measurements and inspection in conjunction with the ATOS ScanBox, a complete optical 3D measuring machine that was developed by GOM for an

On Stand 3209 FEI will be showcasing the latest version of Avizo software for industrial inspection and materials analysis.

Integrating expertise acquired over more than 10 years and developed in collaboration with major industrial partners in the aerospace, automotive, and consumer goods industries, Avizo software allows users to visualise, analyse, measure and inspect parts or materials acquired by X-ray CT, radiography, or microscopy systems.

The software provides a set of tools that addresses the whole research-to-production cycle: from materials research in off-line labs to automated quality control in production environments.

It includes programmable automated analysis workflows (recipes) to perform repeatable inspection scenarios for pores, voids, inclusions, cracks, defects, or fibers detection and analysis. FEI’s experts can also work with users to create custom recipes for

efficient quality control in production and manufacturing processes.

For different part sizes and applications, flexible and partly mobile solutions are available. Using the photogrammetric addon sensor ATOS Plus, bigger components or several parts can be measured simultaneously in an ATOS ScanBox, while increasing the overall accuracy at the same time.

Two versions of the ATOS Capsule are available with different levels of detail. The system captures 8 or 12 million points per scan with changeable measuring areas.

The dimensions of the sensor, its low weight and the short working distance simplify its application in practice.

GOM will also demonstrate the virtual

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QMT Spring 2017

31. Control – Internationale Fachmesse für Qualitätssicherung

. Werkstoffprüfung . Analysegeräte Optoelektronik . QS-Systeme/Service

Messtechnik

09. – 12. MAI 2017 . STUTTGART www.control-messe.de

SHOW PREVIEW assembly of complete car bodies based on full-field measuring results and mobile measuring systems that are portable and can be operated close to production. www.gom.com

Automated laser measurement Third Dimension is launching a Vectro, an automated laser measurement system, and Inspect - its new intuitive inspection software, on Stand 5130.

Vectro has been specifically designed for automated use, for integration either robotically or as a fixtured installation, replicating the capabilities of Third Dimension’s best-selling GapGun Pro – which is widelly used for quality control by manufacturers in the automotive, aerospace and energy industries.

Designed to be simpler, faster and cheaper than the GapGun Robot+ that it replaces, Vectro is ideal for high precision break sharp edge applications or fast throughput of production checks.

Consistent positioning delivers repeatable and reliable results and the VChange sensors can measure a diverse range of features and surfaces.

Inspect has been designed to flexibly analyse a component’s profile when used alongside the GapGun Pro. It’s quick and easy to use, with multi-section drag and drop tools to provide accurate and traceable digital inspection results. It is suited for offline metrology checks where Inspect reduces time and training to calculate multiple dimensions of a complex shape and compare to design specifications. www.third.com

Precision in the round

Oxford Instruments (Stand 4317) will introduce a new handheld metals laser analyser, a new spark probe and an improved spark stand for optical emission spectroscopy.

The new Vulvan handheld laser analyser is said to be one of the fastest metals analysers on the market. It is a LIBS (Laser Induced Breakdown Spectroscopy) handheld tool with a simple user interface and has been designed for the rapid identification of a wide range of alloys in manufacturing plants within multiple industries and the scrap metal processing/ recycling industry.

Despite its light weight, Vulcan is robust (IP54 and MIL-STD-810G certified) and extremely fast – identifying materials with a one second analysis. The results can be saved securely via Wi-Fi in the OiConnect Cloud service and accessed anytime from any location.

Recent developments by Taylor Hobson (Stand 4502) include the Talyrond HS, which delivers multi-part measurement without loss of data, i-Series Multi Axis system for automated measurement of large components and Form Talysurf PGI CNC for high automated high accuracy of small components.

All products are designed to deliver an in depth understanding of characteristics such as surface finish, contour, form, radius, roundness and harmonic analysis, providing vital feedback for improvements in design and production.

The new Talyrond 500 HS - ultra high precision multi-part roundness measurement, Taylor Hobson’s new carousel system, transforms the Talyrond 500 HS into a multipart measurement system.

The counterbalanced design of the carousel system ensures measurement without compromise to the instrument‘s specification.

This portable device simply sits on the spindle table via three point location and plugs into a concealed socket. Control is provided via Ultra software enabling fully automated measurement of multiple parts.

The Talyrond 500 HS is sited to high volume throughput, with zero operator attendance and reduced set-up time.

Taylor Hobson’s new Form Talysurf® i-Series Multi-Axis systems deliver automated surface finish, form and contour measurement at the touch of a button. The system can be programmed to your individual requirements for analysis of crankshafts, heads, blocks, gear box casings and much more. www.taylor-hobson.com

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QMT Spring 2017

Metals laser analyser

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For mobile and portable optical emission spectrometers Oxford Instruments has developed a new spark probe. It can be equipped with a rubber seal for improved analysis on curved materials, such as tubes.

