Faster inspection in large-scale manufacturing

Hexagon’s Manufacturing Intelligence division has a new technology to reduce quality inspection delays in large-scale manufacturing operations. Combining laser tracking with laser radar functionality, it enables manufacturers to measure detailed features and meet tight assembly tolerances from tens of metres away. Built on established measurement and positioning technology, the new Leica Absolute Tracker ATS800 offers significant productivity improvements in large-scale part manufacturing and assembly operations by safely and rapidly measuring critical features.

The new system enables manufacturers to measure fine edges and features across large volumes productivity from a convenient stand-off distance. Whether inspecting large aerospace or automotive structures, ship sections, or wind turbine components, there is no need for operators or robots to be in close proximity to the part. This capability avoids unreliable measurements and safety issues,while also providing significant time savings. 

By combining direct scanning and reflector tracking capabilities, the system replaces two pieces of hardware with a single device. Using Hexagon’s patented PowerLock technology, the ATS800 automatically and immediately ‘locks on’ to a fixed reflector and tracks its movements in real time, providing an absolute position reference. The ability to measure target reflectors also greatly simplifies robotic automation processes, providing precise position referencing within a wider co-ordinate system when the tracker is mounted on a linear rail or an autonomous mobile robot (AMR). 

It is possible to measure an aircraft fuselage, for example, quickly and without bringing target reflectors to the part, reducing total inspection time from hours to minutes. Using multiple devices or an AMR, several fuselage sections or panels can undergo batch inspection overnight, further reducing inspection time and avoiding disruption during shifts. 

More information www.hexagon.com

Renishaw launches longer-length FORTiS encoder

Metrology specialist Renishaw can now offer longer sealed encoder scale lengths to support the development of large machine tools. Customers can choose FORTiS enclosed encoder linear scales as long as 4.24 m.Applications include machine tools for making large casting moulds, vertical turning lathes (VTLs) and gantry-type machines.

The FORTiS encoder design is built upon Renishaw’s ‘Resolute’ encoder technology, providing resistance to the ingress of liquids and solid debris contaminants. It features an extruded enclosure with longitudinally attached interlocking lip seals and sealed end caps. The read-head body is attached to a sealed optical unit via a blade that travels through the DuraSeal lip seals along the length of the encoder.

Linear axis movement causes the read-head and optics to traverse the encoder’s absolute scale (which is fixed to the inside of the enclosure) without mechanical contact.

Customers can choose from two different extrusion profiles to suit their space requirements. The FORTiS-S linear encoder is the standard-size encoder, available with measuring lengths from 140 to 4240 mm, and installs directly to a machined surface via flexure holes in the extrusion’s body.

The FORTiS-N encoder, available with measuring lengths from 70 to 2040 mm, features a narrower cross-section extrusion and a more compact read-head to enable installations in confined spaces. This model mounts directly to a machined surface via two end cap mounting holes or a mounting spar for greater rigidity.

Renishaw FORTiS absolute encoder systems have CE approval and are manufactured in-house using strict quality-controlled processes certified to ISO 9001:2015.

More informationwww.renishaw.com/fortis

Laser radar suitable for automotive metrology

Nikon Metrology has welcomed the recent update to Volume 5.1 of the automotive measurement standards issued by the German Association of the Automotive Industry (VDA). The newly updated VDA standards cover a more comprehensive array of measurement applications within the automotive sector, addressing the industry’s growing demand for more diverse and sophisticated metrology solutions.

“We already offer innovative, traceable measurement solutions based on national and international standards for the automotive industry,” explains Andreas Fuchs, application engineer at Nikon Metrology. “The new standard defines very clearly the procedures for evaluating the precise technology that we provide. After all, with the APDIS laser radar, our portfolio has featured a product for some time now that can also deliver traceable inline measurements as described in VDA Volume 5.1. Incidentally, those who use this technology no longer need a dedicated measuring room for a fixed CMM, enabling them to save a great deal of money, time and space.”

