The Future Metrology Hub An EPSRC Manufacturing Research Hub
Annual Report 2018–2019
2
EPSRC Future Metrology Hub
Welcome
working to build and maintain relationships with new partners and collaborators such as the network of High Value Manufacturing Catapult centres, industry and other academic institutions. Growing this network of partners is a key aspect of our strategy to ensure maximum impact from the Future Metrology Hub project. Dear Friends, Welcome to the 2018/19 Future Metrology Hub report. We have continued to build on our early successes and in this report you will be able to read about many exciting developments. Our core research programme continues to progress well with many of the research teams achieving significant technical breakthroughs. We are developing a range of new optical metrology instruments, focussing on increasing measurement speed and the miniaturisation of devices. As metrology sensor technology develops, so too does the need for highly capable analysis and decision making software. Addressing these technical challenges is not something that can be attempted alone; the Hub is always
The Hub is committed to supporting our outstanding research team in developing their skills and taking advantage of new opportunities. To this end, we have created the Early Career Researcher Forum which brings together researchers from across the Hub and Spoke consortium as well as our other academic feasibility partners. In addition to sharing their research in a mini-conference format, the event also includes skills development sessions such as how to prepare for the upcoming Research Excellence Framework exercise and the bid writing process. I hope you find this report informative and that we will see you at future Hub events. Professor Dame Xiangqian (Jane) Jiang Hub Director
Contents 3
EPSRC Future Manufacturing Hubs
4 Vision 5
Key Achievements
6
Why Metrology is important
8
Measuring our success
12
Research highlights
20 Innovation and Industry 30 Developing People 42
FMH Info
Annual Report 2018–19
3
EPSRC Future Manufacturing Hubs
The EPRSC Future Manufacturing Hubs exist to help manufacturing industries respond to future opportunities and drivers and contribute to a prosperous UK. There are currently thirteen Hubs: Future Manufacturing Hub in Manufacture using Advanced Powder Processes University of Sheffield
Future Research Hub in Electrical Machines
Future Continuous Manufacturing and Advanced Crystallisation Research Hub University of Strathclyde
Future Metrology Hub University of Huddersfield
University of Sheffield
Future Composites Manufacturing Hub University of Nottingham
Future Vaccine Manufacturing Hub Imperial College London
Future Manufacturing Hub in Targeted Healthcare University College London
Future Vaccine Manufacturing Research Hub University College London
Future Liquid Metal Engineering Hub Brunel University London
Strategic University Steel Technology and Innovation Network Manufacturing Hub University of Swansea
Future Compound Semiconductor Manufacturing Hub Cardiff University
Future Photonics Hub University of Southampton
Future Biomanufacturing Research Hub University of Manchester
4
EPSRC Future Metrology Hub
Hub vision The Future Metrology Hub aims to transform the UK’s manufacturing performance by delivering significant improvements in the speed, accuracy and cost of measurement. The vision is driven by the need to develop and deploy new and more effective measurement solutions and practice, and encompasses a wide range of disciplines and a mixture of fundamental and applied research.
‘‘Grand Challenge” research themes are focussed on the development of new technologies that will enable a step-change in the application of embedded metrology solutions in the manufacture of high-value geometric products, in readiness for deployment within autonomous manufacturing systems. This includes the development of new sensor/ instrument technologies across a range of scales that can deliver high speed, high accuracy and affordable real-time measurement of product geometry (size, shape, form, surface texture), as well as new software/systems to resolve two key challenges;
a) the integration of metrology/verification into the design process and b) smart data analytics systems to accurately and efficiently extract and exploit large metrology data sets from multi-scale sensor networks. Applied research programmes are running in parallel to underpin the Hub’s vision, stimulate new areas of research and support the progression of fundamental and early-stage research towards industrial deployment.
Annual Report 2018–19
Key Achievements (to Sept 2019)
30 Keynote speeches
21 New PhD and EngD starts across the consortium
£1.7 million worth of new commercial projects and consultancy
208 Publications
£3.1 million leveraged Research Funding
147 interactions with companies
5
6
EPSRC Future Metrology Hub
Why Metrology is Important Metrology is the science of measurement and underpins all manufacturing technologies. If you cannot measure, then you cannot manufacture.
Access to metrology technology and expertise/skills is vital to the manufacturing sector and is a key enabling technology for the production of high quality, high value products and components. According to the National Physical Laboratory (NPL) Traditional product verification processes typically account for 10-20% of finished product costs, over £15 billion per annum of costs in the UK alone, and rely on gathering and analysing accurate and timely evidence after manufacture. Typically these activities are the preserve of Quality Assurance departments. For established and emerging high-value manufacturing sectors (e.g. aerospace, automotive, flexible electronics, bio-engineering, optics) where precision is paramount, the development
of new metrology technologies and capabilities is critical to success and growth in the UK economy. In particular, this applies to the trend towards in-process metrology and continuous measurement which substantially reduces or removes the need for costly additional processes. In some areas/applications (e.g. optics, bio-medical, additive), without the development of new instrument technologies/methods it becomes impossible to manufacture economically because there is no effective way of measuring – improved metrology technology, in particular embedded metrology, becomes an enabler to these new products and can have a dramatic impact on product quality (reducing defects/scrap rates and increasing productivity).
