When visiting the halls of Schubert Fertigungstechnik GmbH, the large number of robots and automation solutions on the machines immediately catches the eye. The company is not a series manufacturer; typical batch sizes range from three to ten units and are sometimes fewer than 100 pieces. ‘We have been working for a long time to get 18 to 22 hours of autonomous machine time. This means we can run the machines around the clock without having to ask our employees to work night shifts,’ explains Jens Grieser, the managing director responsible for the technical division. ‘Ideally, we would make early and late shifts as unnecessary as possible. But we need to ensure the same high level of quality at all times.’

With this in mind, Erhard Strobel, sales engineer at Blum-Novotest, found a receptive audience in Bartholomä with FormControl X. Schubert was very interested in the BLUM software, a client server-based solution for the automated measurement and evaluation of machining processes. Ultimately four variants of a part are manufactured on one machine, with around 60 parts per variant and a cycle time of between 10 and 40 minutes per part – but only if the machines are running at full capacity. This means it is very important to keep an eye on quality, also during unmanned shifts. Thanks to FormControl X, specialists can be sure that all measured values are upheld. The advantage of measurement being performed during the process is that it is clear when a measured value begins to drift. Action can be taken long before the tolerance range is exceeded. It goes without saying that this is especially true for broken tool edges.

FormControl X is a client server-based software solution for the automated measurement and evaluation of machining processes. BLUM developed the software from scratch based on the tried-and-test FormControl software with a particular focus on the automation of measurement processes. A major advantage of the client server architecture is that the data in the FormControl X database can be accessed from multiple workstations or machines. This allows users to easily create complex measuring programs at their office workstations or review the measured values taken during the previous night. The operator can monitor the tolerance fluctuations of all measured values on a laptop near the machine. The display is generally very simple and can be viewed on a PC, laptop or tablet in a standard web browser.

The flexible options that can be used to influence the machine with FormControl X are very interesting: In one case, for instance, the manufacturing process is only stopped when the same deviation is measured on two parts in a row. This rules out the possibility of a chip adhering to the measuring point during the first measurement. ‘For example, it is possible to measure every fifth part. In the event of an outlier, instead of waiting to measure the next five parts, the machine immediately starts measuring again during the next machining process to rule out a chip at the measuring point,’ explains Erhard Strobel. ‘Only then does the program decide, based on the specifications, whether the next part will be machined, whether the machine will interrupt machining or whether it will switch to the production of another part using different tools.’

The Fanuc Robodrill machining centres are mainly used to manufacture components for tool changers for Schubert packaging machines. For instance, these tools can hold boxes into which a robot places chocolates. If a different package size or shape is required, the tool can be changed and the packaging line automatically switched over. Several pneumatically operated pistons with an H7 fit work in parallel in these tool changers. The bore holes in which the pistons run must be made very precisely and have to parallel to each other with the correct diameter. Measuring every part produced is necessary to ensure reliable operation later on. This is because a stoppage in a packaging machine can be extremely expensive, for instance with the chocolate production processes mentioned above: If the packaging line stops, the production of the sweets must also be shut down because the liquid chocolate and other ingredients will solidify and go bad. In addition, the pre-assembly processes at Schubert are synchronised, which means that deliveries must be made at very short notice. So a problem on the machine also affects processes at the parent company, which accounts for around 70 percent of orders. That is why the accuracy of the measurements in the machine was checked continuously during the beta test prior to the purchase of FormControl X – the deviations were in the range of a few thousandths of a millimetre.

The designers of the packaging machines specify dimensions that are crucial for proper functionality and have to be checked during production. The NC programs are then created in Bartholomä, and the measurement subroutines are incorporated at the appropriate points. ‘We work together here: We, the employees working on the machine, are responsible for quality, which is why we decide together with the NC programmers which dimensions are recorded with the BLUM measurement cycles and stored in FormControl X,’ explains Markus Maier, who supervises the RobodrillPlus Big K systems. ‘This also gives us the knowledge we need to understand the measurements and make improvements.’

