FEATURE ON METROLOGY

Fast countersink measurement routines

Third Dimension has launched a countersink measurement solution for its GapGun range.

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Said to be the first of its kind on the market, the solution can calculate the dimensions of a countersink hole to accurately predict the flushness of fasteners once fitted. What’s more, the innovation can operate in real time on the production lines of aircraft, cars and vans, and in energy and marine markets.
Last year, in the commercial aerospace industry alone, some 1481 planes were manufactured with a total estimated 296 million countersinks. The average requirement is to measure 5% of each aircraft’s 200,000 countersink holes, meaning 10,000 countersink holes would have to be measured for every commercial aircraft produced. Done manually, these checks rely heavily on the competencies of the operator and are extremely time consuming. Conversely, Third Dimension’s patented systems takes just a couple of seconds per measurement, with no possibility of operator error.
The GapGun Countersink Inspection System enables the prediction of fastener flushness much faster and more accurately than mechanical gauges, with the addition of an auditable data trail. Importantly, tolerance bands can be preset, against which the measurement is recorded, before the result can be read on screen or automatically sent to a PC to enable comparison and analysis.
Countersinks are notoriously difficult to measure; one of the main challenges for manufacturers is finding a way that considers how to calculate the centre of the hole. The Third Dimension solution addresses this issue with a specially designed stand-off integrated into the sensor that enables the system to calculate the hole centre and therefore check the required dimensions before the fastener is fixed in place.
For further information www.third.com

Laser scanning halves inspection times

Czech company Lukov Plast, a producer of injection moulded plastic parts, electronic components and electrical sub-assemblies for the automotive industry, reports considerably faster inspection cycles and feature measurements following the purchase of a Nikon Metrology LC15Dx laser scanner.

Miroslav Pavlu, measuring technician at Lukov Plast, explains: “To manufacture assemblies and components that will withstand regular daily use, parts are subjected to various life cycle and climatic tests, as well as quality assurance (QA) procedures and analysis to assess performance. Previously, QA involved using various manual gauges and taking touch-probe measurements on a co-ordinate measuring machine. Larger plastic parts, in particular, were problematic to inspect using tactile techniques as they were difficult to clamp without distortion.”
To control the production of injection mould tools so that manufacturing processes could be steered correctly from the outset, as well as to measure the plastic parts produced, it was decided that inspection needed to be faster, more efficient and more accurate. The ability to check a part against the CAD model and highlight areas of concern using colour mapping was another reason to consider investing in newer technology.
An upgrade from Nikon Metrology proved to be best solution due to its cost effectiveness and the supplier’s experience of retrofitting to third-party systems. Additionally, Nikon’s LC15Dx laser scanning technology with Focus point cloud software was considered best-in-class.
Pavlu says: “The laser scanner has accelerated measurement by about 50%, while and the creation of programs for new parts is about 40% quicker. Costs are also lower due to the use of less dedicated fixtures than are needed for traditional tactile inspection.”
For further information www.nikonmetrology.com

Subcontractor takes ‘Xtreme’ measures

Poole-based subcontractor Alpha Precision Engineering has recently installed two Aberlink Xtreme CNC CMMs.

“Our first manual Aberlink CMM has proved to be easy to use, very accurate and ultra-reliable. Therefore, as the launch of Aberlink’s Xtreme CMMs coincided with a sharp upturn in our business, we placed an order for two of the new machines,” says quality manager Rob Allen. “As Aberlink’s Xtreme CMMs feature temperature compensation and are designed to operate both in inspection departments and on the shop floor, we have installed both of the new Xtreme CMMs in our production facility.
“Our new shop-floor Xtreme CMMs are now in regular use by our production personnel for in-process inspection checks and verifying first-off parts,” he continues. “Rather than lose time taking machined parts to our inspection department, fast and accurate CMM inspection results can now be achieved close to the point of manufacture. This quick feedback enables adjustments to be made when component sizes deviate from nominal conditions.
“Our quality staff also use our new Aberlink CMMs for final inspection routines and for other applications. The CNC nature of the new Xtreme CMMs enables them to be loaded with batches of machined components; the relevant program is then selected and, following the press of a button, a rapid, fully automated CNC measuring routine is started. In addition to storing the captured data related to individual measured features of each component in the batch, when required, we are able to generate detailed inspection reports for each part.”
For further information www.aberlink.com

Update for quality data software

A new release of HxGN Smart Quality online quality data and measurement resource management software, an enterprise IT solution designed to help manufacturers utilise aggregated quality data to gain actionable intelligence and insight for process optimisation, has been announced by Hexagon Manufacturing Intelligence.

Providing a single platform for managing product quality and measurement resources, HxGN Smart Quality homogenises data from disparate systems across multiple locations to offer a company-wide view of quality.
The latest release features OEE-like functionality for all machines connected to HxGN Smart Quality so that manufacturers can assess and compare OEE using a standard metric. Offering insight into both availability and performance, the software supports root-cause analysis for investigating anomalies on an individual piece of equipment in line with TPM principles.
Improvements to the software’s document and work-flow management tool set enable manufacturers to build robust processes for measurement and minimise the risk of common operational errors. The user interface has also been enhanced with an individually configurable dashboard, while user-friendly functionality such as the ability to display part-mounting instructions within Hexagon’s Inspect software, helps to simplify shop-floor operations.
HxGN Smart Quality’s statistical process control capabilities are boosted with the addition of Q-DAS monitoring, which enables near real-time visualisation of measurement and process data. The software’s connectivity credentials are enhanced by the ability to interface with Heidenhain CNC controllers, offering new potential for data exchange with production equipment.
For further information www.hexagonmi.com

Measurement software boosts quality control

Faro Technologies has released its CAM2 2018 software platform for the company’s portable co-ordinate measuring machine products. Along with new reporting dashboards, the software offers improved quality control through Repeat Part Management (RPM) smart tool functionality.

RPM enables a specific inspection process to be created once and then repeated and executed by anyone on the factory floor. Accordingly, this ensures resource-efficient quality control of inspection routines without the need for highly skilled metrology professionals to drive and manage the process.
CAM2 2018 also features integrated web-based dashboard reporting that delivers real-time inspection results and insightful trend analysis in a user-friendly set of adaptable visual reports. As a result, RPM control
centre information can be shared across the organisation in real time, accelerating the ability to take immediate corrective action as required.
“As a full service, high accuracy, portable co-ordinate measuring solution provider, we can provide great value for our customers,” states Pete Edmonds, vice president of factory metrology. “Subsequently, we are focusing our platform development to ensure that our software enables customers to realise the full operational potential of their Faro hardware, ranging from small to large volume measurement. CAM2 2018 is a further evolution of our strategic direction to deliver the tight alignment of our hardware and software portfolios.”
For further information www.faro.com