“Over 60% of British Standards involve measurement or testing” UK Measurement Strategy 2017
Annual Report 2018–19
According to a survey of measurement in industry carried out by the National Physical Laboratory (NPL), which examined the use of measurement throughout the manufacturing lifecycle:
75%
80%
of companies take measurements during product design and development
of companies test bought components to ensure suppliers meet quality standards
76%
95%
of companies take measurements during the production process
of companies test that the final product meets quality standards
7
8
EPSRC Future Metrology Hub
Measuring our success 2018 – 2019
Mathematical Language Developing a machine-readable language is the first step in creating a smart semantic knowledge system. See Page 16
Research Highlights
Optical Instrumentation
Machine Learning
Development of new optical technologies yields increased measurement speed and greater depth of field.
Using complex AI systems to develop a metrology-driven approach to the control of the manufacturing environment.
See Page 14
See Page 18
DAPATECH
Innovation Call
Partnership develops state-of-the-art machine-tool compensation systems that will deliver significant productivity and quality benefits.
The Hub pilots a new scheme to accelerate research impact with an industrial partner. See Page 28
See Page 24
Innovation and Industry
ELCATS
Reliance Precision
Spoke forms part of a consortium of academic and industrial partners to increased capability in aerospace manufacturing.
Developing new technology for Additive Manufacturing leads to spin out company Wayland Additive.
See Page 22
See Page 26
Annual Report 2018–19
Early Career Researcher Symposium
dXCT Conference
Researchers from across the consortium come together to share findings and develop skills.
The Hub hosts the annual dXCT conference I partnership with NPL for over 80 delegates from across industry and academia.
See Page 34
See Page 38
Developing People
Talented Students
Funding Successes
Meet some of the new PhD students who have joined the Hub team.
Hub researchers are successful in securing fellowships, grants and awards.
See Page 32
See Page 36
10
12
EPSRC Future Metrology Hub
Research highlights The Hub research programme comprises several work packages which each address individual challenges which can broadly be separated into three categories: Sensor development, Data analytics, and Metrology assisted manufacture. As the programme progresses, linkages between the categories will be developed into future work packages to deliver industry ready solutions.
Annual Report 2018–19
13
14
EPSRC Future Metrology Hub
Optical Sensors Research Impact Optical sensors are a fundamental technology needed to achieve metrology enabled manufacture using embedded sensors. Several teams working across the consortium are working on different optical techniques. Professor Jon Huntley leads the team at Loughborough University, who are investigating two different sensor technologies.
Frequency Scanning Interferometry is an established technology that is being worked on by many groups across the world. The technique is popular due to its ability to provide an unambiguous distance measurement between a pair of points with good precision. Professor Huntley’s team are seeking to expand on this method to achieve multifunctional measurements on a single machine with not increase in the total instrumentation cost. By increasing the measurement frequency, it is possible to enable measurement of features such as vibration or surface
roughness. However, to achieve this the team must achieve modulation frequencies of 100s of Gigahertz; this is not currently possible and even approaching this figure with current state-of-the-art equipment is incredibly costly. Accuracies in the micron range are possible at ranges of 10+ meters which would make the system particularly suitable for the manufacture and assembly of large scale structures with high precision requirements such as the manufacture of low drag wings. Building on previous successes as part of the Light Controlled Factory project, the team at Loughborough
are working on novel 3D Phase Vision systems using High Speed Fringe Projection. Current commercially available systems using similar technology have limited measurement speeds, typically generating measurements every 5-10 seconds. By substantially increasing the measurement frequency to 4 milliseconds per measurement, the technology would be suitable for use in production environments and would allow autonomous recognition of a variety of parts in different orientations. With a range of several meters, the technology also has applications outside of manufacturing where autonomous recognition of features is essential such as autonomous vehicles.
Annual Report 2018–19
Deflecometry process
At the University of Huddersfield, a related system based on deflectometry is being developed by a team led by Dr Feng Gao. This system will be optimised for close range measurement of specular or high precision surfaces. There are numerous examples of where this would be of benefit ranging from high precision free form moulds through to complex orthopaedic implants and deflectometry offers several advantages over interferometry in these applications. Interferometers are typically capable of very high resolution surface measurements but only over very small areas while
deflectometer based systems can be used for form and surface measurement over much larger areas more quickly but typically at much lower resolution. However, the system being developed by the team at Huddersfield uses a novel arrangement of multiple cameras operating at different focal lengths to overcome this barrier and achieve resolutions approaching the 10s of nanometre range. This technique is particularly suitable for use in production environments due to its relatively low sensitivity to environmental disturbance and robust, low cost instrumentation.
15
16
EPSRC Future Metrology Hub
Category Semantic Language and Smart Systems Mathematical theory provides a potential solution to the challenge of vast and disparate data sets for autonomous decision making.
Professor Paul Scott and Dr Qunfen Qi
As greater numbers of sensors are incorporated through the manufacturing environment, measuring a wide variety of process and environmental variables, methods must be developed to allow the derived data to be used for decision making. This complex and challenging task is being addressed by Professor Paul Scott and Dr Qunfen Qi who are leading a team using mathematical theory to create systems which incorporate the fusion of knowledge from design specification, production, verification and manufacturing sources in a smart machine-readable format. Their aim is to develop the essential underpinnings which will allow machine intelligence systems to make decisions with minimal human input.
Annual Report 2018–19
For data to be meaningful, it is not just the data itself which must be structuralised. It is necessary to be able to understand and communicate all the associated rules, libraries, national and international standards, and common knowledge behind the data before it can be made meaningful. A variety of semantic languages exist however none can sufficiently represent multi-level, dynamic knowledge structures; neither are they adequate to represent the many types of mathematical operations and constraints necessary to be applied in the manufacturing domain. The team are investigating using Category theory, a high-level abstract mathematical theory that formalises mathematical structure and its concepts in terms of a collection of objects and morphisms, to develop a Category Semantic Language (CSL). Instead of a single monolithic layer composed of category structures, the CSL system consists of a multi-level hierarchy which allows representation of different scales.
