New GLOBAL S CMM Offers Advanced Solutions for Enhanced Productivity

Hexagon Manufacturing Intelligence today announced the release of the GLOBAL S measuring solution, the first in an Enhanced Productivity Series (EPS) leveraging the Hexagon portfolio of smart technologies including user experience adaptations, enhanced software and advanced eco-friendly options. The EPS utilises these technologies to simplify tasks related to the creation, execution and analysis of measurement routines. This initiative offers a complete package to the quality engineer creating the measurement routine, the operator executing the inspection and the quality manager analysing the data that will be used to improve processes in the production workflow. The GLOBAL S is the ideal solution for all operations requiring higher productivity in dimensional inspection, like the automotive, aerospace, general and precision manufacturing industries.

PC-DMIS software enhancements allow common tasks such as the selection of probe tips and the import of files to take place three- to eight-times faster than existing solutions. Further improvements such as feature sensor mapping allow the user to associate sensors to features faster when importing inspection plans. The GLOBAL S with Chrome precision level utilises the coordinate measuring machine’s (CMM’s) hardware enhancements to offer superior accuracy at the highest scanning speed. Operators benefit from faster scanning measurement of both predefined and non-predefined paths and optimised path trajectories for faster part-program execution. Using the eco-friendly feature, Eco Mode+, there is a 90% reduction in compressed air consumption when the machine is in idle state. The CMM solution can save up to 25% of compressed air cost under machine standard operating conditions.

GLOBAL S operators will benefit from the new PC-DMIS Inspect option for program selection and execution. This easy-to-use interface within PC-DMIS allows the operator ‘one click’ measurement routine selection. Automated solutions are also provided, ensuring reliable integrations and efficient data flow management. Messaging lights and the ergonomic jogbox provide an enhanced operator experience. Machine alerts regarding temperature, humidity, vibrations, and unexpected stoppage are also available via the PULSE monitoring system.

“The launch of the GLOBAL S is another step towards the future of smart manufacturing,” said Ingo Lindner, Global Product Line Manager, Stationary CMMs at Hexagon Manufacturing Intelligence. “Utilising our smart quality products, we can now enable advanced data flow management and at-a-glance data visualisation that delivers the robust digital thread that quality managers need to drive productivity and profitability goals.”

The GLOBAL S is available via local Hexagon Manufacturing Intelligence commercial operations and dealers.

Hexagon Manufacturing Intelligence CMMs Increase Inspection Performance on Large and Palletised Parts

Hexagon Manufacturing Intelligence is expanding the vision product range with user-friendly and practice-oriented system solutions for the measurement of large or palletised 2D moulded parts.

Series components with geometrically varied and strict-tolerance 2D inspection features require a specialised production measuring solution. The new Optiv Classic 8102 and Optiv Classic 12152 have an XY measurement range of 800 mm x 1000 mm or 1200 mm x 1500 mm and can be combined with the optional PC DMIS Operator Interface (OI) to handle workpiece palletising, enabling a fast and automated inspection process, even for large batches of small serial parts such as clutch discs, fine-blanked parts and sheet metal cut-outs for electric motor construction. Thanks to the extended measurement range accessibility, prepared interchangeable pallets can be supplied semi-automatically by a palletising robot, reducing standstill times and increasing inspection throughput.

The Optiv Classic 8102 and Optiv Classic 12152 are each fitted with a world-class vision sensor system comprised of a high-resolution digital CMOS colour camera combined with a programmable 6.5x CNC motor zoom to enable repeatable, fast, and automatic measuring-point capture. Both new metrology machines are supplied with PC DMIS Pro as standard with the option to upgrade to PC DMIS CAD software to extract all relevant dimensional, shape and position tolerances from imported CAD data. The addition of the PC DMIS OI further enhances the user experience with its simplified user-interface with pre-defined measurement routines whilst minimising the risk of input and interpretation errors across entire component pallets.

“We have added two new broad measurement CMMs to our comprehensive Optiv Classic range to give manufacturers a choice of specialised solutions for large part and palletised applications”, comments Wolfram Fröhlich, Business Unit Director PL sCMM (Vision Unit) at Hexagon Manufacturing Intelligence. “And to complete these production-ready measuring solutions, we offer the intuitive PC DMIS OI so our customers can achieve the very best results possible.”