During the introduction phase of FormControl X, we stayed in very close contact with the BLUM specialists: In addition to the dedicated support of the programmers during beta testing, Schubert was also impressed by the excellent training. Currently, a new part only needs to be programmed every two or three weeks in Bartholomä, but the employees still have a good experience with the software because it is very intuitive. FormControl X also helps them focus more on their actual work. For instance, in the past, time had to be spent in the morning checking the dimensional accuracy of the components manufactured overnight. Now a glance at the screen is all it takes: The graphical display of the FormControl X web client shows whether the tolerances have been upheld. This allows employees to react immediately or continue production straight away.

All dimensions with tolerances of less than a tenth of a millimetre are now measured automatically, as are shape and position tolerances. These are important because many parts are machined in two clamping operations, which means the position of the second machining process depends on the surfaces produced in the first clamping operation. This is another reason why FormControl X brings major improvements to everyday work processes: ‘The software takes care of the measuring tasks for me because they are automated. This means I can concentrate more on my actual work,’ reports Markus Maier. ‘Working on the machine is also more relaxed because the process is transparent and we always know where we are in terms of quality – that’s very reassuring. What’s more, I no longer have to work in shifts since I can finish my work during normal hours – that’s a huge advantage for me!’

The number of employees at Schubert Fertigungstechnik who are being ‘freed’ from shift work could rise soon: Thanks to the positive experiences at the Fanuc centres, there are plans to use FormControl X on many other machines with the aim of increasing productivity. After all, BLUM software is an important part of the automation of machining processes and is playing a decisive role in achieving a very high level of automation in Bartholomä.

FormControl X has proven its worth and entrenched itself at Schubert Fertigungstechnik: ‘For each production batch, the first and last measurement logs are printed out and filed, and apart from that, all measurements are available in the FormControl database. ‘This is useful for assessing the tool service life,‘ summarises Jens Grieser. ’And it’s also reassuring for me to be able to see where we are in terms of quality at any time. Of course, the machines and the range of parts have to be just right so we can get the most out of the software – and that’s the case for us.’

Blum-Novotest, a leading provider of innovative and high-quality measuring and testing technology, is presenting FormControl X for process-reliable automation. “The basis of intelligent automation solutions is process data, which is evaluated live or very quickly and serves as a control variable for optimising the process. The automation reacts to the measurement result and readjusts it so that the process always stays within the predefined limits,” explains Wolfgang Reiser, Head of Technology at Blum-Novotest. “With the new FormControl X software, Blum-Novotest presents such a solution for machining centres, with which even more knowledge can be gained through continuous measurement of workpieces in the machining process.”

While the previous FormControl version (without ‘X’) is based on a scenario in which a machine operator works on a machine with a laptop and processes the measurements at the same time, the trend today is towards the automation of such processes, so that this 1:1 relationship is increasingly rare. In addition, completely new areas of application open up with genuine automation of workpiece measurement. The goal with FormControl X was to enable real measurement automation on the basis of a modern client-server architecture – away from pure logging and towards process integration and automation with the help of the measurement data collected by the software.

In this way, workpieces can be measured directly after each processing, whereby the results already serve as a correction value and basis for optimisation for the next component. For this purpose, the user defines intervention limits when creating the project, according to which the software carries out a corresponding correction. Among other things, this allows tool wear to be compensated; FormControl X recognises the trend that, for example, bores become smaller over time when the tool in question wears out, and can take countermeasures accordingly. This expands the focus of the software: while FormControl focused on higher-priced parts in single-item production, FormControl X also aims at small, medium, and large series production.

Evaluated data and results can be accessed through a web interface via various end devices. The server communicates with the machines on which measurements are taken – this allows an operator to carry out measurement projects on many different machines and have them automatically evaluated. Complex measurement routines, such as the alignment function, can be used to adapt the reference points of the machining programme to the position and shape of the workpiece so that machining can run optimally. Another innovation in FormControl X is the management of measuring equipment and machines. Since this is now located centrally on the server, the data is available across all machines. The definition of the measurement is also very easy and intuitive thanks to a context assistant.

