FEATURE ON METROLOGY

3D measurement for small batches

At the EMO exhibition in Hanover last week, Alicona presented its new ‘cobot’ system, combining collaborative robots with high-resolution optical 3D measuring sensors. The new Compact-Cobot is a universal solution applicable in all industries to verify surface state and dimensional accuracy.

Alicona cobots combine collaborative robots and optical 3D measuring sensors. A measuring sensor is mounted to a mobile robot platform and can be positioned as needed, even for the measurement of components in the machine. This is made possible by intuitive hand-guided controls for the teaching of measurement routines, automatic measurement evaluation and a no-enclosures safety concept.
Cobots require no prior metrology knowledge and make handling, programming and executing measurement routines easy. Using connected automation software, any series of measurements can be defined by an administrator at several positions, which the operator then starts with the press of a button. Control and measurement are fully automated, and upon completion the worker receives a measurement report with OK or not OK details.
In addition, an optional CADCAM connection allows the definition of measurement points and directions directly in the corresponding CAD file. A simulation provides a preview of the process to be performed, supporting safe and secure measurement planning. Virtual operation of the Alicona measurement system comprises the entire handling, from the positioning of a component through to the determination of the measurement area in 3D.
For further information www.alicona.com

GB Precision upgrades microscope

Birmingham-based GB Precision has expanded the benefits obtained from its toolmaker’s microscope by equipping it with a Tucsen TrueChrome Metrics digital image measurement system. The TrueChrome transmits images directly from the microscope, in real time, to an attached PC screen. Last year, Alrad Imaging announced a UK distributorship for Tucsen scientific cameras.

“This has greatly increased the advantages we gain from the microscope, transforming it from solely an inspection tool into a flexible communication device that helps us solve engineering problems,” says GB Precision director Paul Turner. “One of the issues with using a microscope on its own is that, naturally, only one person at a time can view the image. That’s inconvenient when wanting to discuss a specific feature, angle or geometry with members of the team.”
Using the camera attachment, the image is displayed directly on a PC screen, so several people can simultaneously see the component under review and, if the viewing angle, position or magnification needs to be altered, again, all parties see the change immediately. Furthermore, viewing the images on a large PC screen is easier than looking through a microscope eyepiece, making detailed image scrutiny a more comfortable experience.
Another significant benefit is the ability to automatically store data directly to the PC, thus maintaining a detailed record for future use – a growing requirement of customers in sectors such as aerospace, medical and pharmaceutical.
For further information www.alrad.co.uk

£40m metrology centre gets official launch

The Future Metrology Hub, based at the University of Huddersfield and funded by the EPSRC and industry, was officially launched at an event attended by more than 130 scientists, engineers, academics and industrialists from around the UK. They heard a sequence of talks from key figures, including the hub’s director, Professor Dame Jane Jiang (pictured), who provided an overview of its work. She said that metrology is critical to modern manufacturing and pledged that the technology she and her colleagues develop in the lab – such as sensors and artificial intelligence control systems – would be geared-up for use in the real world of industry.

University of Huddersfied, Director of the Future Metrology Hub, Professor Jane Jiang.
11.09.17

There are 29 industrial partners, including firms such as Rolls-Royce, Jaguar Land Rover, GKN Aerospace, BAE Systems, Siemens, Reliance Precision and Carl Zeiss, all of which were represented at the launch. Another key partner is Renishaw, which has collaborated with the University of Huddersfield for a quarter of a century. Renishaw’s group engineering director, Professor Geoff McFarland, gave the keynote address at the launch day.
He described the trajectory of modern manufacturing, with its “intelligent factories with zero waste and optimal efficiency using automated processes”. Metrology was crucial to this, said McFarland, describing the science as “one of our best manufacturing tools”, and it needed to have a presence on the shop floor.
Renishaw has more than 1500 patents and patents pending, said McFarland, “but we don’t have all the answers and there are more and more questions. And that is why we are involved with this wonderful hub.”
For further information https://research.hud.ac.uk/institutes-centres/fmh

IMS drives cost savings at Bosch Rexroth

Drive and control specialist Bosch Rexroth has reported two years of maintenance-free production at its plant in Schweinfurt, Germany, following the installation of its own Integrated Measuring Systems (IMS) on its machine tools, a move that has saved the company tens of thousands of euros in maintenance and running costs.
The plant, which manufactures precision linear motion components such as profiled rails, runner blocks and ball screw drives, as well as entire linear motion systems, has not experienced a single instance of machine downtime, while producing materials with a repeatability of ±0.25 µm.
Bosch Rexroth has now converted its cost savings into a “Total Cost of Ownership“ tool, which allows manufacturers to calculate their own savings, as well as the potential savings for mechanical engineers and end users.
Until 2014, Bosch Rexroth relied on optical position sensors, or glass scales, to achieve the desired accuracy with its metal-cutting equipment. These solutions were expensive because they required regular cleaning and maintenance. At times, they were even responsible for machine failures because they were prone to introducing contaminants. As a result, Bosch Rexroth installed IMS, which can detect the absolute position of an axis down to ±3 µm/m, into its ball and roller runner blocks.
“Accuracy requirements are becoming more exacting in virtually every metal machining application,” says Stefan Dorn, head of advanced engineering and technical product management for linear motion technology. “To meet this challenge, Bosch Rexroth has been using its maintenance-free IMS solutions in upgraded machine tools for more than two years. Since replacing the glass scales, we have achieved five-figure savings in terms of maintenance costs and availability.”
For further information
www.boschrexroth.com

NDT for aerospace

Creaform has announced that it will extend its expertise in NDT to the aerospace industry. By expanding access to its inspection solutions, the company aims to better enable airlines, as well as MRO service companies, to more efficiently perform the evaluations of in-service aircraft safety, while cutting costs and saving downtime.
“As predictive maintenance becomes more prominent, aviation maintenance professionals and aircraft MRO providers are increasingly on the lookout for innovative methods that enable quicker and safer decisions to be made on the outcome of part defects,” says Steeves Roy, NDT product manager at Creaform. “The mapping of external surface defects on aircraft parts, which can prove difficult to obtain using traditional methods – namely hail damage, bird impacts and lightning strikes on the fuselage and wings – can be assessed with 3D scanning. When paired with advanced inspection tools, such a solution cuts down on the operator’s impact on measurements, shortens time to get the final report and reinforces decision making.”
To ensure that the solution matches aviation maintenance industry requirements and properly reflects market needs, Creaform is partnering with major aircraft manufacturers for beta testing. The surface inspection solution dedicated to aerospace applications is set for release in October 2017.
Well-known for its NDT solutions offered to the oil and gas industry, Creaform’s NDT product solution is comprised of its flagship HandyScan 3D portable metrology-grade 3D scanner and its Pipecheck NDT software, both of which allow automatic on-site inspection, detection and characterisation of pipeline defects. With traceable and repeatable inspection data and results, operators can access critical information for making safer decisions.
For further information
www.creaform3d.com