The Optiv Classic 8102 and Optiv Classic 12152 are available now exclusively in the EMEA region and can be ordered from local Hexagon Manufacturing Intelligence commercial operations and dealers.

Renishaw, the world-leading metrology specialist, will exhibit its new XM-60 multi-axis calibrator at IMTS 2016, Chicago, USA and AMB 2016, Stuttgart, Germany. The XM-60 is capable of measuring all six degrees of freedom from a single set-up, in any orientation for linear axes. It offers significant improvement in simplicity and time saving over conventional laser measurement techniques.

As demands on component tolerances increase, manufacturers are now required to consider all error sources from the machines producing parts; angular errors as well as linear and straightness errors. XM-60 captures all these errors in a single set-up. Designed for the machine tool market, the XM-60 multi-axis calibrator complements Renishaw’s calibration product line which includes the XL-80 laser system, XR20-W rotary axis calibrator and QC20-W wireless ballbar. The XM-60 uses the XC-80 environmental compensator to correct for environmental conditions.

The XM-60 multi-axis calibrator provides a highly accurate laser system that incorporates unique technology with a patented optical roll measurement and fibre optic launch system. The compact launch unit is remote from the laser unit, reducing heat effects at the point of measurement. It can be mounted directly to the machine on its side, upside down and even on its back, which is particularly beneficial in areas with difficult machine access.

Reducing uncertainties of measurement is paramount for any user. The Renishaw XM-60 has been designed to measure machine errors directly, reducing the inaccuracies which can result from complex mathematics used in some alternative measurement techniques. Direct measurement makes comparison before and after machine adjustments a quick and simple task with users’ existing part programs for XL-80 measurement. The receiver is fully wireless and powered by rechargeable batteries, avoiding trailing cables during machine moves which could cause inaccuracies or break the laser beam during measurement.

The performance of each XM-60 multi-axis calibrator is traceable to international standards and every unit is also certified before shipment. This provides users with the confidence that their system will deliver the specified accuracy day-after-day where it counts – in the workplace.

To support the release of the XM-60 multi-axis calibrator, a new version of Renishaw’s CARTO software suite will be released to guide users through the workflow of the measurement process. CARTO 2.0 includes Capture and Explore applications which already provide data capture and analysis for the XL-80 laser interferometer system. The CARTO user interface can easily be configured to suit user preferences, with the ability to change themes and customise displays. It is tablet friendly and has expandable menu sections for ease of use on compact screens. Test methods are automatically saved, so for repeat testing users can simply recall an earlier test.
Capture 2.0 features an all new part program generator, supporting Fanuc 30, Heidenhain 530, Mazak Matrix and Siemens 840D controllers, with more to follow in later releases. It has advanced features to automatically set the dwell time in the program, based on the averaging period selected by the user, and ‘matched time’ mode to assist time based capture when using the XL-80 system. In XM-60 mode Capture 2.0 uses the calibrator’s straightness measurement functionality to improve its ease of use.

XM-60 provides users with powerful machine diagnostic capability through the measurement of all degrees of freedom from a ‘single shot’. By capturing three linear and three rotational error sources during any measurement, users can discover the source of their errors, rather than the effect which is often seen when only performing linear measurement. Handling all of this data is performed by the Explore 2.0 application which provides a summary view of all the six channels of data, each of which can be displayed against a wide range of international standards. The management of such high volumes of data is also easily handled within Explore 2.0. A user defined tag can be assigned to any test, or group of tests saved in the database, and data can then be filtered by these tags.

Renishaw’s XM-60 multi-axis calibrator is supplied in a robust Peli system case, with space for accessories and XC-80 compensator kit. The case has been designed to provide safe storage and transportation of the laser system, and in many applications the laser unit can remain in the case during measurement, simplifying the set-up. An optional fixturing kit is available to help with mounting the XM-60 to machines, which is supplied in a carry case for ease of transportation.

Additions to Optiv Performance line broaden application potential with larger measurement range

Leading metrology and manufacturing solution provider Hexagon Manufacturing Intelligence today unveiled its latest multisensor coordinate measuring machines (CMMs), the new Optiv Performance 663 and 664 Dual Z.

The multisensor concept of the Optiv Performance line enables a variety of sensor configurations for tactile and contactless measuring and scanning tasks in a single system. Different workpiece features can be inspected by the appropriate sensors without reclamping, saving valuable measuring time.