In addition, FormControl X now opens up the possibility of creating and evaluating data series over time. What ended up being a log of a single processing in FormControl can now be used to evaluate an entire processing series. This offers the operator completely new insights. In addition, the protocols resulting from the measurements can be extensively and very easily adapted, tolerance limits can be displayed as a number or image; red/green colouring can be defined; and much more.

FormControl X is a further step on the way to integrating measurement results from machine tools into company processes and making them usable in terms of Industry 4.0. “With a networked client-server architecture, the reusability of measurements and interaction with the machine, the new version of the software solution offers many new options for keeping processes transparent and continuously optimising them,” summarises Wolfgang Reiser. “Perhaps the most important aspect for many users, however, is that the machining process can be automated quickly and reliably with FormControl X, which is reflected 1:1 in productivity and in the quality of the finished workpiece.”

InnovMetric, the independent software development company that empowers manufacturers of every size to digitally transform their 3D measurement processes, is announcing the launch of PolyWorks 2023. This new release expands the PolyWorks universal 3D metrology platform to offer a digital ecosystem integrated into the four phases of a manufacturing organization’s global dimensional management process: product design, process design, validation, and production. ​
​
In addition to optimizing the performance of 3D measurement teams through universal platform enhancements, PolyWorks 2023 further reduces the cost of measuring in 3D in three different ways:​

• PolyWorks offers improved Model-Based Definition (MBD) and Measurement System Analysis (MSA) digital workflows that help manufacturing organizations minimize the number of software used within their global dimensional management process. ​
• The PolyWorks data management solution can now be deployed in less than 15 minutes in the cloud and be interconnected with a corporate identity server.​
• Finally, PolyWorks integrates new root cause analysis tools into its data management solution that can automatically identify the factors that impact production quality.​

“For 10 years, we have invested heavily in digital technologies, which today allows us to help our customers increase their use of 3D measurement data while reducing their operating costs. What is our secret? We digitally interconnect our customers’ platforms, such as CAD and PLM, PolyWorks, and Microsoft solutions. As a result, we can now easily provide business processes that previously required three or four different software and react in real time to problems on the production line while our decisions are based on factual 3D measurement data. Moreover, our customers can now deploy our data management solution in less than 15 minutes, which is a major breakthrough for small- and medium-sized enterprises,” says Marc Soucy, President of InnovMetric. He concludes, “For manufacturing organizations that are still questioning the relevance of their digital transformation, the question to ask is no longer why, but when.”​

Product and process design phases

The PolyWorks|Inspector solution helps reduce time-to-market by measuring, controlling, and analyzing 3D dimensions at every stage of the product and process design phases. With PolyWorks|Inspector 2023, 3D measurement specialists can now set up measurement templates and perform 3D measurement tasks more efficiently. They can:​

• Analyze and edit large measurement sequences quickly by finding steps using keyword searches or navigating through step types, such as errors and warnings; ​
• Replace the source objects of a dependent feature and preserve all related objects, data alignments, and reports created from this feature;​
• Create curve-based features in a single click over a polygonal model of a measured piece to rapidly inspect a piece without CAD data.​

Mixed reality display technologies provide localized visual guidance, measurement feedback, and access to inspection functionalities, without encumbering the hands of operators. The PolyWorks|AR 2023 mixed reality app offers new powerful tools to guide laser scanning, review inspection results, and collaborate with colleagues. Users can now:

• Position the hologram of the PolyWorks|Inspector 3D Scene window within the operator’s field of view to see scanning progression, perform additional scanning in areas of poor data
  quality, and pinpoint exactly where to scan features;​
• Review feature deviations and color maps directly over the measured piece;​
• Call colleagues through Microsoft Teams to review inspection results collaboratively and discuss manufacturing issues efficiently.