Observable Real Entities
Not Observable Abstract Entities
Measurement Process
POSET of
Adjoint Functors
Measurands
POSET of Observable Entities
Reconstruction Knowledge Required
Inverse Problem
The team is currently working on the creation of a smart semantics editor called CatLab which will enable users to model, query and reason about semantics. Together, CSL and CatLab can be applied to the design and measurement environment where
knowledge and information need to be represented, reasoned, exchanged and merged in a smart machine readable format. The system is termed smart as it allows different types of machines to work harmoniously and collaboratively with little human intervention.
17
18
EPSRC Future Metrology Hub
Machine Learning Machine Learning allows autonomous systems to respond more effectively to changing environments
There is a long history of sensors being incorporated into machine tools to provide data for process monitoring and control. Monitoring the condition of the machine throughout the manufacturing process allows greater control of variables such as temperature and tool wear with a consequent improvement in the quality of the finished part.
However, current techniques are limited in their ability to deal with large numbers of constantly changing variables and mostly rely on sets of predetermined conditions and models to trigger adjustments to the process. As the number and variety of sensors incorporated on machines grows, traditional systems will increasingly struggle to fully
utilise the data available to optimise the manufacturing process. However, if this can be achieved, there is significant potential for systems to be automated and to become capable of responding dynamically to varying manufacturing conditions.
Professor Andrew Longstaff leads the Hub team investigating the potential for Artificial Intelligence (AI) to increase capability in this area. The challenge facing this group is the need to take large volumes of disparate data generated by the sensors on machines and identify the linkages between the data and the end product. Machine Learning is an attractive method of approaching this challenge however, there is a risk of systems finding false correlations which lead to bad decisions and what is needed, is an ability for a system to identify causation.
Annual Report 2018–19
19
Training
Testing
There are two general approaches to using AI to solve this problem. The first relates to the work being carried out by the Hub’s Spoke at the University of Sheffield led by Professor Visakan Kadirkmanathan. Their expertise in Data Science uses a top down approach to identify causation using very large data sets. Professor Longstaff’s team uses a more bottom up approach which builds on their engineering knowledge and background in machine tool performance enhancement. The models used in AI systems are reliant on high quality data. By understanding the different types of sensor, how they work and how they can be best positioned, it is
possible to reduce uncertainty and acquire data more efficiently. It is also possible to improve the quality of data through increased traceability of sensors and data transfer/ latency rates, this is particularly important in learning models. By using processes that are inspired by well established metrology principles for dealing with uncertainty and traceability, confidence levels in the validity of predictions can be substantially improved. The team’s current focus is on how such systems could be deployed into manufacturing environments and in particular, the need to train models for their working environment. Models are only trained for the conditions that they
were developed in and may not cope well with a need to extrapolate from unusual data patterns. Developing a single model which is capable of dealing with all potential combinations is both challenging due to its complexity and limiting due to the need to develop a bespoke model for each individual application. An alternative solution may be the development of multiple models to deal with specific conditions and which make use of machine learning to enable the decision making process of when to switch between models. A variety of approaches and learning techniques are being investigated such as deep convolutional neural networks and fuzzy switching.
Innovation and Industry A key priority as the Hub’s research programme is maturing is to make sure that research outputs are being applied to deliver meaningful industry impact. This is being achieved through a wide variety of activities including training courses, measurement services work, consultancy, collaborative R&D projects and the commercialisation of new intellectual property.
Because of the broad and underpinning nature of metrology, our research team work with a wide variety of industry partners from across many different sectors, and the following pages contain some examples of the work we have been doing with industry over the past year.
22
EPSRC Future Metrology Hub
ELCAT project Spoke partner, University of Bath, secures significant funding as member of ELCAT project as part of a consortium spanning academia and industry.
Annual Report 2018–19
The production of aerospace structures and assemblies such as wings is a complex and challenging task, particularly with the increased use of composite components and specialised geometry. These materials are critical in maintaining the structural integrity of the aircraft while also achieving increasingly energy efficient operation. Demand to achieve higher production rates while maintaining manufacturing precision is difficult using conventional technology. The Enhanced Low Cost Automation Technology (ELCAT) project is an ÂŁ8.9m project led by GKN Aerospace and funded by the Advanced Technology Institute (ATI) and Innovate UK. The consortium also brings together industrial expertise from Exechon, a manufacturer of parallel kinematic machines, The University of Nottingham, experts in cell organisation and one way assembly, and metrology expertise from the team at the University of Bath.
The team at bath will be building on their experience in metrology enabled autonomous controlled robots to achieve greater automation of what is currently a very labour intensive process. To meet the anticipated production rates requires less dependence on jig fixtures and an ability for manufacturing systems to move dynamically around the part. Using techniques such as laser tracking, the team will develop systems capable of autosyncronisation of multiple robotic machines to ensure that the robots not only fulfil their individual roles accurately, but will also be able to act in unison to avoid collisions and work efficiently as a system. To achieve this, it is necessary to simulate the network behaviour under conditions that replicate the dynamic demands of the manufacturing process at large scales. Once initial laboratory tests have been completed, they system will be expanded to a factory scale at the new GKN Global Technology Centre in Bristol.
23
In addition to the challenge of incorporating the metrology and control systems, the team at Bath will also be developing auto-calibration systems to provide real-time calibration of the robots and tools. These systems will enable greater accuracy and control while also yielding greater productivity through reduced downtime.
24
EPSRC Future Metrology Hub
DAPATECH Machine-tool researchers team up with technology company DAPATECH to deliver major productivity improvements.