The new spark probe is smaller, lighter and more ergonomic than its predecessor.

The analytical performance has been improved significantly by increasing the light transmission rate.

Optimised spark stand Spark analysis typically creates condensate in the spark stand of the stationary spectrometer. For maintaining good performance, it is usually necessary to clean the spark stand after 1000-1500 sparks. Oxford Instruments has now optimised the argon flow in the spark stand of its Foundry-Master benchtop analyser series and expanded the cleaning interval up to 5000 sparks (depending on the matrix). This saves the user significant time and increases the availability of the instrument. www.oxford-instruments.com

PRODUCTS

Touch-based testing Controlling the software additive process The new Bluehill Universal software for Instron machines aims to bring enhanced functionality and improved workflows.

Built from the ground-up for touch interaction, Bluehill Universal features a portrait layout with visual design while giving a comprehensive view of the test workspace on a large-format touch monitor.

Large touchpoints and intuitive gestures make the user experience simpler and smarter.

New features include QuickTest which allows an operator to run a simple test without having to build a new test method. Method-building can be intimidating for users who haven’t been trained or who are new to materials testing, so QuickTest is perfect for new or infrequent testers.

Users can simply tap the QuickTest button, enter a test speed, and tap start. A pre-defined graph and results table populates the most common results, such as Maximum Force and Displacement at Break.

Instron Connect allows users to securely report technical queries directly to Technical Support via the Bluehill Universal user interface.

When a message is sent from Instron Connect, it carries all of the important system information, such as frame model number, software version, etc., helping users get back to testing faster than ever. Secure screen-sharing tools can speed up the support process even further.

Instron Connect also helps users keep track of their system calibrations and software versions. Setting up a new verification or updating to the latest software is as easy as a tap on the screen. www.Instron.com

Linde Gases has launched a measuring and analysis unit which will enable metal additive manufacturers to analyse and control more precisely the level of oxygen and humidity within the printer chamber.

The additive manufacturing process operates within a closed chamber filled with high purity inert gas such as argon or nitrogen. However, impurities due to incomplete purging, small machine leakages and metal powder can have an influence on the oxygen level. A variation in oxygen content in the chamber can result in differences in mechanical properties or chemical composition of the end product – for example a decrease in fatigue resistance.

Linde’s ADDvance O2 precision system was developed in response to a need identified by Airbus Group Innovations, and can detect O2 levels up to 10 parts per million (ppm) within the printer chamber and then modify the gas atmosphere by adjusting the level of argon or nitrogen.

If the oxygen or humidity levels are too high, it can negatively impact the quality and performance of the item being printed.

The launch of ADDvance™ O2 precision follows the opening of Linde’s dedicated industrial gases laboratory for additive manufacturing in Unterschleissheim, near Munich, Germany. The focus of the laboratory is to research the effect of different atmospheric gases and gas mixtures on the different metal powders used in additive manufacturing in order to optimise the various layering processes. www.linde.com

Measuring laminated foil tubes RIFTEK, represented exclusively in the UK & Ireland by Ixthus Instrumentation, recently designed

and suppled a customised scanning system that automatically measures and records geometric parameters for welded cylindrical laminated foil tubes.

The RF092 machine employs three RIFTEK laser triangulation sensors that are rotated around the sample tube and combine to measure the multi-layered foil thickness as well as the weld overlap and depth, in addition to the tube length and its diameter.

Manufactured using ABL or PBL (aluminium or plastic barrier laminates), these types of tubes are extensively used for packaging pastes or gels such as cosmetics, toothpaste and more aggressive materials where leakage of any kind cannot be tolerated. The tubes are typically formed and sealed by an axial weld and the machine was commissioned by RIFTEK’s customer as part of a quality control procedure that helps ensure they meet the appropriate EN 13461:2009 manufacturing standard.

The rotating laser scanning principle developed by RIFTEK builds upon other systems for the measurement of inner diameter and tube parameters using triangulation sensors that are more commonly associated with linear distance measurement - but are nevertheless proving to be a competitive alternative to other forms of cylindrical geometry and thickness measurement.

The automated machine is supplied complete with motorised linear and rotary positioners that present and align the sensor head so that the tube axis centreline coincides with rotation axis. The machine includes calibration cylinders for three tube diameters to suit the customer’s current production programme although more sizes could easily be included.

The measured parameter specifications for the RF902 include diameters from 13 to 50 mm with accuracy to +/- 10μm, foil thickness range from 0.05 to 0.5 mm with foil and weld thickness accuracy to +/5μm, as well as length accuracy to /- 0.1mm. www.ixthus.co.uk

QMT Spring 2017 www.qmtmag.com

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PRODUCTS

Automated scanning

Camera-based portable CMM

Manchester Metrology is now an Official Reseller of the CyberGage 360, which offers speed, accuracy and one-button simplicity for noncontact automated 3D scanning inspection.