The PolyWorks|PMI+Loop Model-Based Definition solution allows manufacturing organizations to manage all the dimensional controls defined by the design and manufacturing teams within their native CAD platform. By associating dimensional controls to CAD geometries within CAD software, PolyWorks|PMI+Loop can automatically update these controls when the CAD model is modified and provide the digital traceability needed to accelerate the integration of a CAD design change within an inspection project. With version 2023, InnovMetric has improved the speed of its MBD solution by an order of magnitude and significantly reduced CAD file size. PolyWorks|PMI+Loop is available for the Siemens NX, PTC Creo, and DS SolidWorks CAD platforms.​

Validation phase
Measurement System Analysis tools are essential to guarantee the capability of 3D measurement processes prior to certifying production tools. Since version 2021, users could launch a repeatability or gauge R&R study directly from PolyWorks|Inspector, be guided to capture the required probe,  scan, or gauge data, and review the results within an updateable Excel spreadsheet linked to the inspection project. With PolyWorks 2023, InnovMetric has improved the speed of data transfer to Excel while removing previous limitations in terms of the number of dimensional controls, iterations, measured pieces, and operators.​

Production phase
PolyWorks 2023 offers major evolutions to manage data from production lines and resolve manufacturing issues faster:

• Customers can now store up to one million pieces sampled from a production line within a single inspection project;​
• Operators can monitor the production’s dimensional trends at a glance by displaying hundreds of charts at once within the PolyWorks|DataLoop Web Interface;​
• PolyWorks|DataLoop users can now automatically find the root causes of issues by performing statistical analyses of association, identifying the factors that impact production quality, and reviewing results presented in plain language with clear graphical aids.

Data management
The PolyWorks|DataLoop data management solution stores 3D measurement data on central servers and digitally interconnects all the people that capture or need access to 3D measurement information. With version 2023, InnovMetric has simplified the deployment of PolyWorks|DataLoop:

• InnovMetric now offers templates to install, configure, and start its data management solution on the Microsoft Azure or Amazon AWS cloud infrastructure in less than 15 minutes;​
• PolyWorks|DataLoop now supports Azure AD and the SAML 2.0 authentication protocol to interconnect with corporate identity servers.
  ​

This year, global engineering technologies business, Renishaw, is celebrating its 50th anniversary. The company, which was founded on 4 April 1973, will mark this significant milestone with a year of global activities including open house events at its largest sites, family days for employees and a ‘50 at 50′ charity initiative which will see £150,000 donated to 50 not-for-profit organisations in the 36 countries where it has offices.

The Company was formed to commercialise the invention of a touch-trigger probe by now Executive Chairman, Sir David McMurtry, that solved a dimensional measurement problem faced by Rolls-Royce when manufacturing the Olympus engines that powered the supersonic Concorde aircraft. The probe also solved similar challenges being faced by many precision manufacturers around the world, ultimately allowing measurement on co-ordinate measuring machines (CMMs) to be automated for the first time.

Rolls-Royce took out a patent on McMurtry’s original design, which was filed on 21 September 1972, with him acknowledged as the inventor. He discussed the touch-trigger probe with a colleague, John Deer, now Renishaw’s Non-executive Deputy Chairman, who also saw the wider commercial opportunities for the invention and Rolls-Royce agreed to license the patent to them but would only do so if they had a limited liability company. For expediency, they therefore purchased an ‘off-the-shelf’ company and on 4 April 1973, the first Renishaw company, Renishaw Electrical Ltd., was registered.

McMurtry and Deer quickly saw the potential for the use of probes on computer numerical control (CNC) machine tools and in 1977 Renishaw launched its first commercial probe for machine tools. Although today, a significant amount of Renishaw’s business is still derived from contact and non-contact laser measurement systems for CMMs and machine tools, the Company now supplies a wide range of metrology systems for calibration, position feedback and gauging, plus associated accessories including styli and fixturing. It has also applied its core expertise in measurement, manufacturing and process control to develop systems for non-destructive testing using Raman spectroscopy, robots and drug delivery systems for brain surgery, and is also a technology leader in the field of metal additive manufacturing (3D printing).