Hub researchers have teamed up with commercial partner DAPATECH Systems to develop state-of-the-art machine-tool compensation systems that will deliver significant productivity and quality benefits to precision manufacturers.
After extensive development and testing with customers in the UK, USA and Asia, DAPATECH Systems have launched their first new product, called iTEC (intelligent Thermal Error Compensation), with further products in development.
Demonstrating iTEC on a customer’s Robodrill
Annual Report 2018–19
Research into the modelling, prediction and reduction of machine-tool errors is a core theme of the EPSRC Future Metrology Hub, and a long-established research strength at Huddersfield. Machine errors can be caused by a variety of geometric, thermal and dynamic effects, leading to product quality and machine productivity problems. One specific example that the iTEC system has been designed to address is thermally-induced errors, both from machine generated heat and from changing environmental conditions. By modelling and understanding thermal growth within a machine structure, it becomes possible to develop predictive models which, when combined with real-time temperature sensing and feedback control systems, can continually correct the machine to maintain accuracy.
Whilst the core modelling, sensing and error compensation technologies were developed within the University, turning this into a low-cost, secure, deployable solution for industry was still a significant challenge, requiring a different set of skills. The research team had worked with DAPATECH’s Managing Director, Alex Ponfoort, on projects in the past, so the company was a natural partner to take this technology to market. Working alongside the research team through an exclusive licensing arrangement, DAPATECH have now created a technologically advanced machine-tool compensation system, and a number of customer trials have shown significant benefits in productivity, for example eliminating lengthy machine warm-up cycles. Roll-out of advanced
25
compensation systems has historically been confined to large, high-value machines, but iTEC’s low cost solution is opening up a potentially huge market for enhanced accuracy and productivity in small, mass-produced machine-tools. More information on the iTEC system can be found at www.dapatech.com
26
EPSRC Future Metrology Hub
Reliance/Wayland Collaboration with Reliance Precision delivers new Additive Manufacturing technology.
Researchers from the Metrology Hub have been working alongside Huddersfield-based engineering company Reliance Precision, and the University’s Ion Beam Research Centre, to develop new technology for Additive Manufacturing (AM). Additive Manufacturing (AM) offers unrivalled flexibility in terms of part geometry, material composition and production volumes. It could revolutionise the high value manufacturing sector and in particular the aerospace industry, enabling complex, lightweight, high performance parts to be produced with less material waste. Despite the clear potential, until recently AM has been largely restricted to the production of prototypes and components for rig testing. With support from Innovate UK, a collaborative R&D project (‘RAMP-UP’) developed a new electron-beam AM system to address some of the critical challenges for widespread adoption of AM for the production of critical ‘flying’ parts in aerospace applications. This included the development of in-process metrology to support increased quality and productivity. As a result of the project, Reliance have spun off a new company, Wayland Additive, to take the new technology to market, with the help of a £3million funding injection from Longwall Ventures and the Angel CoFund. The new company plans to sell its first machines in 2021.
Annual Report 2018–19
More information on the new e-beam technology being developed by Wayland Additive can be found at www.linkedin.com/company/ wayland-additive/
In Process Manufacture
Finished Part
27
28
EPSRC Future Metrology Hub
Innovation Call Pilot Pilot innovation project with MTT accelerating the application of machine-tool digital twins.
A number of theoretical models that can predict errors in production processes, and their impact on manufactured parts, have been developed within the Hub’s core research programme and are showing early potential for industrial application. One promising example is an Adaptive NeuroFuzzy Interference System (ANFIS) approach to monitor and significantly enhance the accuracy of production machines, taking into account multiple sources of inaccuracy (geometry, thermal effects, residual stress, and vibration). In a bid to move this technology significantly closer to market deployment, researchers are working with Hub partner MTT (Machine Tool Technologies Ltd) to integrate their models into the Company’s ‘MMPS’ platform; a prototype software-based product for machine-tool and process simulation. Using some of the Hub’s flexible funding and direct support from MTT, the project aims to accelerate development (from TRL 3/4 to TRL 5/6) within 12 months and will include test and demonstration of the new platform on three different manufacturing processes at MTT customers.
For MTT, successful delivery of the project will provide them with the case studies they need to bring MMPS into their key target markets of aerospace, defence and automotive. For the research team, the project will accelerate impact from their research, and the sensor nets installed at MTT’s customers will also be useful in generating data sets that will feed into other part of the Hub’s core research programme. For more information on MTT Ltd can be found at mtt.uk.com
Placing a sensor
Sensors in Situ
Annual Report 2018–19
29
Developing People To support our team of world leading researchers and technical experts, The Future metrology hub is committed to providing excellent access to training and career development opportunities. The Hub hosts a wide range of activities aimed at allowing our research
community to come together to share best practice and learn from each other. In addition to our own staff, the Hub engages with the wider community through mechanisms such as our Surface Metrology School which continues to prove popular with both industry and academia.
32
EPSRC Future Metrology Hub
Student profiles
Gauthier Fieux University of Bath Supervisor Professor Patrick Keogh Why did you choose to study at the University of Bath? I was originally drawn to the University of Bath by the reputation of its Mechanical Engineering department and the partnership with the university where I did my undergraduate studies. This gave me the opportunity to come first as an exchange student and meet Patrick who supervised my final year project. There, I discovered the field of magnetic bearings levitation, as well as an inspiring and supporting environment full of opportunities to learn new things and develop on a personal level. What is your PhD about? My PhD is about the control of the vibrations and the deformation of high speed rotors that are supported under magnetic bearing levitation. It has applications in a wide range of fields, from machining spindles to gas turbines in airplanes, flywheels for energy storage or reaction wheels for spacecraft steering.