Based on the same technology as the highly-successful Optiv Performance 443, the new CMMs feature low-vibration granite construction, precise mechanical linear guides on all axes, backlash-free precision drives, and integrated temperature compensation – resulting in a level of structural quality that means the machines can be used close to production. With the Optiv Performance 663 boasting a measurement range of 610 x 610 x 305 mm and the Optiv Performance 664 taking the Z-direction range up to 405 mm, the new CMMs further increase the range of parts that can be inspected.

To ensure optimal use of the entire measurement volume, the new Optiv Performance models can be equipped with Hexagon’s Optiv Dual Z option, giving them two independent vertical axes for the optical and tactile sensors. This prevents the inactive sensor from impeding machine movement, so features deep within the workpiece remain accessible for easier part programming and the risk of collisions is minimal. Optiv Dual Z technology also enables the use of a motorised indexable probe head as a carrier for the tactile sensor.

The Optiv Performance 663 and 664 Dual Z also offer a simple and quick solution for measuring tasks involving rotationally symmetrical workpieces. Features distributed around the circumference of the part are made accessible by clamping in the workpiece using the CNC rotary axis. This Optiv Dual Rotary option allows the entire rotary axis to swivel on an additional axis.

“Our customers are increasingly asking for versatile equipment and the new Optiv Performance 663 and 664 Dual Z models were created to fulfil this exact need,” said Wolfram Fröhlich, Commercial Product Manager at Hexagon Manufacturing Intelligence. “It is a futureproof measuring system capable of handling a variety of different measuring and testing tasks. The innovative Optiv Dual Z and Optiv Dual Rotary options help CMM users to find the ideal positioning of sensors and the workpiece for measurement performance beyond current limits.”

Also available as an option on the Optiv Performance 663 and 664 Dual Z is Hexagon’s CMM monitoring system MMS PULSE. Using a network of sensors to monitor temperature, vibrations, humidity and machine status, MMS PULSE provides machine operators with a more complete picture of the environment when results are obtained.

The Optiv Performance 663 and 664 Dual Z CMMs are available worldwide from today. More information is available through local Hexagon commercial operations and dealers.

 The quality of the products a company produces, and their assurance of that quality, can mean all the difference to successfully acquiring contracts. Maintaining that quality also significantly increases the chances of repeat business. High-Tech Engineering, a precision engineering company based in Dunstable, Bedfordshire, UK, has always focused on the quality of the parts it produces. Now with its latest addition, a Renishaw Equator gauging system, it is reaching 100% part inspection and zero scrap whilst halving the operator requirements and reducing part production costs by 27%.

Started in 1985 by Managing Director, Steve Tickner, High-Tech Engineering built a reputation in the motorsport industry for delivering high quality machined parts. The company has since moved into the aerospace sector and gained some key industry approvals, including becoming a preferred supplier to Rolls-Royce and BAE Systems.

Recently High-Tech won a contract to produce precision milled titanium parts for a large aerospace customer. Due to the nature of the parts, High-Tech was instructed to carry out
100% part inspection. Steve Tickner explains, “We knew from the start that we would need to find an inspection method which could not only meet the cycle time requirements for the part, but would be a cost effective solution for us as well. Relying on the CMM we already had wasn’t going to be an option. We couldn’t risk any bottlenecks. We knew that we would either need another CMM or something else which could give us the measuring capacity. That’s what led us to the Renishaw Equator.”

Equator gauging system acquisition

It was through a simple internet search that Steve came to learn of the Equator gauging system. After some research and following meetings with representatives from Renishaw, High-Tech was impressed with what the Equator gauging system could offer, and was particularly pleased with the overall price of the system.

Commenting on why High-Tech bought the Renishaw Equator gauging system, Steve says: “Space on our factory floor is at a premium. Within the space we set aside for this cell we had to include faster, more efficient technology. This meant that a co-ordinate measuring machine (CMM) with a temperature controlled environment was far too big to be practical. The Equator suited the space perfectly as it’s a compact machine. The added bonus is the fact it is thermally insensitive and doesn’t require any air supply, meaning we didn’t need to spend additional time, money and effort putting in another temperature controlled room or extra piping.”