Over the past 50 years, Renishaw’s products have revolutionised key aspects of component manufacturing and scientific research, contributing to the ability to make the high performing, precision products that we use in our daily lives. From the manufacture of aircraft, cars, smartphones, electric vehicle batteries and solar panels, to brain surgery and dentistry, there is barely an industry that does not in some way benefit from the Company’s ongoing innovations.

Today the Company is listed on the London Stock Exchange’s FTSE 250 index, with a current valuation around £3 billion. It employs 5,200 employees in 36 countries, including 3,400 staff at its sites in the UK, primarily in Gloucestershire and South Wales.

Will Lee, Renishaw’s Chief Executive says, “This is a year to reflect on the tremendous achievements of our co-founders and employees past and present, who have done so much to advance precision manufacturing globally, and to look forward with confidence to future decades of innovation and growth.”

He adds, “The formula that has ensured Renishaw’s success over the past 50 years remains at the heart of our approach to business – investing heavily in research and development to ensure a continuing stream of world-leading products; a commitment to high-quality in-house manufacturing that ensures we can meet the exacting requirements of our global customers; and a focus on excellent local customer service and support through our wholly owned subsidiary operations.”

Lee concludes, “On behalf of Renishaw, I would also like to thank our customers and suppliers, many of whom we have had close relationships with for most of our history and with whom we have shared mutual success, and our other stakeholders, including our local communities who have been highly supportive of our growth and have also shared in our success.”

Automate processes reliably
Blum-Novotest, the leading supplier of innovative and high-quality measuring and testing technology, will present FormControl X for reliable process automation at the AMB in Stuttgart and IMTS in Chicago. “The foundation of intelligent automation solutions is process data that is evaluated live or very quickly and serves as a control variable for process optimisation. The automation reacts to the measurement result and readjusts to ensure that the process always remains within the predefined limits”, explains Wolfgang Reiser, Technology Division Manager at Blum-Novotest. “With the new FormControl X software, Blum-Novotest is presenting a solution for machining centres which can be used to gain much more knowledge by continuously measuring workpieces in the machining process”.

While the previous FormControl version (without the “X”) was based on a scenario in which a machine operator works at a machine with the laptop and processes the measurements at the same time, the trend today is moving towards automating such processes, meaning this 1:1 relationship is now fairly rare. Genuine automation of workpiece measurement also opens up completely new areas of application. That is why the goal with FormControl X was to enable real measurement automation on the basis of a modern client-server architecture – this means moving away from pure logging and towards process integration and automation with the help of the measurement data collected by the software.

In this way, workpieces can be measured directly after each machining operation, and the results serve as a correction value and basis for optimisation for the next component. To do so, the user defines intervention limits when creating the project, which the software uses to make corresponding corrections. This makes it possible to compensate for tool wear, among other things. FormControl X works in line with the trend that bore holes, for example, get smaller and smaller as the corresponding tool wears out, and can counteract this process. This widens the focus of the software: While FormControl was focused on higher-priced parts in individual production, FormControl X also targets small, medium, and large series production.

Evaluated data and results are accessible in a web interface using various end devices. The server communicates with the machines on which measurements are taken, so an operator can run measurement projects on many different machines and have them evaluated automatically. Complex measuring routines such as the alignment function can be used to adapt the reference points of the machining programme to the position as well as the shape of the workpiece to ensure that machining runs optimally. Another innovation in FormControl X is the management of measuring devices and machines. Since it is now centrally located on the server, the data is available for all machines. Definition of the measurement is also very simple and intuitive thanks to a context wizard.