My aim is to minimise unwanted vibrations that decrease the performance and increase operating costs. I am therefore undertaking research into a novel internal topology for rotors in those very demanding and space constrained environments, including an embedded sensing and actuation system. The metrology associated with the rotor deformation is complex and forms a significant component of my PhD. What do you enjoy most about working with the Future Metrology Hub? Being part of the Future Metrology Hub is an amazing opportunity to meet and share ideas with researchers from excellent universities across the UK. It is also the place to discover and talk to specialists from fields that are completely new for me, which opens many interesting paths to explore for my own research topic. The Early Career Researchers Symposium, where I had the privilege to give a presentation on the premise of my project, was also a great opportunity as I had never done a conference presentation before. It gave me the chance to present my PhD work in front of other researchers in a friendly and supportive environment and to receive valuable feedback on my ongoing ideas.
Where do you hope your PhD will lead for the research and for you personally? I hope that I will be able to bring my contribution to the field of autonomous rotors, which is an emerging field with a very wide range of possibilities that have opened in the recent years due to the miniaturisation of electronics. My research could have application outside the field of rotor dynamics as it already tackles fundamental problems such as those associated with flexible structure spring design and sensing in remote and traditionally inaccessible places in machines. On a personal level, I have already learnt so much and met so many interesting people during this first year, and I am greatly looking forward to what will happen next. Even though a PhD is a challenging path, in the supportive environment like the Hub it becomes an opportunity to give my best and have an impact in the world.
Annual Report 2018–19
33
effective ultrasonic phase-shift setup is a novel solution which has the potential of improving both the dimensional accuracy and surface integrity of manufactured workpieces.
Olaide Olabode University of Huddersfield Supervisor Dr Simon Fletcher Who is your PhD supervisor and where are you based? Dr Simon Fletcher is my main supervisor and I am based at the University of Huddersfield, in the Engineering Control and Machine Performance Group. Co supervisors: Andrew Longstaff, Naeem Mian. Why did you decide to study at the University of Huddersfield? One of the major reasons why I was attracted to Huddersfield is the Engineering Control and Machine Performance Group who are globally respected for their industry focused research. Additionally, the technical abilities that members of the group bring to manufacturing systems improvement, measurement and processes analysis, measurement and correction of errors in CNC machine tools attracted me to study here. What is your PhD about? The aim of my PhD is to develop a novel temperature measurement method for measuring the core temperature of metals during subtractive manufacturing process. To achieve this, I am using the dependence of the speed of an ultrasonic wave on the temperature of the medium through which it passes to measure the core temperature of metals with a resolution of up to 0.5 °C and accuracy of ± 1 °C. Achieving these results with a cost
What do you enjoy the most about working within the Future Metrology Hub? The excellent support I receive from my supervisory team and working with the competent technicians in charge of the wide array of devices and equipment available in the hub for carrying out world class research are the things I enjoy the most. Also, the diverse academic backgrounds of other PGRs in our Hub helps to broaden my outlook and their contributions during our weekly research progression monitoring meetings are invaluable. Where do you hope your PhD will lead for the research and for you personally? I look forward to seeing the method I am currently developing being used in actual subtractive manufacturing processes. I also look forward to taking on more challenging machine tool metrology problems with potential global impacts.
Wen Guo Loughborough University Supervisor Professor Jon Huntley What attached you to study at Loughborough? I felt there was a good academic atmosphere as well as a comfortable living environment. What is you PhD about? My PhD is about developing a high speed 3D vision system. My project aims to provide a step change in the performance of robot 3D vision systems – over two orders of magnitude increase in data acquisition rate. This will be achieved through an innovative optical system design based on LED light sources and novel fringe analysis algorithms implemented on high speed embedded processors. Where do you hope your PhD will lead – for the research and you personally? Personally, I hope that through my project I will improve my independent research ability and enrich my knowledge base and professional skills in wider but related fields. High speed 3D measurement techniques can be applied to many aspects of our lives, from topography measurement to face ID systems. My research aims to improve the projection speed of structured light and thus increase the speed of 3D measurement technology. What do you enjoy most about working with the Future Metrology Hub? Lots! There is a rich knowledge reserve, technological innovation and active academic exchange.
34
EPSRC Future Metrology Hub
Early Career Researcher Symposium
In January 2019, The Future Metrology Hub organised and ran our first Early Career Researcher Symposium. The event was created to provide researchers from across the Hub and Spoke consortium, as well as supporting partners from Hub funded research projects, a chance to promote their research, share best practice and look for opportunities for collaboration. Held over two days, the event was attended by over 50 early career researchers and included presentations and a poster displays which showcased current metrology research and its applications in advance manufacturing, including machine tools and the use of optical sensors. In addition to metrology research, specific sessions were included on skills development for early career researchers, these included how to prepare for REF and bid writing for research grants. The event was organised by a team made up of researchers from each of the Hub and Spokes and chaired by Senior Research Fellow Dr Hussam Muhamedsalih. The organising committee believe that the symposium is an ideal way to develop skills within the Hub/Spoke consortium and that strengthening the metrology research community across the UK as a whole is an important aspect of the Hub programme. The symposium will be a regular event over the life of the Hub, and it is hoped that delegate numbers will increase as the consortium expands and new researchers join the team.