High-Tech is currently using the Renishaw Equator gauging system to perform 100% inspection of a complex aerospace part. It works by comparing the manufactured parts against a matching master part, gauging all the features in a single operation with an immediate pass/fail decision, along with a report of the component dimensions.

Comprehensive measurement in half the time of the existing CMM option

The Equator gauging system is used to gauge around 150 features including a number of bores, thicknesses and form measurements on the part with typical tolerances of ±25 µm. The Equator gauging system does this within 10 minutes and well within the production requirements, far less than the machining time. This is almost a 50% reduction in cycle time compared to running the program on High-Tech’s CMMs.

Process control, run by the machine tool operator

Production at High-Tech runs 24 hours per day, 5 days per week and is split into 2 overlapping shifts. During this time Equator is used by a number of operators with varying skill sets. Previously, High-Tech Engineering would have relied on its CMMs, housed away from the machine tool in a temperature-controlled quality room. Using the CMM for the latest job would have involved two separate operators, firstly the operator machining the part and secondly the operator with the specialist skills to operate the CMM. By using an Equator instead, newly trained staff can use dimensions from a certified component, approved by the QC operators, to “zero” the Equator gauging system and set its accuracy for subsequent measurements. This has allowed the same operator who machined the part to measure the part, halving the operator time required.

Flexibility and future proofing

The Equator gauging system is fully programmable and can be used on multiple parts, meaning High-Tech Engineering can perform highly repeatable and rapid automated routines across numerous contracts resulting in significantly reduced labour costs.

Ease of use – push-button simplicity

Commenting on this, Mr Tickner states, “All of the operators can use Equator. It really is easy; just load the part and push the button. It completely simplifies the process and frees up manpower, which in turn helps to deliver ROI very rapidly for the cell.”

High-Tech has managed to reduce the cost of producing the aerospace part by 27% with the Equator gauging system being a factor in that. This has had a real impact on the competitiveness of this sort of production, allowing the company to make the same precision quality parts, whilst also delivering better value to its customers. It is through implementing these types of solutions and continually striving to improve their processes that High-Tech has been awarded 6 consecutive SC21 silver awards, which is unrivalled in the UK. This award recognises excellence within the aerospace and defence industry, for the quality of the products a company produces, as well as its ability to supply them. To receive a silver award a company must consistently achieve at least 95% for delivery performance and at least 99.5% on quality of parts to all of its customers.
Mr Tickner explains “Since we started using Equator we have not made a single bad part. The Equator is allowing the operators to operate complete process control. They all look at the Process Monitor screen, part of the Equator software, which lists all of the features being gauged. Next to the feature name there is a little bar which turns from green to amber to red as the size or location for each feature begins to drift. The operators know which tool on the machine is responsible for each feature and so can take corrective measures to occasionally tweak the process, to come back well within tolerance. As we carry out 100% inspection, it would be very hard to make a part wrong.” He continues, “We are also using the gauge data to trial different types of tool, to see which gives us the best level of efficiency – something which might save us more money in the future.”

Outlook

Following the success of this manufacturing cell, Mr Tickner plans to use the Equator gauging system as part of future cells he will be commissioning for jobs in the pipeline. He concludes: “When you find something which helps you make a perfect part every time, reduces manpower commitments, reduces overall costs and doesn’t cost a fortune itself, it’s a winning solution. All of the benefits are passed on to our customers who know they are getting the best quality at the best price”.

Renishaw, the global engineering technologies company, is opening a new Additive Manufacturing Solutions Centre on 15th June in Pune, India. The new facility will provide a secure development environment in which customers can expand their knowledge and confidence using additive manufacturing (AM) technology. The Solutions Centre will be equipped with the latest AM systems and staffed by knowledgeable engineers to allow fast access to deploying the technology, all at fixed predictable costs.

Additive manufacturing, often referred to as metal 3D printing, is widely recognised as a transformational manufacturing technology that will impact on everything from components in aircraft engines and satellites, to dental restorations and surgery for facial reconstruction. Renishaw, which is the UK’s only supplier of metal AM machines, sees the new Indian centre as a cornerstone in its ambition to be a major contributor to the adoption of AM in the established and fast growing high technology Indian manufacturing sector.

Rhydian Pountney, Renishaw’s Director responsible for Indian Sales and Marketing Operations mentions, “We are delighted to be opening the first Solutions Centre in India. The thrust of the additive manufacturing centres is to create a platform on which to work in close partnership with our customers to help them realise the benefits of AM in their products and manufacturing processes.”

