ADVANCES IN DEFECT DETECTION
LASER WELD INSPECTION FOR SAFETY CRITICAL WELDS
Automotive OEMs and suppliers, along with any other manufacturers that require Six Sigma production from their robotic welding cells, can benefit significantly from automated laser weld inspection. In conjunction with their world-leading robotic arc welding solutions, Motoman (Dayton, OH) offers laser inspection systems that automate checking of safety-critical welds.
To provide automated weld inspection, the laser camera scans the weld profile for visible discontinuities, such as voids, convexity, undersize and/or undercut conditions. The laser sensor is flexible, and the user can set accept, warn and reject limits on discontinuities. Output from the sensor can be used to separate nonconforming parts from production.
For Six Sigma production, the camera supplements arc monitoring by verifying that welds "look good" and are in the proper location. The laser camera provides quantifiable inspection results 24/7/365. Nonconforming parts are separated from production, reducing the need to use third-party containment.
Using laser weld inspection as part of the manufacturing process keeps poor quality or missing welds from being covered with additional brackets or other components. Laser cameras can also be used to inspect the final weldment to detect nonconforming parts prior to assembly operations.
Free Product Info #01
5-AXIS CMM INSPECTION OFFERS REVOLUTIONARY THROUGHPUT
Renscan5 ultra-high-speed scanning technology delivers tremendous throughput gains in coordinate measuring machine (CMM) 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, from Renishaw Inc. (Hoffman Estates, IL), meets industry needs for reduced WIP, greater process control, and ever tighter tolerances by delivering 10X and more data points. The breakthrough system combines a dynamic, infinite positioning REVO measurement head with 5-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.
This five-axis system virtually eliminates the measurement errors normally associated with existing three-axis scanning systems by allowing the smaller measuring head, a 3D 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. Low-mass, low-inertia design allows ultra-high-speed data capture — up to 4000 points a sec vs. 200-300 data points for conventional scanning.
The head uses synchronized motion when scanning to quickly follow changes in part geometry, without introducing its own dynamic errors, allowing the CMM to move at a constant velocity along a constant vector as measurements are being taken, removing the inertial errors that result from acceleration of the machine during conventional 3-axis scanning. Two rotary drives (360 deg in hor plane, 120 deg in vert plane) provide wrist-like action to optimize part access and enable infinite adjustment to the part surface while measuring.
A highly innovative "tip sensing" probe mounted to the measuring head further minimizes the errors caused by the dynamic effects of high-speed motion and allows the use of long styli without reducing accuracy. A laser light system accurately measures the exact position of the probe tip with a beam of light directed from within the probe body down a hollow stylus to a reflector at the stylus tip.
Unlike conventional styli that need to be very stiff, the new hollow stylus is designed to bend and deflect the return path of the laser beam, which is received by a Position Sensing Detector (PSD) mounted in the probe body. Software algorithms combine PSD input with head geometry and CMM axis scale, calculating exact stylus tip position in space, on the fly. The probe delivers 1 mic accuracy at 250 mm from the axis of rotation at 500 mm/sec.
The probe allows single tip calibration to be accurate at all angles of rotation. This can save hours in set-up routines on complex geometry parts, maximizing availability of the CMM.
This system is available with the new second-generation UCC2 universal CMM controller featuring patented MoveScan™ software that synchronizes and smoothes motion between the CMM and the head. On-the-fly repositioning of head and stylus between part features shortens scanning time of indexing systems.
Free Product Info #02
NMI SYSTEM MEETS EN10247 STANDARD FOR STEEL ANALYSIS
Carl Zeiss, Inc. (Thornwood, NY) introduces a new system for analyzing Non-Metallic Inclusions (NMI) based on the Axio Imager.Z1m upright microscope or the Axio Observer.Z1m inverted microscope to provide the optimal conditions for reliable and convenient measurements of non-metallic inclusions in steel.
This system fully supports the new EN 10247 European standard for determining the content of non-metallic inclusions in steel, as well as previously existing standards including, DIN 50602, ASTM E 45, ISO 4967; JIS G 0555.
The system can be tailored for further image analysis applications such as grain size analysis and particle analysis, and ensures reliable, reproducible and convenient measurements. All the components of the microscope, ranging from the camera to the motorized stage, are controlled by AxioVision Software for full functionality.
Quality is determined through an automated process performed by repeatable mathematical calculations that dramatically improve prior methods involving visual comparison of a sample to a reference chart image. The system allows automatic objective analysis on up to six samples at a time using batch mode, and can output the results of a batch measurement either individually or combined.
The integrated NMI software can perform measurements on a large MosaiX image (a composite of many individual tile images) to address the inaccurate classifications that occur when inclusions cut off at the image edge are not recorded in their entirety during independent individual tile analysis.