Annual Report 2018–19
“Because we are spread over such a wide area and it is such a diverse field, it is difficult for everyone to know what is happening. We thought the symposium would be a really good opportunity for the researchers to network, find out what other people are doing and look for areas of collaboration.” Dr Christian Young, Hub Manager
Invited keynote speakers included Dr Alistair Forbes from NPL and Dr Armin Reichold from the University of Oxford. While among the delegates, prizes were awarded to Saif Al-Bashir from the University of Huddersfield and Tobias Reichold from Loughborough University for the best presentations. Additionally, Runan Zhang from the University of Bath was awarded best poster. The event wasn’t just about research, it was a valuable opportunity for the team to socialise and build relationships outside of their normal working groups. In place of the usual team building activities that might be expected, the organising committee invited Tim Young to perform his acclaimed one man performance “The Trials of Galileo” written by Nick Young. The play seemed particularly appropriate given Galileo’s lifetime of work in developing and refining optical instruments. The performance was well received and sparked many interesting conversations over dinner.
Hussam and Tim Young as Galileo
Saif and Tobias shared award for best presentation
35
36
EPSRC Future Metrology Hub
Funding Successes
Dr Qunfen Qi – EPSRC Fellowship Senior Research Fellow Dr Qunfen Qi has been awarded an EPSRC Fellowship to investigate novel methods of facilitating autonomous advanced manufacturing. The grant, worth over £480,000, will be spread over three years and is titled “A semantic infrastructure for advanced manufacturing”. In the new era of digitalisation, machines will communicate and exchange large amounts of data to ensure they can work harmoniously and collaboratively with little human intervention.
Currently, machines use symbolic language to represent the data, but they cannot directly interpret its meaning. As a result, information loss and incorrect interpretation can often happen during communication. To improve manufacturing intelligence, the manufacturing system needs to “understand” the data, which we refer to as “semantics” of the data. If the manufacturing system can be represented at a semantic level, the data will become knowledge to the machine and enable it to be ready for exchange, interrogation and reuse. This fellowship aims to affect a step change in manufacturing intelligence, to support rigorous semantic exchanges between different manufacturing phases, and to allow formalisation and reuse of new/existing knowledge from advanced manufacturing.
Dr Qi’s research within the Hub focusses on development of a novel semantic infrastructure for advanced manufacturing by supporting knowledge representation, interrogation, reasoning and exchange for smart design, manufacturing and measurement of advanced products. Particular focus has been directed on the development of a toolbox to formalise knowledge in/ between design, manufacturing and measurement, especially for additive manufacturing (AM). The resulting semantic infrastructure will allow the machine to “interpret” the meaning of the data/ information. To be more specific: how the design parameters (geometries, tolerances and materials) are related to each other; how the design parameters relate with the AM process/post process parameters (layer thickness, build orientation); and how the design and process parameters contribute to the measurement details (methods, calibration, etc.). It is envisaged that the work will provide a new universal language for any data/information involved in a manufacturing value chain and will permit a comprehensive infrastructure to digitalise the fast growing AM industry.
Annual Report 2018–19
37
Dr Hussam Muhamedsalih – Royal Academy of Engineering Enterprise Fellowship In March 2019 Dr Hussam Muhamedsalih, a senior research fellow in the Hub, started an intensive 12 month Enterprise Fellowship funded by the Royal Academy of Engineering (RAEng). This project is aligned to his work as a Researcher in Residence at the Centre for Process Innovation (CPI) and seeks to take a prototype in process interferometry instrument from Technical Readiness Level 4 (TRL4) to TRL9. The Fellowship will help Dr Muhamedsalih to demonstrate the full potential of the device and identify potential opportunities for commercialisation. In addition to the £60K funding, RAEng will be providing extensive mentoring and support to develop skills outside of research technical expertise such as PR and marketing.
Making new connections is crucial to the project’s success and since starting, Dr Muhamedsalih has travelled to China and Finland, attended the Enlight Conference, the Industrial Metrology Forum and met with NPL to promote the project. This has provided the opportunity to talk to industry experts about the challenges they face and how technology such as the prototype interferometry instrument can help solve their problems, as well as
being able explore possible markets and relationships with other organisations. In particular, one relationship which has developed as a result, and which could benefit not just this project but other work in the Hub, is that with JITRI in China. JITRI is high profile industrial technology research centre. Following initial meetings, JITRI sent a delegation to the Hub in October to meet with our research staff while members of the Hub carried out a return visit to the JITRI labs in December.
“My RAEng fellowship has allowed me to build my entrepreneurship skills in order to translate my fundamental research to business innovation and establish strategical business partnerships. This has allowed me to structure my business model and test it out by intensive direct interaction with industry and potential clients.” Dr Hussam Muhamedsalih
38
EPSRC Future Metrology Hub
Funding Successes “This funding is helping us to develop a product that will be widely useful and will help patients secure the right treatment to allow them to achieve the best outcome.” Nicolas Bryan, NHS Urologist and Lead clinical partner
Dr James Williamson – Grow MedTech Feasibility Funding Hub researcher Dr James Williamson has partnered with NHS consultant urologist Nicolas Bryan and digital innovations company Elaros to produce a measurement device for the benefit of Lower Urinary Tract Symptoms (LUTS) sufferers. LUTS refer to a group of medical symptoms that can significantly affect quality of life for men and women. In the UK, millions of people are affected by LUTS, or urinary incontinence, and hundreds of millions are affected worldwide. One of the main obstacles to successful treatment is the availability of a straightforward test to measure how severely the patient is being affected. Dr Williamson and the team are working on the development of a new device, UScale, which provides a more effective way of taking measurements. Using UScale, the patient urinates into a disposable container connected to a digital scale.