FormControl X now also makes it possible to create and evaluate data series over time. What with FormControl ended in a protocol of a single machining operation can now be used to evaluate entire machining series. This offers the operator completely new ways to gain knowledge. The protocols resulting from the measurements can also be adapted very easily and extensively, tolerance limits can be displayed as a number or image, red/green colouring can be defined and much more.

FormControl X is another step on the path to integrating measurement results from machine tools into company processes and making them usable for Industry 4.0 applications. “With a networked client-server architecture, the reusability of measurements and the interaction with the machine, the new version of the software solution offers many new options for keeping processes transparent and optimising them on an ongoing basis”, Wolfgang Reiser says in summary. “However, perhaps the most important aspect for many users will be that with FormControl X, the machining process can be automated quickly and reliably, which is reflected 1:1 in productivity and in the quality of the manufactured workpiece”.

The Renishaw Equator flexible gauge is now offered with IPC (intelligent process control) software, providing the functionality to fully automate tool offset updates in CNC manufacturing processes. Improved capability in precision part machining, reduced setting and process adjustment time, and integration with automation systems are some of the benefits that users can now expect.

IPC is used with the existing software running on the Equator controller, using recent historical gauging data to determine process corrections. Connection to a compatible machine tool can be as simple as connecting an Ethernet cable from the Equator to a CNC machine. This capability has already been used by Renishaw customers worldwide to achieve considerable performance gains across a wide variety of industries, applications and CNC machine types, including lathes, machining centres and highly automated machining cells.

Controlling processes with frequent gauging

The new IPC software allows constant monitoring and adjustment of a machining operation, keeping part dimensions close to nominal and well within process control limits. This means that any process drift is quickly corrected, improving part quality and manufacturing capability, along with reducing scrap. The proximity of the Equator gauge to the CNC process allows rapid measurement and process adjustment at the point of manufacture, avoiding time delays or relying on finished part (tailgate) inspection.

The IPC software can average results across several parts to determine the true process mean for adjustment of each cutting tool. For process control purposes, it is usual that only one machined feature per tool offset will require gauging, as compared to many features for typical Quality Assurance (QA) applications. The frequency and control of offset updates can be configured on a feature by feature basis depending on design tolerances, process variation and tool wear rates.

Reduce dependence on skilled operators

The ability to correct a process automatically with IPC software eliminates the potential for manual data entry errors and removes the requirement for an expert to decipher traditional measurement reports into a process correction value at the CNC machine.

One-to-one or One-to-many – update multiple machines from one Equator gauge

An Equator gauging system can be connected to one or multiple CNC machine tools, so that parts from different machines can be gauged on one Equator, with the offset updates being sent to the corresponding machine (part / machine identification is required). Connection to multiple machines requires an Ethernet hub or is via an existing factory network. Closed loop unmanned process control of a cell of machines is possible and a key requirement when used in conjunction with factory automation systems.

Intelligent process control of cutting tools

Options within the IPC software can constantly monitor the process and detect excessive tool offset update values, indicating tool failure or high rates of wear, and automatically signal to the machine that the tool needs changing.

Where IPC software is of benefit

IPC software has proven to be particularly useful for conventional CNC lathes or Swiss-style sliding head machines where integration of a conventional machine tool probing system may be difficult due to machine configuration or tool station availability. Using the Equator gauging system is also beneficial where measurement due to feature access or size would be difficult to undertake on the machine tool. Also, the use of off-machine gauging and IPC as a parallel activity is the preferred solution where minimum machining cycle time is a critical requirement.

IPC compatibility

The first release of the new IPC software allows connection to one or multiple machine tools, with direct Ethernet links from the Equator Controller to Fanuc, Mazak and Okuma CNC controls.

Fanuc controls that have been tested and proven include the 0i, 30i, 31i and 32i, with the Focas2 option installed.

Mazak controls currently supported are the Smooth X, Smooth G, Matrix2 and Matrix controls with the Mazak API installed.

The Okuma OSP300L and OSP300M controls are supported, on machines with the Thinc API installed.

