Metrology Assisted Assembly & Automated Inspection - Leica ...

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Unlike the Leica Geosystems 6DoF MAP systemdescribed previously, where we use the 6DoF informationto correct a positioning device; we now need topre-program the robot to know how and where to scan.This needs to be programmed into the Robot ProcessManager before hand, but then once the robot programis started, the robots accuracy becomes arbitrary sincethe absolute position is measured using our 6DoFtechnology. This allows for a very accurate point cloudto be collected over an extremely large measurementvolume. The appropriate software package shouldbe selected depending on the type of analysis that isrequired by the job. For instance, if the process requiresdetailed feature extraction from the cloud of points,then a package like PC-Dmis or Metrolog may be beneficial,however if complex free form surface analysis,and flush and gap measurements need to be analyzed,then a package like Polyworks may be more applicable.No matter which way is used, at the end the customer/integrator has complete control over exactly how thedata is processed and how the results are finally reported.This process could be implemented for “hand-held”usage as well by simply removing the Robot ProcessManager, and replacing it with a trained operator. Asmentioned earlier, the robotic positioning system hasno relation to the achievable accuracy of the measurements.The robot (or operator) only needs to beaccurate enough to make sure that the measurementsare in the correct location. This same concept need notonly be applied to the Leica T-Scan, but can be appliedto a line scanner on the Leica T-Probe, or a Leica T-Macas well. It is possible to mount a Leica T-Mac like theLeica T-Scan on any robot or gantry positioning system.It can even be mounted as a sensor on a machine toolto allow for in process inspection.Take for instance a structural assembly stations, whereadditional measurement functionality could be extendedfrom a standard Laser Tracker integration. A LeicaT-Mac could be added to the machine tool to allowboth positioning control, and adaptive control of theend-effector (i.e. a drilling machine). In addition to this,a laser probe could be added to this configuration to allowfor non-contact surface measurements aiding withas-built surface inspection, and or automated shimming.With one core piece of hardware (e.g. a 6DoFLaser Tracker) the entire structural assembly systemcould be controlled and automated, and again it couldbe done either with an integrated software packagelike Spatial Analyzer, or Metrologic, or with an independentApplication Process Manager, and MeasurementProcess Manager like PC-DMIS.In the above example we are using a Leica T-Mac and anon-contact laser probe attached to a robot to measurelike a standard shop floor CMM. This configurationcould also be extended to a touch trigger probe thatwould effectively turn the system into an ultra largevolume CMM with better than 0.1mm absolute accuracyover the entire volume. A robotic arm could be mountedon a translation slide that would allow it to reach Page14 of 15 across, and slide down the full length of thestructure. This would allow such a device to measuresomething as large as a meter wing fixture.Many of these Leica T-Mac/Leica T-Probe/PC-DMISautomation concepts are currently in the prototypephase within Leica Geosystems. However, due to thecomplex nature of these systems, we are looking forfurther specifications for final products from our leadcustomers, that would allow the opportunity to createcutting edge solutions based on technologically maturecore components. The specific extensions to the 6DoFhardware are detailed in the following chapters. Pleasebe aware that these solutions are only in the prototypestage, and are not yet completed final products.12 Application Specific Measurement Processes
Extension of Leica T-Mac by non-contact sensorNon-contact probes are already used together withconventional CMMs. These devices use specific triangulationsensors and deliver a trigger pulse if the laserbeam is at focus position to the surface point. This triggerpulse would be used for both 6DoF data collection,and to stop the robot movement in process.Extensions of Leica T-Mac by a touch trigger sensorTESA (part of the Hexagon Metrology group) currentlymanufactures a series of touch trigger probesdirectly related to this application. Overall the technicalenhancement would be the equivalent to thenon-contact sensor, with the only difference beingthat the trigger pulse is generated by surfacecontact and not optically.Multi-sided Machine Control ProbeInstead of just one working surface with reflectorsand marker LED’s the goal would be that a combinationof different frames (up to 4 frames with 7 LED’sper face) could be interchanged. This would create ascaleable solution with options extending from 1 to4 sides.Leica T-Probe / Leica T-Mac integrated line ScannerConnecting a line scanning device to create a lowprice solution would be useful for many standardapplications, especially in the direction of automatedsurface scanning. This type of sensor could beconnected to a Leica T-Mac, or Leica T-Probe like itexists already, or it could be used with a multi sidedMachine Control Probe as described above. The integrationshown below allows the scanning head to berotated +/- 60° around the center position for betterlaser line control.Application Specific Measurement Processes 13
Page 1 and 2: Leica Geosystems Laser TrackerMetro
Page 3: IntroductionThe Metrology division
Page 6 and 7: A “Front End” Software Independ
Page 8 and 9: Application Specific Measurement Pr
Page 10: In this case it would be possible t

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