14 MEASUREMENT other hand, laser profile sensors may be needed for surfaces with “matte” like finishes. Metrology platform that is significantly faster than conventional systems During the development of ZeroTouch, special attention was given to problems that conventional CMMs face: obtaining quick, accurate and reproducible results to keep pace with manufacturing cycle times. Most traditional inspection systems have issues specifically with speed, ease-of-use and machine availability. As a result, traditional measurement technology does not lend itself to inline inspection or even fast sampling. Providing the operator a tool that is easy to use to perform rapid quality checks of various types of parts produced by different lines is vital to ensure the qualification of manufacturing lines, in addition to speeding up the production ramp. CMMs are typically located in environmentally controlled inspection rooms, which often impact machine availability. If the parts are to be inspected in the metrology room during the production process, part "queues" are to be expected, due to limited machine availability coupled with long CMM setup times. ZeroTouch has been designed precisely to mitigate these issues, being fast, flexible, easy to use, and compatible with the manufacturing environment. ZeroTouch enables 100% part inspection. In addition, the ZeroTouch is characterized by its ease of use. By giving the operator an easy-touse tool, different types of parts produced on different lines can be quickly inspected. Such capability will enable the rapid qualification of manufacturing lines and speed up production ramp. ZeroTouch’s unique architecture features 5 independent axes; a rotating bridge – Gonio like – equipped with multiple, non-contact sensors, including lasers and chromatic confocal sensors, which dramatically increase inspection speeds in measuring the entire part surface, as there is no sensor change time. The sensor bridge is configurable allowing for the most optimal and appropriate sensor selections to suit part geometries and surfaces, in addition to the complex dimensions being measured. Such innovations associated with a horizontal rotary table and 3 translation axes result in higher throughput of parts and increased capacity, enabling 100% in-line inspection rather than just sampling. The innovative design of ZeroTouch presents a remarkable improvement in surmounting the challenge of repeatability in a hostile manufacturing environment. Since it can perform multiple measurements in parallel using different sensors, parts and assemblies can be analyzed significantly faster than a conventional CMM. “The sensors can be configured to the specific GD&T measurements and the part, and in one scan the system can capture data points to create a high-density 3D model,” says Mendez. “This makes it possible to measure objects made of a wide variety of materials with complex geometries, including holes, undercuts, bevels, and surfaces, quickly and with micrometer precision. At the same time, the system provides very high reproducibility and repeatability of results.” The various non-contact sensors on the metrology bridge can be easily calibrated by software directly via the metrology platform. Further time is saved by the simplicity with which parts and assemblies can be placed on the measuring table, instead of requiring complex positioning fixtures. This, not only decreases the metrology preparation time but also enables direct cost savings in fixture design, development and management. “It was also important that ZeroTouch shows no signs of wear, and delivers the same performance year after year,” says Mendez. “So we gave it a planar air bearing system”. The moving parts, such as the measurement platform and sensors, generate virtually no friction during the measuring process. Part inspection plans can be created within a few hours and stored in the manufacturing execution system (MES) for management and retrieval. “The user is assisted by menu-guided intuitive tools, making deep programming knowledge superfluous now,” says Mendez. “Instead, inspection plans can be prepared using drag-and-drop functions.” Measurement data for each component is retained to ensure data integrity. Thereafter, component-specific plans can be accessed in the MES for fast measurement. Optionally, components or assemblies can be given barcodes to be read by an onboard barcode reader. The respective inspection plan is then automatically loaded from the MES. The control software provides high personal safety by ensuring that the system does not move as long as the doors of the switchgear cabinet are open or if the system light curtain has interference. Software with integrated analysis tools for faster quality control The three-dimensional point cloud can be analyzed immediately after the measurement process. Integrations to proven analysis tools enable the accurate comparison of the scan results with part CAD models or a reference part previously scanned and measured to not only check for geometric and dimensional tolerances, but for other previously undetected issues such as surface aspect defects. Using statistical process control (SPC), faults or outside-tolerance deviations can be quickly detected and appropriate reporting can be sent back to the MES. This could enable the adjustments of process parameters in upstream manufacturing processes to minimize rejects downstream. The current system measures 240 x 150 x 190 cm (L x W x H) and weighs 3550 kg. It can measure parts measuring up to 300 x 300 x 300 mm and weighing up to 10 kg. It uses a high performance GPU PC with Intel Core i7-7700T processor, and two capacitive industrial monitors with touchscreens. In the next issue: Complete <strong>Finishing</strong> Plant Health and Safety Anodizing and Galvanizing <strong>Finishing</strong> - <strong>July</strong>/<strong>August</strong> <strong>2020</strong>
INNOVATIVE AUTOMATIC COATING. SprayPackE Automatic control unit • Quick installation & individual extensions Contact • Step by step instructions for process control Wagner Spraytech (UK) Ltd • a Efficient Member of & WAGNER resource-saving GROUP coating • Telephone: High coating 01327 quality 368410 • enquiries@wagner-group.com IoT ready wagner-group.com Contact Wagner Spraytech (UK) Ltd a Member of WAGNER GROUP Telephone: 01327 368410 enquiries@wagner-group.com
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