Future software releases will further increase CNC control compatibility.

The versatile gauge

The Equator gauging system is unique in its design and method of operation, and has already changed the thinking of thousands of production engineers, making it their gauge of choice. The versatility and repeatability that Equator offers is re-defining the world of gauging and, now available with IPC software, it offers an even wider range of capabilities to manufacturers globally.

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.

Quality is not monitored, it is produced. Suppliers to the automotive sector will tell you a tale or two about this. They not only need to deliver their parts to large car manufacturers ‘just in time’, the parts must also be near fault-free. Quality control is no longer just for finished products – measurement technologies now actively control the entire manufacturing process. If product quality isn’t up to standard, business can be lost.

The importance of precision measurement is now a recognized reality in today’s manufacturing world. As technology has improved, so have the tools available to manufacturers – both in their function and in their accuracy.

A broad range of tactile and optical measurement technologies are now available. The most common – and basic – of these tactile, or touch, technologies is a group of devices collectively known as hand tools. This family includes such classics as micrometers and calipers. They are some of the most frequently used hand measuring instruments, but they are
not without fault. Because they rely on the user to take the measurement properly and correctly interpret the result, measurements can vary greatly depending on the operator. Furthermore, hand tools also do not easily provide the measurement documentation demanded by today’s customers.

Optical, or non-contact, measurement technology has been greatly improved in recent years. Though they often work reliably, offer the advantage of being contact-free, and are increasingly easy to use, many of these devices do not provide the high level of accuracy of tactile methods. Those optical devices that do yield relatively accurate results can only take measurements in two dimensions. When industry and market demands require three dimensional measurements in the micron range, tactile methods continue to be the best option.

Though traditional in their use and common in manufacturing, lower-cost tactile technologies like hand tools are not enough by themselves to ensure long-term manufacturing quality. Traditional hand tools and improving optical methods can be used to support other measurement processes, but to achieve the measurement accuracies demanded today, they often cannot be viewed as stand- alone full solutions.

Complex manufacturing processes
It is not just about accuracy. Parts and components are becoming increasingly more complex as a result of faster, more accurate processing techniques. Measurement technologies need to keep pace with this reality. If users want to safeguard complex manufacturing processes, they must make use of improved coordinate measurement technologies.

In modern manufacturing, a wide variety of products are produced in a single process. This is an additional challenge for measurement engineers as control must be maintained over manufacturing processes at all times. Such control is currently only possible with flexible coordinate measurement technologies.

Design engineers also play an important part as their work is yet another area where companies use coordinate measurement technologies. While designing new or improved parts on their computer, they generally do not worry about how easy or difficult it will be to inspect it later on. Often, such measurement problems can only be handled using a coordinate measuring device. Fabrication methods that take measurement technologies into consideration could help alleviate this problem.

Skeptical quality managers claim that manufacturing methods have become more complicated since the introduction of CAD systems. In reality, their level of freedom has increased which has only made the quality engineer’s job more difficult. Coordinate measurement technologies help resolve this dilemma.

Traceability
A decisive advantage of coordinate measurement technologies is their traceability. Conformity
to national and international standards is extremely relevant as it is the only way to validate measurement results. It enables users to verify that their parts are in tolerance with a high level of confidence. Companies integrated into the global value-added chains rely heavily on traceability.

Coordinate measuring machine design
Coordinate measurement technology is often deemed as the ultimate authority in the metrology sector – and with good reason. Coordinate measuring machines (CMMs) have experienced an extremely rapid level of development since their introduction in the 1950s.

CMMs collect detailed dimensional data by moving a ball tip sensing device called a probe along
the surface of the part being measured. Basically, all CMMs determine the coordinates of a point in space. Linear encoders built into each axis allow them to track their movement relative to the probe with very high precision. High end devices used properly and under ideal conditions can give results that deviate from the true value by as little as 0.1μm.

