Conventional measurement systems such as coordinate measuring machines (CMMs) are utilized for quality control in various industries. They 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. In addition, inspection tasks requested for manufacturing often collide with other measurement requests such as those from other manufacturing lines, pre-production tests or R&D. Changeovers to measure other parts and the attendant programming also add to the delay. Further, tactile probes typically operate at slower speeds as they require physical contact with the part surface and therefore are characterized by long measurement cycle times. Moreover, contact based measurement technologies are not suitable for generating large amounts of data points required for complex surfaces. Because of these limitations, systems like CMMs are not an ideal solution for 3D inspection on the production line.
To solve these problems, DWFritz Automation has developed the ZeroTouch measuring platform. Its architecture features 5 independent axes and a rotating bridge. The system combines multiple non-contact sensor technologies such as laser and chromatic confocal sensors with multi-spectral illumination to rapidly measure in three dimensions and in real 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 system’s proprietary software then creates a highly accurate dense 3D point cloud which 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. In addition, by simplifying complicated programming procedures, ZeroTouch reduces the system configuration time to just a few hours saving substantial production time and costs. Therefore, part inspection plans can be created within a few hours by using drag-and-drop functions and can be stored in the manufacturing execution system (MES) for management and retrieval.
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 touch screens.
For more information on the ZeroTouch high-speed measurement platform and other solutions such as automation and metrology systems for many industries, visit www.dwfritz.com.
DWFritz Automation was founded in 1973 by Dennis Fritz and is headquartered in Oregon, USA. The company started out by offering engineering services, and by the 1980s counted global brands like HP, Intel, and Boeing among its clients. In the 1990s, DWFritz Automation focused increasingly on the development and manufacture of high-precision automation and metrology systems for many industries, including aerospace, medical technology, mechanical engineering, automotive, and consumer electronics. Today, the company employs over 500 people at locations in the US, France and China.
###