“Renishaw’s vision is to make AM a mainstream manufacturing technology, used in series production of high performance parts for aerospace, medical, automotive, oil & gas, mould & die and consumer products. The technology will enable companies to design and make innovative products with spectacular gains in performance and efficiency,” says Clive Martell, Head of Global Additive Manufacturing.

When adopting any disruptive new manufacturing technology, companies will go through a rigorous assessment process to understand the potential benefits, and to prove the reliability and capability of the production process. The investment in time, resources and equipment to achieve this can be significant.

Renishaw Solutions Centres will lower this entry barrier by providing cost-effective access to machinery, facilities and AM expertise. Solutions Centres will provide a confidential development environment in which firms can explore the benefits that AM can bring to their products, and quickly build their knowledge and confidence in AM as a production technology.

Marc Saunders, Director – Global Solutions Centres comments, “Whilst AM can create complex geometries in a single process step, some level of finishing is generally required to produce functional products. Renishaw’s knowledge of metrology, machining and finishing processes can help customers to develop an integrated manufacturing solution for their innovative new product.”

Whilst the new Pune Solutions Centre highlights Renishaw’s continuing investment in the development, manufacture and application of AM technologies, it also maintains the company’s long term commitment to the Indian market. It will sit alongside Renishaw’s existing key strategic additive manufacturing development locations in the UK, USA, Canada, Germany & China, with additional centres also planned for other key markets.

The metalworking industry has always placed great emphasis on having tools that can increase measurement accuracy, help with quality control, support reliability, and that can support the objective of ‘making it right the first time’. However, as manufacturers attempt to grow their trade in the global business environment, the need for measurement accuracy has become an even higher priority due to the time- and cost-savings that businesses can potentially achieve.

3D measurement solutions for the metalworking industry have been available for some time now. Some common applications that make use of these advanced technologies include Parts Inspection, Alignment, Reverse Engineering, and Dimensional Measurement. All four categories are similar in the way that their need for measurement and documentation accuracy is tightly woven into each of their core activities. To elaborate, measurement accuracy is widely agreed to be a most important aspect in mechanical parts inspections. Machine misalignment on the other hand can delay an entire manufacturing line. Reverse engineering, essentially a measurement and documentation process, requires a high degree of accuracy, and of course, dimensional measurement goes hand-in-hand with measurement accuracy.

As the demand for measurement and documentation accuracy grows, it is likely that traditional tools such as handheld calipers will eventually be phased out and replaced by advanced laser scanning and 3D measurement solutions. Here, we identify four factors driving this need for accuracy.

Need for Greater Operational Precision

Naturally, manufacturers need to ensure that their measurement and documentation objectives are met. With the right 3D metrology equipment, manufacturers can be one step closer to gaining tighter size tolerances, achieving precisely calculated designs, and securing built-in form deviations to assure maximum measurement accuracy.

Application – Inspection & Reverse Engineering

Manufacturers can employ several metrology methods to meet these measurement objectives. The FARO Cobalt Array 3D Imager is a new device that supports metalworking manufacturers in this aspect. A metrology-grade, non-contact scanner, the Cobalt Array is capable of providing manufacturers with reliable and accurate 3D scan data within an automated or manual workflow. With no restrictions on the number of sensors in an array, the Cobalt Array enables the expansion of field of views to scan wider areas, improves the inspection time, and achieves greater productivity. The device’s high resolution, automatic exposure, and high dynamic range enables consistent and more accurate measurements, even when it comes to complex

components with finer details. An ideal device for quality inspection and reverse engineering applications, the Cobalt Array is a unique fusion of technology that emphasizes accurate scanning results.

Separately, the FaroArm is another tried and proven tool by the metalworking industry that promises superior operational precision. Flow Link Systems (FLS) – a casting and valve component supplier based in Coimbatore, India – places great emphasis on quality and customer satisfaction. Both of these attributes were push factors that steered FLS to purchase the FaroArm, providing the manufacturer with an immediate increase in measurement accuracy levels. From formerly working with up to 30 microns’ tolerance using handheld tools and templates, the FaroArm improved FLS’s measurement accuracy to a tolerance level of about 24 microns. With the FaroArm, FLS is now able to obtain accurate measurements for concentricity and cylindricity tolerance in half the time that was previously spent.