Sample evaluation is not only more accurate, but it is much faster and easier than the previous manual and visual evaluation methods, especially if the sample is measured against multiple standards.
Free Product Info #03
LARGE-SCALE METROLOGY WORKSPACE ON THE SPOT
Metris (Stuttgart, Germany) presents iSpace, which activates a large scale metrology workspace where objects can be measured and tracked accurately.
Predefined configuration packages allow iSpace systems to be easily installed at economies never achievable in the past. The embedded auto-calibration function provides accurate and continuous system monitoring, guaranteeing robust and reliable operation.
This system is based on proven global positioning technology that turns workspaces into scalable metrology workvolumes by using a network of iGPS transmitters that create a measurement field that is extendable by adding more iGPS devices.
The innovative network concept of this large-scale metrology solution guarantees uniform accuracy throughout the entire workspace. iGPS serves multiple concurrent users, and offers the unique capability to measure and track multiple objects simultaneously.
iSpace bundles iGPS technology into seven off-the-shelf configurations with measurement volumes ranging from 400 to 1200 sq m, available in different classes to suit the accuracy requirements of the customer.
The quick setup system is typically deployed in metrology applications to accurately position measurement devices, such as handheld probes, articulated arms and laser radars that can be repositioned at any time without having to manually redefine their new locations each time they are moved.
By eliminating these interruptions, operators take measurements non-stop anywhere within the entire metrology workspace, resulting in faster turnaround times. iSpace-enabled applications include the tracking of parts, tools and automatically guided vehicles (AGVs), part joining and assembly.
Free Product Info #04
LARGE CAPACITY MULTI-SENSOR VIDEO MEASUREMENT
The L.S. Starrett Company (Athol, MA) introduces the Galileo AV1824 Video Measurement System to extend the speed, power and accuracy of this intermediate class of video systems to larger parts.
This system increases versatility through its multi-sensor measuring capabilities of vision, touch probe, and laser scanning. It is ideal for QC labs, research, engineering and manufacturing.
The color optical system provides zoom magnification of 12:1 with a programmable magnification range from 15X to 550X with auxiliary lenses. A dual output LED illuminator, ring light and co-axial illumination provides exceptional lighting. Four-quadrant high incidence angle LED-transmitted illumination is also available. Other options include a PH 6 contact probe with TP20 module, Optimet Mark III Laser Probe and a CNC rotary positioning device. The system includes dual flat panel LCD displays.
Its large work envelope has a measurement volume of 24 in x 18 in x 6 in (610 mm x 455 mm x 155 mm) on a (X-Y-Z) measuring stage and a motion volume of 24.2 in x 18.2 in x 6.2 in (615 mm x 460 mm x 160 mm).
Overall size is 39 in x 39 in x 60 in (1,000 mm x 1,000 mm x 1,525 mm). The system weighs approximately 900 lb. Maximum workload (evenly distributed) is 220 lb (100 kg) without translight, or 44 lb (20 kg) with the translight. A stable granite base ensures accuracy within 0.00060 in overall at E1=5.0+15L/1,000 and an Encoder Resolution of 0.5 µm (0.0000039 in).
The AV1824 includes industry-leading Metronics Quadra-Chek® QC-5000 3D Metrology Software with video edge detection and full CNC control. Utilizing the familiar MS Windows® operating system, QC-5000 software is full-featured and intuitive to obtain, store, manage and distribute precision measurement data directly from the lab or the shop floor.
Free Product Info #05
NEW LATHE & SPINDLE ALIGNMENT TOOL
Pinpoint Laser Systems (Newburyport, MA) introduces a new measuring and alignment system for lathes, turning equipment, spindles and related machinery.
This Spindle Alignment Tool is easy to use, versatile and affordable. Ideal for aligning lathes and turning centers, adjusting boring mills, aligning drive shafts, and adjusting barfeeders. The Microgage system provides information on runout, centerline offset, parallelism, concentricity and other useful parameters that can guide machinery back to optimal alignment and improved profits.
This system is simple and quick to use, with a round laser secured into a chuck or attached to the end of a shaft or spindle. A dual-axis receiver is placed on the tailstock, tool holder or another piece of equipment that can receive the laser beam.
As the laser and the receiver move relative to each other, the digital display precisely reads the alignment and machine characteristics. This tool can measure to a precision of 0.0001 in or better. The laser allows for alignments over distances as great as 150 ft.
The introduction of Microgage 2D adds precision, easy-to-follow screen instructions and new optical and digital technology to the alignment of spindles and lathes. The Kit operates on batteries and all components are machined of solid anodized aluminum or stainless steel for wear resistance.
A serial and USB interface connect to a laptop or PC and link to popular spreadsheets for plotting and analyzing data for maintenance records, customer compliance and other uses. A compact carrying case stores the components and is easily carried right out onto the manufacturing floor.
Free Product Info #06
