March 2008 Edition

IMTS readers' choice

QUALITY/INSPECTION SOLUTIONS

 

 

 

 

 

First of its kind

Hommel-Etamic of Rochester Hills, MI, has introduced a solution for automated in-line part inspection of bores, such as those found in connecting rods, brake master cylinders, injection system components, and hydraulic valves that cannot tolerate surface finish defects.

Consisting of an optical sensor, computer, and a slide to position the sensor, the IPS-10 internal inspection system is the first device of its kind worldwide. It is designed to be installed within a production line to inspect bores with a diameter of 14mm to 50mm and depths to 450mm. Typical cycle times are only seconds per part to produce a complete optical inspection of a bore's inside surface

Parts to be inspected must have a clean, dry surface in order to use this optical inspection method, according to the company. The system detects surface flaws such as cavities, scratches, porosity, valleys, edge flaws and unmachined surfaces fully automatically. The completeness and position of transverse holes and grooves is also possible in the same step.

A 360° panoramic view optical system inserted into the bore creates an image of the bore's inside surface. Circumferential lines in the bore are projected in circular lines in the image level. This image is scanned continuously by a fast CMOS ring sensor array. Simultaneous forward movement of the inspection sensor and circular scanning creates an undistorted image of the inside surface which shows a rolled-out representation. Identical illumination conditions at every point produce brilliant, rich-contrast images. The optimum illumination and scanning speed of the camera make this inspection system superior to other solutions.

Hommel-Etamic

Backlit conveyor

A custom integrator of turnkey automated inspection machines for quality control, Cincinnati Automation "saw the light" – adopting a new LED backlit conveyor to convert automotive part gaging from a step-by-step to continuous process, more than tripling throughput. The AccuVision conveyor from Conveyor Technologies Ltd. features a grid of high-intensity LED lights beaming up through a translucent urethane conveyor belt.

Pick-and-place backlit gaging was limited to about 10 parts per minute, compared to 36 a minute for the new continuous conveyor system. The higher processing speed is governed by the speed of the part loading system.

The continuous gaging system is configured to run 40 different part numbers for the automotive supplier, ranging from 5" up to 8" OD. Robot grippers load the parts three at a time on the 66" x 12" translucent belt. Parts advance along the belt to the LED light field, where each is visually gaged by an overhead Keyence digital camera with an 8.5" field of view. At the end of the conveyor, a second Keyence camera with a 0.5" field of view gages the side geometry, catching the lead edge just as it extends beyond the conveyor. Parts then pass off the conveyor to an incline slide with a diverter flap. Failed parts drop through a slot in the incline. The flap lowers for good parts, covering the slot and allowing parts to pass down to the next station. The Keyence cameras in the CA system deliver two mega-pixel imaging.

Conveyor Technologies Ltd.

On-Machine Verification

Delcam has added a multi-axis option to the On-Machine Verification version of its PowerINSPECT inspection software, the world's leading hardware-independent software system for the comparison of components or tooling against 3-D CAD data. With this option, companies with four-, five- or six-axis equipment will be able to undertake comprehensive verification of their parts on their machine tools, both during and after machining.

The main advantage of the new option will be the ability to check any undercuts, without any need for repositioning the workpiece. Similarly, it will be possible to check inside features that are not accessible from the z direction. The OMV version of PowerINSPECT offers all the advantages associated with the software for use on dedicated inspection equipment. It gives both quick and easy comparison of tooling and sample components against CAD data, and produces clear, comprehensive reports that can be understood by everyone involved in the product development process, not just inspection specialists.

The system allows off-line programming of the inspection sequence for the machine tool, with fully integrated simulation, and so minimizes the time taken on the machine for verification.

The most obvious benefit of On-Machine Verification is for those companies that do not have existing inspection capabilities, such as companies that machine parts so large that the cost of a dedicated inspection facility is prohibitive. Most modern machine tools either come with, or can be retrofitted with, probing capabilities. With the OMV version of PowerINSPECT, this same equipment can now be used for verification at little extra cost. Delcam

PG-Series Bore Gages

Sunnen's PG-Series Bore Gages are ideal for fast, simple, economical process control in a lean manufacturing environment, combining lab-precise accuracy (±0.000025"/0.0006mm) with a shop-hardened, all-mechanical design. PG-Series gages bring reliable ID gaging to the manufacturing floor with no need for electrical or air connections, making them immune to fluctuations in line voltage or air pressure.

