IDS: Trained quickly, inspected swiftly

Careful quality control is essential to ensure that only flawless indexable inserts leave production and meet high durability and reliability requirements. A flagship project by automation and measurement technology specialists Xactools and IDS Imaging Development Systems demonstrates how AI can help visual inspection make quantum leaps. The companies developed a fully automated handling and inspection system for a global manufacturer of indexable inserts based in Scandinavia.

A total of eight high-resolution industrial cameras and two spider robots handle and inspect the indexable inserts for defects, which monitor and load three rotary table nests and one pin pallet each. DENKnet’s AI forms the heart of the complex image processing system between cameras, robots and a multi-GPU computing rack to help drive zero-defect production.

The indexable insert manufacturer has around 2800 products in its portfolio, divided into almost 100 geometry families. The aim was to automate handling and defect inspection for them all.

The first challenge resulted from the numerous colours, whereby the AI required extreme training to variations and lighting conditions. But in addition to visual appearance, it is also about insert geometry. Categories such as triangle, rectangle, rhombus and square can be found in countless variations. Around 20 to 30 images were needed to teach each geometry family.

The team integrated AI into the production line in just a few months, achieving almost perfectly reliable AI results for checking right from the start.

“Indexable inserts identified as defective are sorted and grouped according to the size and position of the defect,” says Daniel Routschka, sales manager – AI at IDS Imaging Development Systems. “The AI image analysis detects more than 99% of production errors.”

More information https://en.ids-imaging.com

Thread gauges aid custom race car solution

Bowers Group’s precision measurement expertise played a crucial role in supporting the University of Wolverhampton Racing Team (UWR) with the manufacture of an adaptor plate. Used by OEMs such as Morgan, Mini and Toyota, adaptor plates convert the standard oil heat exchanger on the BMW B48 variant engine into an external oil cooler system. To ensure the accurate measurements of critical components, Bowers Group supplied an XT3 Holematic thread gauge, aiding UWR in achieving optimal performance.

UWR and the Morgan Motor Company were in an ongoing partnership to help convert two CX platform Plus 4 cars from road production vehicles into racing cars. The UWR team scheduled track test days to gather performance data on the new racing cars, where they discovered high engine and oil temperatures that could impact performance.

After exploring additional venting options that did not provide the desired impact, UWR designed an adaptor plate to replace the standard heat exchanger on the oil filter housing. This plate would enable the installation of an external oil cooler system, which was much better suited to lower both oil and engine temperatures in unison.

The team sought assistance from its partners and sponsors, including Bowers Group, Quickgrind, and Tungaloy UK, for the tooling and manufacturing of the plate. With time critical to resolve the issue as quickly as possible, Bowers Group promptly supplied an XT3 Holematic thread gauge to test the connections of the adaptor plate and ensure the team could build it accurately. Precision measurement was crucial for plate, which acts as a fluid barrier and pathway for both oil and engine coolant.

More information www.bowersgroup.co.uk

Extra stability for portable measuring arms

All 34 portable measuring arms offered in six-axis touch-probing and seven-axis multi-sensor variants by LK Metrology, are now available as standard with a 4.5-inch diameter mounting ring that allows the unit to sit on a larger base (3.5-inch ring previously). The new Version 3 Freedom arms are subsequently capable of measuring to higher precision. LK can supply a mounting ring adapter if an existing user already owns an LK tripod or stand with a 3.5-inch mount. Mechanical, magnetic and vacuum fixing alternatives are available.

As previously, the latest mobile metrology solutions feature a lightweight carbon-fibre tubular construction. Position feedback arrives courtesy of absolute rather than incremental rotary encoders, with the arms available in three accuracy categories: Classic, Select and Ultimate. Each is now capable of significantly higher accuracy measurement of size, position and form, whether using a tactile probe or laser scanner. Probing accuracy carries certification to ISO 10360-12 with functionality guaranteed up to 40°C.

The work-hardened six-axis arms offer full IP54 protection from water splashes and the ingress of dust and particles, delivering reliable, repeatable 3D inspection and measurement in harsh industrial environments. Also provided is enhanced RDS v6.4 software running on Windows for communicating with the arm via Wi-Fi or USB. The software offers improved monitoring of parameters such as ambient temperature and stress on the articulated joints, as well as base vibration, displacement, tilt and inclination.

The seven-axis Freedom Arm v3 does not offer IP54 protection but is able to deploy a laser scanner and a tactile probe to enable multi-sensor metrology. An OLED touch-screen display provides the operator with convenient fingertip control, raising inspection productivity by avoiding having to go back and forth between the arm and a computer.

More information www.lkmetrology.com

Sustainability at ASG

ASG Group, the Stockport-based aerospace conglomerate, is making significant strides in decarbonising aerospace manufacturing. With a long-term vision for sustainability, the company is spearheading initiatives across its subsidiaries, including ASG Produmax in Bradford, Bromborough-based ASG AMF and ASG King & Fowler in Liverpool. Group managing director Simon Weston says: “From partnering with local councils to investing in renewable energy and innovative processes, we are dedicated to reducing our environmental impact and leading the industry towards a sustainable future.”

More information www.asg-group.co

Global recertification for composites firm

Velocity Composites has been recertified for the AS9100D and AS9120B quality management standards across all three of its manufacturing sites in the UK and US. Matt Archer, chief commercial and compliance officer at Velocity Composites, says: “The continued certification reinforces our commitment to striving for zero defects and sustaining an exceptional service for our customers.”

Velocity Composites manufactures carbon fibre and ancillary material kits for use in the aerospace and associated industries. The company manages the end-to-end raw material supply chain and reduces the amount of material required by customers, as well as the associated waste.

More information www.velocity-composites.com