The device records the weight, and the patient can simply empty the receptacle and throw it in the bin before leaving the bathroom. To compliment this new device, a digital bladder diary devised by Elaros helps maintain an accurate, easily accessible record. The project team have been awarded £20,000 Proof of Feasibility funding from the Grow MedTech project; a consortium of Yorkshire universities led by the University of Leeds which provides specialist support for innovation in medical technologies. This funding will allow the team to develop a wireless version of UScale, that will automatically save data to the cloud, allowing clinicians to access it without additional software. This refined prototype will be tested with patients in Nicolas Bryan’s clinic, to get feedback on the device and to compare compliance with traditional methods.
Annual Report 2018–19
39
Zhen Tong – EPSRC equipment bid Senior Research Fellow Zhen Tong, leader of the Ultraprecision Manufacturing Group based within the Metrology Hub at Huddersfield, and Professor Jane Jiang (Hub Director), have successfully bid for an EPSRC equipment grant. The award, which totals over £800,000 will be used to purchase an advanced five axis, ultraprecision, freeform generator equipped with diamond turning, micro-milling, grinding and fly-cutting capabilities. This state of the art piece of equipment will be used to create a unique platform in the UK to support research for next generation freeform and structured surfaces. Freeform and micro/nano structured functional surfaces will underpin many next generation engineering projects such as novel optics in astronomy, aerospace, automotive, semiconductor and imaging systems for medical and food safety.
In addition to developing skills and expertise in house, the Ultra-precision Manufacturing Group will collaborate with others within the University and with external partners to produce knowledge and tools to support their projects. Projected benefits of the research enabled by the freeform generator will be far reaching and include increasing the competitiveness of UK companies able to offer
unique products, new business formation and the installation of pioneering technology in the UK. The long term gains to the UK manufacturing sector include providing an economic advantage and contributing to the maintenance of the UK’s position as a leader in research and innovation excellence.
40
EPSRC Future Metrology Hub
4th Dimensional X-ray Computed Tomography Conference
In partnership with NPL, the Hub hosted the 4th Annual Dimensional X-ray Computed Tomography Conference (dXCT) on 25-26 June 2019 at the University of Huddersfield. The Organising Committee was led by Dr Paul Bills and Dr Radu Racasan. This successful event attracted over 100 presenters, delegates and exhibitors. In addition to the conference, an optional, skills development training day was held on 24 June. The dXCT Conference is the UK’s first international scientific conference dedicated to dimensional X-ray computed tomography and was launched as a one-day event by NPL’s Engineering Measurement Division in 2016. The purpose of the conference is to present and disseminate the latest developments in the field and its industrial impact across a variety of applications and to define synergies and opportunities for collaboration between different organisations and commercial representatives.
Annual Report 2018–19
This year, the conference was extended from one to two days and included a dinner and networking event at the Yorkshire Sculpture Park and a discussion session on BSI standardisation. The conference included 26 presentations and 10 posters with contributors from across academia, medicine and industry. Keynote speakers included: Markus Bartscher from PTB, Desi Bacheva from Hieta Technologies, Wenjuan Sun from NPL and Harry Hothi from University College London, who, in an unusual experience for the conference delegates, delivered his presentation remotely while preparing for surgery! The prize for the best presentation went to Mason Rowbottom from the University of Huddersfield and for the best poster to Reuben Lindroos from the University of Southampton. The exhibition featured stands from specialist companies showcasing the latest software, light technology, optics and imaging scientific equipment.
The conference received very positive feedback from the delegates with respondents appreciating the breadth of topics and speakers, the networking and knowledge exchange opportunities and the smooth organisation of the event. The next dXCT conference will be held at the University of Manchester in 2020.
41
Our Network of Activity
CORE RESEARCH PARTNERS COLLABORATIONS RESEARCHER IN RESIDENCE MANUFACTURING HUB FEASIBILITY CALL PARTNERS
Advanced Forming Research Centre Automating Process Optimisation from a Metrology Informed Digital Twin
Newcastle University Boosting Inspection Metrology Productivity Through AI
1
The University of Leeds GrowMedTech
Advanced Manufacturing Research Centre Researcher in Residence Prof Andrew Longstaff
University of Warwick Investigation of fibre content and fibre orientation distributions in compression moulded carbon fibre SMC
Cardiff University Measurement of Carrier-Induced Electro-refraction in InAs/In(Ga)As Quantum Dots
The University of Bath Immersive Metrology System
The Future Photonics Hub Compact Tailored Scattering Spectrometer
12
Core Research Partners (5) The University of Huddersfield (6) The University of Sheffield (8) Loughborough University (13) The University of Bath (14) National Physical Laboratory