The Cobalt Array and the FaroArm are just two examples of how advanced 3D metrology measurement and documentation solutions can aid manufacturers in achieving accurate measurements and scanning results. With a reliable yet portable coordinate measuring machine, manufacturers can easily verify product quality through performance assessments including 3D inspections, tool certifications, and computer-aided design (CAD) comparison.

Need for Accurate Reporting

Today, it is common for industrial suppliers to require accurate reporting of dimensional information for statistical analysis, and to safeguard quality processes. These reports can present measurement data clearly and unambiguously, allowing manufacturers to add comparison data or reproduce data for possible correction of components and production parameters. With ever-increasing quality demands, companies are under pressure to invest in innovative solutions that can support instantaneous and accurate quality reporting on first-article and production inspection, as well as to ensure supplier quality management.

Application – First-article, Production, and Quality Inspection

Yanmar, a Japanese diesel engine manufacturer, is another satisifed FaroArm user. As the nature of Yanmar’s research projects required 3D measurement, Yanmar introduced the portable FaroArm to provide technical support. Even when used by different operators, the FaroArm achieved the same measurement accuracy, allowing Yanmar to secure the same level of quality control across departments. Since then, the manufacturer has used the FaroArm for product and quality inspection, amongst other uses.

The FaroArm does not only provide highly precise measurements, but also conducts

first-article, production, and quality inspections extremely well. The handy metrology device is also widely known for its effortless ability to generate reports. The FaroArm is able to determine and record the location of a probe in 3D space before reporting the results through software, allowing manufacturers to compile a database of scanned data measurements.

For hard to reach areas or narrow spaces, the FARO Scanner Freestyle3D is an ideal high quality handheld scanner that aids in free-form components inspection. The Freestyle3D incorporates state-of-the-art scanning technology with enhanced scanning accuracy of 1mm at a 1-meter range, and features a traceable calibration accessory that can provide manufacturers with verifiable data accuracy. The device can be easily calibrated on-site to generate high quality data in PDF format for easy reporting of measurement information.

Need for Lean Manufacturing

Lean thinking or lean manufacturing is an efficient concept, pioneered by Toyota, to shorten the time spent between manufacturing stages. The process is largely centered on manufacturing products on demand through a technique called pull production. Manufacturers then develop products only when required, eliminating unnecessary wastage, ultimately achieving both time- and cost-savings. In order to manage pull production, measurements need to be made dimensionally correct from the start to avoid time delays for rework. Measurement accuracy is therefore of paramount importance in lean manufacturing.

Application – Hot Forging & Mobile Inspection

Within the metalworking industry, hot forging processes are popular due to the advantages of increased ductility, strain hardening of metal part elimination, and reduced material strength. However, retrieving accurate measurements from hot forging operations can be challenging as the high temperatures make it difficult for sensors to label characteristic points. Manufacturers are therefore beginning to prefer non-contact measurement systems that offer a long range, in order to take measurements of hot work pieces at a distance.

There are several devices now available that can efficiently support manufacturers
as they carry out hot forging processes. The FARO Laser Scanner Focus3D is one such solution. An ideal instrument for 3D modeling and documentation, the Focus3D’s non-contact dimensional measurement ability, as well as its large and flexible measuring scope, makes the device particularly suitable for some manufacturers. Additionally, the point cloud data obtained by the device can be quickly converted to 3D CAD data, enabling the direct creation of 3D design drawings, effectively shortening entire workflows for lean manufacturing.

When it comes to mobile inspection, FARO’s analysis has shown that for dedicated inspections of large products or assemblies, a fixed multiple imager array of Cobalt sensors will be faster, more easily integrated, more affordable, more accurate, and easier to maintain when compared to robot-based imagers or laser line systems. In this sense, the Cobalt Array directly supports the concept of lean manufacturing, as more accurate dimensions can make a world of difference in time-pressed manufacturing environments. The FaroArm is yet another advanced metrology device that has won much favor amongst metalworking manufacturers. User-friendly, accurate, and fast, the FaroArm helps to boost overall productivity, and can be utilized for immediate mobile inspection onsite, facilitating uninterrupted production during inspection.