The APDIS laser radar measures details at a distance without needing handheld probes, targets or surface preparation, making it suitable for automating repetitive inspection tasks with high accuracy. The system covers many manufacturing, industrial and research applications, including those that involve hard-to-reach features and are complex, delicate or labour-intensive.

Additional benefits include fast and accurate automated measurements with minimal set-up time for high productivity with flexible and portable installation. This capability allows for the absolute and accurate measurement of parts during production or wherever required, including directly on the production line. In particular, Nikon Metrology says the APDIS laser radar displays its strengths in the automotive industry. For example, the system can measure automotive features with absolute accuracy at high speed with no part preparation, whether inline or offline.

More information www.bit.ly/3Tt6d9a

Reducing rail-tip measurement time by 97.5%

Bowers Group recently assisted DPMS in the development of an advanced rail-tip measurement solution that reduces the time needed to inspect milling wheels by 97.5%.Collaborating with its distributor H Roberts, Bowers Group worked to construct a tailored solution for the tip measurement station. 

Andrew Yarrow, mechanical engineer at DPMS, says: “We believe our rail-tip measurement system has the ability to transform rail maintenance globally. Collaborating with Bowers Group has been instrumental in achieving our goals of functionality and accuracy. Together, we navigated challenges to develop a system that prioritises accuracy, user efficiency and safety in a high-risk industry.”

Rail operators work tirelessly to maintain and upgrade track infrastructure and ensure smooth operation. A key aspect of this objective is the milling process, where train-mounted wheels with rotating carbide tips remove irregularities and defects from rail surfaces, enhancing train performance and safety.

Inaccurate measurement of milling wheel cutting heads can lead to uneven rail surfaces, affecting train stability and comfort, and causing excessive wear and tear on both the grinding wheel and the rail.DPMS developed a tip measurement station that allows for synchronised inspection of both the left and right milling wheels. Here, Sylvac P5i inductive probes from Bowers enable direct connection to a laptop. The Bowers Group team of experts developed a customised reporting program, using Sylcom, allowing for the export of data to Excel for report generation.

This new system enabled the mounting of all five readout heads in a stack, permitting immediate measurements and collecting data simultaneously. The result?A more accurateprocess that supportssimultaneous measurements. DPMS thus witnessed a reduction in measuring time for both milling wheels from over 1 hour to just 90 seconds.

More information www.bowersgroup.co.uk

Mitutoyo aids quality control at HB Bearings

Based in Huddersfield, HB Bearings specialises in the manufacture of metric and imperial bearings that are difficult to source. Bearing types manufactured include radial, deep groove ball, cylindrical roller, angular contact, duplexand others.In accordance with the company’s policy of regularly updating its facilities, HB Bearings took the recent decision to replace its existing bearing run-out test rig.

Darren Mawhinney, technical director at HB Bearings, says: “Having previously established an excellent relationship with staff at close-by Mitutoyo in Elland, I contacted them with my ideas for our proposed new bearing run-out test rig. They quickly understood our requirements, then, through close liaison and co-operation, a design soon evolved into the required system.”

He continues: “Now up and running, we’re delighted with the system’s speed, ease of use and accuracy. Simplicity is critical in the test application and we can operate the new rig with just one click. Compared with our previous rig, a major improvement is the inclusion of a coarse scale, enabling the fast and easy alignment of components. In addition to inspecting our HB bearing range, the new system is able to perform accurate quality control checks on our Gamet Bearings brand, super-precision bearings with a radial runout specification of 0.5 µm.

“Even though our previous jig was fit for purpose, our new bespoke Mitutoyo system has further improved confidence in the premium quality of our bearings.”

Simon Elliot, general manager at Mitutoyo Gauging Technology, adds: “We were delighted to work closely with the staff of HB Bearings to enable the delivery of a system that exactly matched the company’s requirements, at a cost effective price.”

More information www.mitutoyo.co.uk