Joint Feasibility Call (5) The Future Metrology Hub (7) The Future Composites Manufacture Hub (12) The Future Compound Semiconductor Manufacturing Hub (15) The Future Photonics Hub
Centre for Process Innovation Researcher in Residence – Dr Hussam Muhamedsalih – Dr Feng Gao
The University of Sheffield High-temperature, highly integrated, aerosol printed metrology sensors on-a-chip
Nuclear Advanced Manufacturing Research Centre Researcher in Residence Dr Simon Fletcher
2 3
The University of Sheffield In-Situ Ultrasonic Sensors for Monitoring Tool and Workpiece During Grinding Processes
4 5 6 8
The University of Nottingham Fast Instrumented Laser Cutting of Industrial Fibre Reinforced Composites
7
9 10
Manufacturing Technology Centre Researcher in Residence – Dr Shan Lou
11 14
13 15
Cranfield University Contactless Dielectric Process Monitoring (CDPM) of Composites Manufacturing
National Physical Laboratory
44
EPSRC Future Metrology Hub
Hub Governance Hub Executive Group The Hub Executive Group is comprised of the Hub director and Hub operations director, research spoke leaders and senior co-investigators responsible for managing research topics. The group meets quarterly and is responsible for monitoring the progress of research activities, allocation of resources and determining the strategic direction of the Hub Professor Paul Scott University of Huddersfield
Professor Visakan Kadirkamanathan University of Sheffield
Professor Andrew Longstaff University of Huddersfield
Ben Morgan AMRC
Professor Liam Blunt University of Huddersfield
Professor Dame Xiangqian (Jane) Jiang DBE Hub Director
Simon McKenna Hub Operations Director
Professor Patrick Keogh University of Bath
Christian Young Hub Manager
Professor Jon Huntley Loughborough University
Scientific Advisory Board The Scientific Advisory Board (SAB) offers independent guidance and support to the Hub Executive Group by providing advice on areas such as strategic direction and research themes. The board is composed of a group of international experts in metrology technology and applications and meets twice per year. Chair
Board
Professor Ken Young Technology Director, Manufacturing Technology Centre (MTC)
Professor Isobel Pollock-Hulf OBE Visiting Professor in Engineering and Design, University of Leeds
Professor David Delpy Emeritus Professor of Biomedical Optics, University College London
Professor David Whitehouse Emeritus Professor of Engineering Science, University of Warwick
Professor Vijay Srinivasan Chief of the Systems Integration Division of the Engineering Laboratory, National Institute of Standards and Technology (NIST)
Professor Hans Nørgaard Hansen Head of Department of Mechanical Engineering, Technical University of Denmark
Mark Summers Head of Advanced Manufacturing, National Physical Laboratory (NPL)
Lynne McGregor Innovation Lead in the Manufacturing and Materials Sector, Innovate UK
Katie Walker Portfolio Manager, Engineering and Physical Sciences Research Council (EPSRC)
They are broken down into:
Hub Supporters
METROLOGY EQUIPMENT EQUIPMENT MANUFACTURERS MANUFACTURERS RESEARCH/INNOVATION ORGANISATIONS MANUFACTURING END USERS
The Hub is supported by over 70 70 companies, academic institutions, and regional and government bodies.
METROLOGY SERVICES COMPANIES COMPANIES MACHINERY MANUFACTURERS OTHER (INCLUDING (INCLUDING SOFTWARE SOFTWARE SERVICES SERVICES AND A ND SOLUTIONS) SOLUTIONS)
TWI Future Photonics Hub Future Composites Manufacturing Hub Future Compound Semiconductor Manufacturing Hub Lawrence Livermore National Laboratory United States Air Force MTA Leeds City Region EUSPEN MAPP MeDe CIM
NAMRC
Newburgh Reliance Moog Cooke NTR IBS BV Craftsman Holtex Teknek
USERS
DIGITALSURF BRUKER
MTC
NCC
RELIANCE
UNITED GRINDING
The following are a list of company names for OTHER (INCLUDING SOFTWARE SERVICES AND SOLUTIONS) DePuy 3M Corin Stryker JRI
PTB
Biomet Elaros Thornton & Ross IBM Delcam PTC OCF DRTS DigitalSurf
IBS BV
NTR OCF
NPL
MAPP
DELCAM
MOOG
ROLLS ROYCE
TWI
DMG Mori Holroyd
CHMTI
DEPUY
MANUFACTURERS
HIETA
FORENSIC PATHWAYS
IBM
NIKON
FUTURE COMPOSITES Zeeko The following are a list of MANUFACTURING HUB ELAROS United Grinding company names for MACHINERY
BIOMET
NEWBURGH
QIOPTIQ
Campden BRI Insphere Forensic Pathways
The following are a list of company names for METROLOGY SERVICES COMPANIES MTT
CORIN
RENISHAW
CRAFTSMAN
LEEDS CITY REGION
THORNTON & ROSS
Rolls-Royce GKN AWE Airbus Airbus Defence L3 Commercial Aviation Qioptiq QinetiQ Jaguar Land Rover Cummins
CHMTI
FUTURE PHOTONICS HUB Borg Warner The following are a list of company PTC HOLTEX HiETA names for MANUFACTURING END
EUSPEN
FUTURE COMPOUND SEMICONDUCTOR MANUFACTURING HUB
GKN
CPI AIRBUS
TEKNEK
COOKE AWE
CAMPDEN BRI
L3 COMMERCIAL AVIATION JRI
AMRC
MTC NAMRC NCC CPI NPL NPVP PTB NIST ATI
ATI
LAWRENCE LIVERMORE NATIONAL LABORATORY AMRC
CARL ZEISS
The following are a list of company names for RESEARCH/INNOVATION ORGANISATIONS
NIST
TAYLOR CUMMINS HOBSON JAGUAR LAND ROVER institutions, and regional and government bodies.
Renishaw Taylor Hobson
INSPHERE ZEEKO
NPVP
DRTS
HOLROYD 3M
Carl Zeiss Heagon Nikon Bruker
MTT
BORG WARNER UNITED STATES AIR FORCE MTA academic STRYKER The Hub is supported by over 70 companies,
HEAGON QINETIQ
The following are a list of company names for METROLOGY EQUIPMENT MANUFACTURERS
DMG MORI MEDE CIM AIRBUS DEFENCE
For more information please contact: Mr Christian Young Hub Manager
EPSRC Future Metrology Hub Centre for Precision Technologies University of Huddersfield Huddersfield HD1 3DH Tel. 01484 473709 Email. metrology@hud.ac.uk Website. www.metrology.org.uk Twitter. @HudMetrology
20105