Need for Work Place Health & Safety Practices

Working with machinery can be dangerous as operators are exposed to risks that may lead to bodily injuries. Safety and control measures therefore need to be integrated in order to create and maintain a secure working environment. As government bodies continue to regulate in favor of safe working practices to minimize or eliminate worker injuries, manufacturers are responding by taking greater precaution towards protecting their manpower resources.

Application – In-line Inspection

When working with fixed coordinate measuring machines (CMMs), bulky and heavy parts need to be moved from the shop floor to measuring rooms. This is potentially hazardous if not managed properly, as the activity compromises on workers’ safety. The portability feature across FARO’s range of 3D measurement and documentation solutions directly addresses this concern, as FARO devices can be brought to the parts for measurement instead. The ability to perform in-line inspections enables employees to conduct measurement assessments safely, and also provides manufacturers with better accuracy and time-savings.

The Solution that Keeps on Giving

Why then should manufacturers consider 3D metrology tools? Comparatively, 2D tools are less capable of providing the type of precision support that is needed by the metalworking industry. Although the latter is able to define measures such as distance, diameter, and area, the results provide only a rough estimation at best. The difference in measurement quality between 3D and 2D tools is also especially evident when the spotlight is on measuring complex shapes, or for direct comparison to CAD files. Furthermore, when used by different employees, the limitations of 2D tools become more pronounced, as variations in measurement results are often recorded between operators, showing a lack in reliability.

The old adage, “you get what you pay for”, holds true. Some degree of capital investment needs to be made for greater measurement accuracy. At the end of the day, top manufacturers place great importance on producing quality products in the most efficient manner. 3D measurement and scanning tools are proving to be some of the most optimum solutions for the metalworking industry. They are, therefore, worthwhile investments that pay for themselves when it comes to time- and cost-savings in the long run.

By Mr Eddy Lek, Product Marketing Manager, Asia Pacific, FARO Technologies

New Versions of HP-S-X1 Series Scanning Probes Offer Better System Flexibility and Robustness

Hexagon Manufacturing Intelligence has released new versions of its HP-S-X1 series of compact probes for tactile scanning. As well as featuring a new bearing system for better joint repeatability, HP-S-X1 range probes now accept longer horizontal styli for improved flexibility – with no need to change modules.

Featuring small external dimensions and supporting stylus lengths of up to 225 mm, HP-S-X1 probes enable coordinate measuring machines (CMMs) to take measurements of features deep inside a workpiece. Magnetic interfaces allow automated stylus changes, and they support all standard inspection modes including single-point contact measurement, self-centring measurement and continuous high-speed scanning, providing quick and precise data acquisition for all kinds of surface contours.

The HP-S-X1 range of tactile scanning probes includes the HP-S-X1C centrally-mounted version for high-stability in measurement and the HP-S-X1S and HP-S-X1H models, which offer the option to use an indexing probe head for better part accessibility. In the latest versions, the HP-S-X1C and HP-S-X1H models accept horizontal styli of up to 100 mm, while the HP-S-X1S can now take horizontal styli of up to 20 mm without changing modules. A standard interface allows all the probes to be used on Hexagon probe heads.

“The latest versions of the HP-S-X1 scanning probe have been redesigned to improve durability, and also allow better setup flexibility without the need to change modules,” explains Micha Neininger, Product Manager – Sensors at Hexagon Manufacturing Intelligence. “Usually, to get this range of stylus configuration options, you would need a multiple-module system. With the HP-S-X1 range, users save the time it takes to change modules, so they are always able to apply the best configuration for the job, without compromise.”

The latest versions of the HP-S-X1 compact scanning probe range are available to order worldwide from today. More information is available through local Hexagon commercial operations and dealers.

Hexagon AB, a leading global provider of information technologies that drive productivity and quality across geospatial and industrial enterprise applications, recently announced the acquisition of AICON 3D Systems, a leading provider of optical and portable non-contact 3D measuring systems for industrial manufacturing.

Founded in 1990 and based in Braunschweig, Germany, AICON has been meeting the measurement needs of renowned automotive manufacturers and companies in the aerospace, shipbuilding, renewable energy and mechanical engineering markets for over 25 years. Its technology portfolio includes portable coordinate measuring machines for universal applications and specialised optical 3D measuring systems that enable efficient, high-precision monitoring, quality assurance and control in manufacturing production.

With over 140 employees, AICON has a direct presence in Germany, subsidiaries in China, Korea, Japan, and the US and a network of resellers worldwide supported by its field support resources.

