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.”

Blum TC76-DIGILOG touch probe at Lehmann

A complex component, incorporating four long slots among other features, was posing problems for Timo Lehmann, CEO of Karlheinz Lehmann GmbH in Oberwolfach. The solution was ultimately provided by a Cincom M32 lathe in conjunction with the TC76-DIGILOG touch probe from Blum-Novotest.

“Highly complex components are part and parcel of our business. But implementing a quick-coupler for compressed air input was a tough nut to crack,” says Timo Lehmann of the challenges posed by a project for Parker Hannifin GmbH, a world leader in drive and control technology and pneumatics. “The key components are hardened and coated free cutting steel, threads, bores, and four lightly tapered slots. The slots were the crucial point of the whole design.”

The parallelism of the slots was only allowed to vary by 2 µm from the reference values. Otherwise the fully automated machine, assembling the component unit at Parker-Hannifin, would abruptly stop. Moreover, the quick-coupling would not work if the tolerance was exceeded. When assembled, the lightly tapered slots contain balls, which must not protrude too far yet, must also never be allowed to fall through the slot. Through this design, the Parker quick-couplers prevent the otherwise common snapping noise when detaching, and also allow single-hand operation. Just as challenging as the production process is the task of measuring the slots. The BLUM TC76-DIGILOG touch probe proved the only cost-effective means of verifying the design’s dimensional accuracy.

Analogue measurement is always advantageous for assessing areas or lines. If a switching digital probe were to be used in the Lehmann application, for example, a very large number of points on the slots would have to be measured in order to attain an adequate resolution. By contrast, the TC76-DIGILOG is scanned across the surface at a measuring speed of 2 m/min. As this is happening, the system generates an extremely large number of values (50,000 per second in fact) in a fraction of the time based on analogue data acquisition.

The combination of the Cincom M32 and TC76-DIGILOG has been running smoothly and efficiently in Parker Hannifin’s production operations since February 2015. The sequence is as follows: At the start of a production run, a reference part is clamped onto the machine and the complete contour of the corresponding slot is scanned and recorded. The master profile recorded in this way is entered in the evaluation software. The subsequent production workpieces are compared against the recorded profile, and any that exceed the tolerance are discarded. As a result, the tight tolerances of the slot are reliably checked immediately after the cutting process in the lathe. In-machine measurement itself delivers enormous benefits. If it is run without problem in the idle times, as in Parker Hannifin’s quick-coupler production, it is hard to beat. It allows Lehmann to implement 100 percent checking, with error trends being detected at an early stage by evaluation software.

Incidentally: it doesn’t matter whether the TC76-DIGILOG is fitted in a grinding machine or a milling machine. And thanks to its increased scanning forces, it is even outstandingly well suited to the tough demands of applications in lathes. The TC76-DIGILOG scans the part accurately and non-directionally, measuring with supreme precision thanks to the patented shark360 measuring mechanism. “Neither coolant nor viscous oils impair the reliability of the measurement data. With its high scanning force, the touch probe simply pushes through the coolant,” adds David Cousins.

The Blum-Novotest/Citizen combination is also used for other large production lots from 10,000 to 30,000 pieces. The processed materials are wide-ranging: from stainless steels, heat-treatable steels and free cutting steel, to aluminium. “Given that we were close to having to refuse the quick-coupler order from Parker Hannifin, we are delighted to have found such a powerful solution in the combination of Blum touch probe and Citizen machine,” Timo Lehmann concludes with satisfaction.

Machining contractor Karlheinz Lehmann GmbH is based in Oberwolfach in Germany’s Black Forest. At its 1,000 square metre site, the family business employs 17 people, operating 20 state-of-the-art CNC lathes and milling machines, mostly in the manufacture of high-precision rotationally symmetrical parts. The company has been trading for over 40 years, and is now managed in the second generation by the founder’s son and daughter. Lehmann employs state-of-the-art technology to manufacture small and large production runs in a three-shift operation – though the night shift is unmanned. The traditional family company’s motto is “Cutting skills in perfect precision”, and it is based on those principles that it has established a customer base including major international corporations such as Parker Hannifin.