Compact and easily portable, the gages can be mounted right at machining stations. Unique gaging fixtures enable simple two-minute setup, while eliminating the need and expense for plug gages, mikes, Jo Blocks, master rings or micrometers. The PG Bore Gage removes complexity, skill and "feel" from the measurement process, allowing machine operators to precisely confirm part size with a visually intuitive analog scale.

PG-Series Bore Gages can be used to examine the entire bore for diameter, taper, barrel, bell mouth, out-of-round and lobing.

Sunnen

Marposs sweep gage

Marposs Corp. offers a new electronic "sweep" gage incorporating Bluetooth wireless technology for inspection of parts having holes that have a position tolerance. The new M1 Wave Sweep Gage, which was developed in conjunction with Zero Gage, a division of Benny Gage Inc., Plymouth, MI, is based on Marposs' unique M1 Wave manual wireless bore gage. By adapting the M1 Wave with a special linear probe, Marposs integrates a wireless electronic gage with a sweep gage, depth gage or virtually any other mechanical device to enhance data acquisition and recording procedures and to improve gage reliability and operator convenience.

Because the gage is wireless, the new M1 Wave Sweep Gage relieves operators of twisted cables that result in early failure through cord breakage, and eliminates all their maintenance costs. Unlike other gages with add-on wireless capability that provide only a data snapshot through burst communication, the M1 Wave sweep gage takes advantage of the speed and bandwidth provided by the Bluetooth wireless technology.

 Marposs Corp.

Fluke thermometers

Fluke Corporation, the global leader in handheld electronic test and measurement technology, today announced the Fluke 566 and Fluke 568 Thermometers, which feature broad infrared temperature measurement functionality, an on-screen menu system and a dot-matrix display enabling users to take even complex measurements quickly, easily, and from greater distances.

Both of the rugged Fluke 566 and Fluke 568 handheld thermometers combine contact and non-contact temperature measurement capability in one single, easy-to-use tool, providing a total and convenient temperature measurement solution for industrial, electrical and maintenance professionals. The thermometers provide a broad temperature measurement range from -40 °C to 800 °C /-40 °F to 1472 °F (Fluke 568) or -40 °C to 650 °C/-40 °F to 1202 °F (Fluke 566) at 1 percent measurement accuracy, making them appropriate for a wide variety of inspection applications.

With a user interface designed for intuitive operation and available in six languages, users can access advanced features such as adjustable emissivity, alarms and data logging with a few pushes of a button via a soft-key menu displayed on the dot-matrix LCD screen. The display has two levels of backlight to facilitate viewing even in challenging lighting conditions.

 Fluke Corp.

Position sensors

Macro Sensors, a sensor company specializing in the manufacture of Linear Position and LVDT-based linear sensors and gaging probes, offers a metric version of its 24V DC-LVDT position sensors. Constructed entirely of stainless steel, the HSE/HSER 750 Series of 19.0 mm diameter DC-operated LVDTs are hermetically sealed, making them impervious to dirt, water, steam and other corrosive elements. These CE-approved and highly rugged units are ideal for use in hydraulic cylinder positioning, valve position sensing, automatic assembly equipment and other industrial applications with hostile conditions and corrosive environments.

In addition to its heavy-duty housing, the sensor's coil windings are sealed against hostile environments to IEC standard IP-68. A single-ended LVDT, the HSE Series 750 units terminate through a sealed axial connector that prohibits the core from passing completely through the coil assembly. Electrical termination for the HSER Series 750 DC-LVDTs, however, is made through a sealed radial connector located near one end. The radial connector offers a through-bore design that permits access to either ends of the LVDT's core for better mechanical support and core guidance, and easier cleanout.

Macro Sensors

Numbering tool

Mate Precision Tooling leads the punching industry with another first – the all new Mate Enumerator Sequential Numbering Tool designed to stamp sequential serial numbers, dates and codes on fabricated parts. The unique tool system extends the punching capabilities of today's CNC punch presses and delivers added value to products in a way previously not possible. Sequential numbering up to six digits long allows for accurate product traceability required in today's quality processes. It is accomplished within the punching process, eliminating the need for complex machine programming or a costly secondary operation.

The Mate Enumerator is a thick turret 3½" D station special assembly with integral punch holder. At the core of the assembly is a robust spring-loaded stamping head with six numerical stamp wheels. Each wheel features the numbers from 0 to 9 engraved around the circumference. The Mate Enumerator operates in two modes:

Sequential Number Mode: Use this mode to create sequential numbers.