“AICON is a recognised brand with strong core technical competence across its development teams and its scanner portfolio is a strategic fit,” said Hexagon President and CEO Ola Rollén. “We also see opportunities for international expansion of AICON’s wider portfolio throughout Hexagon’s global footprint.”

Also, the CEOs of AICON 3D Systems, Carl-Thomas Schneider and Werner Bösemann, further commented: “Joining Hexagon is a great opportunity to bring our first-class AICON scanner products to a wide range of customers worldwide.”

AICON will be fully consolidated as of April. The company’s turnover for 2015 amounted to approximately 19 MEUR.

This latest release promises to revolutionize the market by enabling a universal end-to-end 3D metrology workflow.

InnovMetric Software Inc., the leading provider of universal 3D metrology software solutions, today announced the launch of PolyWorks 2016, the latest release of the company’s universal 3D metrology software platform. PolyWorks 2016 fully supports probing and laser scanning on stationary CNC CMMs, and delivers a truly universal 3D metrology workflow that will allow users to operate any type of portable metrology and CNC CMM measurement device within a common framework, from a single software module, and using similar tools and methods.

“Portable metrology and CNC CMM metrology devices used to be operated in very different ways. Offline CMM programming and online CNC measurements were traditionally performed in different modules using different tool sets. This time is now over,” said Marc Soucy, President of InnovMetric. “More than ten years ago, InnovMetric embarked on an ambitious journey to deliver a universal hardware-independent 3D metrology software platform to our customers. With PolyWorks 2016, the definition of what constitutes a universal platform takes on an entirely new meaning: a universal hub that interfaces with any type of 3D metrology measurement device, and offers a universal workflow for performing all inspection tasks. This innovative end-to-end approach will significantly lower the total cost of software ownership for industrial manufacturers as it eliminates metrology workflow silos, decreases the cost of training, facilitates broader collaboration between teams, ensures consistency in measurement results, and increases workforce mobility.”

With PolyWorks 2016, portable metrology and CNC CMM operators are now able to:

• Define a measurement plan without being physically connected to a specific measurement device;
• Specify geometry controls on measurement objects and prepare inspection reports;
• Connect to a non-contact or a contact-based portable metrology device, or to a CNC CMM controller (from Hexagon, Mitutoyo, Nikon, Pantec, Wenzel, and I++ servers), to play the measurement sequence;
• Review measured object geometry controls and reports, or multipiece inspection results through the built-in SPC functionality.

Operating portable metrology and CNC CMM devices within a common framework is now possible with the introduction of two new major components in PolyWorks 2016: the measurement sequence editor and the offline simulation. 

Measurement sequence editor

Since 2012, PolyWorks has offered the powerful Play Inspection tool that automatically generates a step-by-step guided measurement sequence to capture 3D datasets of a new piece using portable metrology devices. PolyWorks 2016 expands the capabilities of the Play Inspection technology by allowing the customization of its automatically generated sequence. Using the new sequence editor, users can now:

• Configure the order of measurement operations;
• Control device position moves;
• Trigger CMM-specific operations, such as moving the probe head to a specific location or changing the orientation of a measurement tool;
• Easily add guidance messages and images;
• Create conditional blocks of operations;
• Insert macro scripts, opening up unlimited process customization possibilities.

Offline simulation

PolyWorks 2016 also delivers a new easy-to-use offline simulation functionality that automatically generates simulated point cloud data and probed points from a CAD model of the measured part, while going through a simulated measurement workflow. Offline simulation allows users to quickly create simulated measured object components, Data alignments, Data color maps, geometry control tables, 3D scene snapshots, and inspection reports before the real measurement task, without needing access to a measurement device. The PolyWorks 2016 offline simulation also fully supports CNC CMMs, allowing users to control the probing and laser scanning tool orientations and trajectories on a virtual device.

Universal inspection projects

Thanks to the universal 3D metrology architecture of PolyWorks 2016, only minimal changes will need to be made to a PolyWorks inspection project so that it can be used with multiple hardware platforms to optimize object measurement methodologies and adapt them to different measurement principles. As a result, PolyWorks 2016 opens a new era for universal inspection projects and device interoperability, ensuring total flexibility for customers to select the appropriate measurement devices for their needs and maximize the return on their 3D metrology investments.