Advances in Automated Profile Measurement for ... - ASCONA

Advances in Automated Profile Measurement for Aluminium Extrusions
Often the top three quality issues faced by aluminium extruders include out-of-tolerance profile
dimensions. Dimensional profile integrity is affected by many variables; however the
conventional approach to measuring dimensions at the press is the use of manual tools such as a
caliper and micrometer. The result is a reactive stance in the extrusion process where
unnecessary costs are incurred due to running bad dies, increased labour for rework or customer
returns and lower press productivity. Clearly the need for an effective automated measurement
system exists to enable a proactive approach to dimensional quality in aluminium extrusion.
The Contur Projector from ASCONA GmbH is the latest technology available for aluminium profile
measurement. Developed in conjunction with leading extruders in Europe, the Contur Projector
reflects innovations in both hardware and software that allow such a system to work in the
production environment. The common issues of system location, sample preparation and system
ease-of-use have been solved in the Contur Projector development.
ASCONA is an R&D driven company based in Meckenbeuren Germany with expertise in advanced
optical measurement. Their mission is to develop industry-leading measurement technology that
helps the customer achieve world-class quality for their customers. The goal is higher profits
AND higher quality from improved dimensional control in aluminium extrusion.
Location at the press is critical to support the
extrusion team to monitor dimensional
performance through frequent and complete
measurements. The Contur Projector
construction provides protection from dirt,
vibration and temperature – issues common in
the extrusion environment. The optical lens,
exclusively developed with Carl Zeiss GmbH,
provides the system with a direct, telecentric
view of the profile with a guaranteed accuracy
of +/-10µ – an excellent achievement for the
production floor!
Sample preparation for any measurement
system is a critical requirement to ensure
reliable results. The Contur Projector
demonstrates the latest patented innovation
where the sample orientation is horizontal. A
horizontal perspective requires that the sample
only has no burrs; therefore preparation can be
quickly and easily done by any user. Typical
preparation time is approximately 30 seconds
using only a debur process from a standard saw
cut. There is no requirement to ensure an exact saw cut or sharp edge since these factors do
not impact measurements done in the Contur Projector. In addition, the sample length of 200
mm or more improves safety for the user when cutting aluminium and has no impact on
measurement reliability.
The Contur Projector utilizes software developed by ASCONA to meet the design, measurement,
reporting and analysis requirements for the extruder. Design and reference data set up begins
with either a CAD file or a sample part. In either case, the basis for reference measurement is
the profile shape. After this is imported, each measurement can be defined by only a few mouse

clicks. Advanced intelligence in the Contur Projector software enables quick set up of all
reference measures, which in some cases could be hundreds of measurement points. Through
the use of profile reference points and macros, repeated measures or symmetrical shapes are
quickly set up. Typically, new profiles can be set up by the engineering or quality staff for the
Contur Projector in approximately 3-5 minutes with no programming required. During the
extrusion process, the
measurement cycle itself is
less than 10 seconds which is
well below a 1-billet cycle
time, thereby allowing the
extrusion team to see all
dimensional results quickly for
decision making purposes. If
the die is running out-oftolerance,
then the press
should be stopped – or even
better, the ability to predict
when a die will fail offers a
significant cost avoidance
opportunity to replace the die
before scrap is incurred.
As well, if customer tolerance requirements change, the user is able to modify the reference file
and reassess actual dimensional results since the Contur Projector captures the exact profile
image on the network. Quality audits are easily supported since every measurement is logged in
the database which is critical for advanced application traceability standards (e.g. automotive and
aerospace).
Finally, the importance of reporting should not be minimized as this is often the customer view of
the measurement system. The Contur Projector provides extensive reporting capability for both
internal and external users. Summarized and detailed tolerance reports are available
immediately after a measurement cycle is completed. These may be run adhoc or as a standard
procedure for customer documentation with every order. Also, if more advanced reports are
needed, custom reports can be created in the software to show only the information required by
the customer. The Contur Projector reports are internet-enabled so only an internet browser is
required for another user to review dimensional tolerance reports – which is a very efficient
method to report this information.
ASCONA’s latest system release for the Contur Projector includes measurement of profiles up to
290mm x 650mm, cycle time down to 3 seconds at 10µ repeatable accuracy, and weight-based
measurements so kg/mt (or lbs/ft) are automatically calculated with every sample.
Overall the Contur Projector from ASCONA truly delivers on the new vision for aluminium
dimensional measurement where operator independence can be achieved through the latest
technological advances. Proactive quality requires the measurement system to support
frequency, productivity and traceability. The result improved dimensional quality and press
operations – or restated, improved profits for the extruder and improved quality assurance and
tighter tolerances for the customer.