Some CMMs are manually operated while others are computer controlled for automated inspections. When first introduced, all CMMs required a specialized operator to manually move the probe from point to point to take measurements. These devices were not computerized and still required the operator to record and calculate measurement data and results.

Today’s manufacturers increasingly rely on the precision provided by CMMs. This fact is due to the accuracy and traceability they provide to an ever demanding market.

Functionality
The parts to be measured by CMMs are usually digitized point-by-point. Touch probes trigger when contact is made with the surface, automatically recording the resulting position. To ensure the effectiveness of the process, encoders and sensors must be routinely calibrated.

The measurement values are processed using a host computer and the captured points are used to calculate basic geometry. These include deformities, curves, and freeform shapes. The computer
is also responsible for controlling the measurement machine itself. Results can be easily graphed – optimizing the reporting process.

Measurement technology as a service
The recommendation, or demand, to use CMMs is often made by a company’s engineering or quality department. The measurement technology manufacturer must work with the prospect’s engineers in order to ensure the technology provided fulfills the customer’s requirements. CMM software must be flexible and adaptable to various needs to ensure that the quality of the parts and part components being manufactured is not compromised.

Often, measurement technology manufacturers offer various solutions for a company’s entire product portfolio and the unique problems each presents; giving those looking for improved measurement and manufacturing processes more control of their measurement strategy.

A better solution
Today’s CMMs are offered in different performance classes and can be customized to match individual requirements. Regardless of company size, CMMs are an integral part of the quality control process. Large, small, and even medium-sized companies all can have similar applications and even more similar goals: to manufacture the best possible product using the best possible process.

Though CMMs have been improved from their early days in the 1950s, they still operate using the same principles as when they were invented. Accuracy has been improved as well as functionality, but what has become known as traditional, or fixed, CMMs still have their own flaws. The most obvious of those is their need to remain in a fixed position.

To effectively monitor manufacturing processes, dimensions must be checked quickly and accurately right on the production line.

A suitable alternative to fixed CMMs is the portable CMM. They take the accuracy and consistency of traditional machines right to the manufacturing floor where they can be moved around and used at will. This minimizes or eliminates the down time created by having to take parts to a CMM room.

Traditional CMMs still carry relative high price tags and complexity. Portables have not only broken the inspection room barrier, they are far less expensive and relatively easier to use than their traditional cousins. Portable CMMs deliver faster ROIs, improved functionality, and a better user experience.

Content and Image courtesy: FARO Technologies 

InnovMetric Software Inc., the leading provider of universal 3D metrology software solutions, proudly announced today that worldwide demand for PolyWorks® in fiscal year 2016 (ending March 31, 2017) led to a 20% global sales revenue increase compared to the previous fiscal year. This growth was fueled by all-time record sales of 3300 new licenses of PolyWorks.

The PolyWorks sales growth in the three largest Asian markets, China, Japan, and India, has reached an impressive 35%. Moreover, PolyWorks support/maintenance contract sales in North America and in Western European countries have also significantly increased, by 30% and 40% respectively.

“2016 represented a defining moment in our company’s history: we achieved our 2006 vision of delivering a universal 3D metrology software platform by unifying the worlds of portable metrology and CNC CMMs. Although an impressive achievement in itself, what truly made PolyWorks 2016 a milestone in the metrology industry is the fact that it delivered a truly universal 3D metrology workflow. Portable metrology and CNC CMM operators were now able to define and execute their measurement plans, and review the measurement results, using the same tools and methods within a single software module,” said Marc Soucy, President of InnovMetric. “Commercially, it was also a transition year, as our large manufacturing OEM customers needed to assess all the cost-reduction opportunities brought by a universal platform before embracing our unique vision. The remarkable growth in license and support/maintenance sales worldwide shows that PolyWorks 2016 is gaining acceptance and is starting to take root. This is exciting news that should lead to major sales opportunities in FY2017 as we prepare to celebrate the sale of the 20,000th PolyWorks license in June.”