Fixed Number Mode: Use this mode to create fixed numbers such as date, batch number, or part number.

 Mate Precision Tooling

Ultra-high-speed scanning

Renscan5 ultra-high-speed scanning technology delivers tremendous throughput gains in coordinate measuring machine inspection of critical and complex parts. Early adopters report 680 percent improvement on automotive cylinders heads and 922 percent faster processing of jet engine blisks. Renscan5 meets industry needs for reduced WIP, greater process control, and ever tighter tolerances by delivering 10X and more data points on greatly reduced cycle times – up to 4,000 points/sec. The breakthrough system combines a dynamic, infinite positioning measurement head with five-axis machine control and a first-ever laser-corrected probe to measure at speeds up to 500 mm/sec. vs. conventional CMM scanning at 5-15 mm/sec.

Renscan5 virtually eliminates the measurement errors normally associated with existing three-axis scanning systems. The five-axis system achieves this by allowing the smaller REVO measuring head, a 3-D measuring device in its own right, to perform most of the motion during inspection routines. This minimizes dynamic errors caused in acceleration/deceleration of the larger mass of a CMM structure.

Renishaw

Tool touch probes

With the introduction of the TS 740 infrared touch probe, Heidenhain offers machine tool users the opportunity to perform measuring tasks that require an especially high probing accuracy and repeatability. Boasting a probing accuracy of ± 1 µm and a repeatability factor of 2 s£ FACE="TimesNewRomanPS" SIZE="2"> 0.25 µm, the TS 740 workpiece touch probe is one of the most accurate 3D touch probes for machine tools in the market today.

To do this, the Heidenhain TS 740 touch probe features a new sensor whose principle of function is completely different from that of the optical sensor of its standard touch probes. The new technology involves the use of three sensor elements. When probing a workpiece, the stylus is deflected so that a force acts on these elements. This results in the generation of charges that are detected by the electronics and converted into trigger signals. This system allows for more accurate results.

Heidenhain Corp.

Thread inspection instrument

General Inspection LLC has recently installed a new computer-controlled missing internal thread detection instrument to a large die cast manufacturer in Kentucky. This NCTP-200 is a four channel computer controlled instrument using a new menu driven, digital keypad that allows operators to quickly calibrate, program and save settings and have the system ready for inspection in less than 2 minutes.

Four spring-loaded probes are mounted on a plate that is fixtured over the die cast components transfer line. Once the parts are transferred into position a pneumatic slide drives the probes into each of the 4 holes. Within a tenth of a second the NCTP-200 determines if the holes are properly threaded and provides an immediate signal back to the machine controls. If the part is rejected a lock down feature holds the defective component in place until the operator presses the unlock button and removes the product from the transfer line.

General Inspection LLC

Laser trackers

Exact Metrology Inc. has added four Leica Geosystems laser trackers to its extensive line-up of portable metrology equipment. Exact Metrology purchased a Leica LTD840 with a Leica T-Probe, and three Leica LTD709 laser trackers to further expand their contract inspection and reverse engineering service capabilities.

Exact Metrology Inc. is a full service contract measurement company that provides on-site inspection, reverse engineering, non-contact laser scanning, and 2-D/3-D digitizing services as well as contract programming, software training, part programming, and measurement equipment implementation.

The Leica LTD709 offers a measurement range of up to 9m (30ft) for Portable Coordinate Measuring Machine (PCMM) applications, which is an increase of 25 percent over the model it replaces. At the same time, the LTD709 boasts a measurement range of 25m (82ft) when used with a reflector.

Leica

DPAInspect system

"Added value by integration" – AICON follows this guideline with its photogrammetry system DPAInspect like no second supplier in the market. The portable 3-D industrial measuring system is not only designed as a stand-alone solution to measure parts. It may also be combined with all established and leading surface measuring systems and measurement software packages.

The 3-D industrial measuring system DPAInspect works with a digital camera as acquisition device. Thus it is able to measure parts in any location.

Measurement software packages such as PolyWorks/InspectorTM, Geomagic or Rapidform integrate DPAInspect as a plug-in. Consequently, the 3-D measuring data collected with the DPAInspect camera are directly transferred to the available measurement software for analyzing, e.g., for a comparison with CAD data. In doing so, the user stays in his usual software environment and starts the AICON DPAInspect plug-in simply with a click.

 AICON 3D Systems