Hexagon Manufacturing Intelligence has released a new camera-based portable coordinate measuring machine (CMM) for highly precise shop-floor measurements. The AICON MoveInspect XR8 detects geometric conditions and changes in three dimensions to deliver highly-accurate measurement data.

Based on AICON MoveInspect Technology, the MoveInspect XR8 can simultaneously capture multiple points. This makes the system significantly faster in many applications, and therefore capable of offering clear time- and cost-saving benefits.

The CMM consists of a camera beam with two high-resolution eightmegapixel cameras. Its calibrated cameras are equipped with invisible flashes that eliminate dependence on environmental lighting, and the system’s ruggedised housing makes it suited to almost any industrial environment.

The AICON MI.Probe handheld probing device gives complete freedom of movement, while the MoveInspect software determines the 3D coordinates of object points or the six degrees of freedom (6DoF) data of solid bodies at any time.

Problems typically presented by vibrations, noise, and position changes are solved by a dynamic referencing function. This allows the system to automatically detect and compensate for disturbances immediately, ensuring reliable results in even unstable shop-floor environments.

Designed for use in general purpose metrology, the CyberGage360 has a range of potential industrial applications from automotive to aerospace where high accuracy and high speed throughput are important.

The CyberGage can dramatically speed up quality assurance of inprocess inspection and/or incoming/ outgoing parts inspection; lowers cost of quality & speeds up product timeto-market.

It can generate a precise full 360-degree automated 3D surface scan in less than 3 minutes and facilitates near-production line highvolume scanning and high speed throughput.

No part fixture is required, no part alignment is necessary and results are automatically compared to CAD. Manchester Metrology is a market leader in the inspection of engineered components working with clients in the UK and worldwide. Specialists in the measurement of engineered components, Manchester Metrology offers laser scanner equipment hire, stocking a wide range of calibrated measurement equipment for hire including Faro arms, laser trackers, laser scanners, Faro Focus X330 and the Einscan Pro. In addition to equipment hire, Manchester Metrology also has a vast range of probes, mounting options and accessories for metrology equipment www.manchester-metrology.co.uk

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The MoveInspect XR8 system can also simplify and accelerate assembly and positioning processes, and can replace costly assembly gauges. The system monitors the process, guiding the operator in positioning the part, while immediate feedback serves as a final inspection of the positioning and assembly process. www.aicon3D.com

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CMMs for large and palletised parts Hexagon Manufacturing Intelligence is expanding its vision product range with systems for the measurement of large or palletised 2D moulded parts.

Series components with geometrically varied and stricttolerance 2D inspection features require a specialised production measuring solution. The new Optiv

Classic 8102 and Optiv Classic 12152 have an XY measurement range of 800mm x 1000mm or 1200mm x 1500mm and can be combined with the optional PC DMIS Operator Interface (OI) to handle workpiece palletising, enabling a fast and automated inspection process, even for large batches of small serial parts such as clutch discs, fine-blanked parts and sheet metal cut-outs for electric motor construction. Thanks to the extended measurement range accessibility, prepared interchangeable pallets can be supplied semi-automatically by a palletising robot, reducing standstill times and increasing inspection throughput.

The Optiv Classic 8102 and Optiv Classic 12152 are each fitted with a vision sensor system comprising a high-resolution digital CMOS colour camera combined with a programmable 6.5x CNC motor zoom to enable repeatable, fast, and automatic measuringpoint capture. Both new metrology machines are supplied with PC DMIS Pro as standard with the option to upgrade to PC DMIS CAD software to extract all relevant dimensional, shape and position tolerances from imported CAD data. The addition of the PC DMIS OI further enhances the user experience with its simplified user-interface with pre-defined measurement routines whilst minimising the risk of input and interpretation errors across entire component pallets. www.HexagonMI.com

QMT Spring 2017

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

OT2 Core Wireless Laser Tracker

Increase efficiency of your quality inspection process with API´s newest Wireless Measurement Solution.

Essential Laser Tracking Measurement capability at an affordable price. Its compact size and wireless operation offers high accuracy measurement with the convenience of portability and ease of use.

Features and benefits include:

• • • • • • • •

Portability and Flexibility Fully Integrated Unit On-Board Wireless Technology Battery Operation High-Accuracy ADM (Absolute Distance Measurement) Autolock for Seamless Measurements Virtual Level – Align to Gravity with one click Environmental Compensation

We cordially invite you to visit our booth at Control 2017 (Hall 3, Stand No. 3506).

Arrange a free product presentation: +49 (0) 62217298050 | info.eu@apisensor.com