Hexagon Manufacturing Intelligence Prepares Leitz PMM-C and Leitz PMM-Xi Lines for SENMATION

Hexagon Manufacturing Intelligence has announced an upgrade for the Leitz PMM-C and Leitz PMM-Xi coordinate measuring machines (CMMs) to ensure the ultra-high accuracy metrology solutions are more adaptable for user needs now and in the future.

The Future-Ready Concept from Hexagon will optimise the machines for the SENMATION intelligent sensor automation system, by replacing the current pre-cabling with a universal alternative. The new pre-cabling concept will be installed on all standard configuration Leitz PMM-C and Leitz PMM-Xi CMMs allowing for more flexible application changes without costly downtime.

The SENMATION intelligent sensor automation system allows different probe heads to be used within a simple measurement procedure without human interaction. Automated measurement cycles can be introduced to further increase speed and optimise the manufacturing process. Rework and rejection rates will also be reduced, creating a faster and more reliable quality assurance system.

Both the Leitz PMM-C and Leitz PMM-Xi machines can now handle an extended measurement portfolio including fixed and indexing probes and optical measurement options. Machines with the update will no longer need engineers to switch pre-cabling to facilitate application changes, allowing for better flexibility in the manufacturing process, reducing downtime costs and making the CMM more adaptable to changes in future technologies and processes.

“We are always looking for ways to improve and develop our CMMs and have taken the opportunity to make some of our best machines even better,” explains Holger Fritze, General Manager at Hexagon Manufacturing Intelligence Germany. “By introducing the Future-Ready Concept our aim is to eradicate unnecessary downtime for our customers, speeding up measurement routines and allowing more flexibility in their workflows now, and in the future.”

The Future-Ready Concept will be introduced to standard configuration Leitz PMM-C and Leitz PMM-Xi machines from next year. More information is available through local Hexagon commercial operations and dealers.

Guide and measuring device in one: The IMS-A integrated measuring system captures the absolute position inductively with a high degree of precision, even under mechanical loads and in polluted environ

Linear guides with absolute value recording as accurate as glass scales, but more robust

Whether in machining operations, 3D printing or electronic handling – ever greater accuracy and availability are essential. The new Rexroth IMS-A measuring system, which is integrated in linear guides, is helping to achieve just that. It detects the absolute position of the axis to +/- 4 micrometers. What’s more, the measuring system is immune to contamination, vibrations, shocks and magnetic interference and needs no buffer batteries in the event of a power failure. Thanks to the complete integration of the sensor and evaluation electronics in the ball and roller runner blocks, design engineers can avoid external measurement systems and air purge systems.

Turning machines back on again following a power failure can result in a critical situation. The controller in many applications needs to know the position of each axis immediately. Purely incremental measuring systems need to first complete a reference run for this. This extends the ramp-up time and, in a loaded state, can result in damage to the workpieces and tools. The new integrated IMS-A measuring system from Rexroth immediately recognizes the absolute position of the axis with a high degree of precision when the machine is switched on and reports them to the controller without carrying out a reference
run. For this, the system does not require buffer batteries that need to be replaced regularly.

Inductive and wear free
Thanks to the inductive measuring principle, the IMS-A operates without physical contact and is therefore a wear-free assembly. The measuring scale cannot be interfered with or destroyed by external magnetic fields. The IMS-A is not sensitive to vibrations up to 10 G and shocks up to 50 G. The sensors and evaluation electronics are located in protective housing on the end face of the runner block. Even in working spaces with coolants, dust, shavings and other contaminants, the IMS-A does not require elaborate energy-eating, high-maintenance air purge systems. Even electrical and magnetic interference fields do not affect the measurement results. This ability makes the IMS-A destined to also be combined with linear motors, for example. Here it combines precision with high dynamic performance requirements and gains the full dynamics of ball and roller rail systems from Rexroth. The permissible acceleration is up to 500 m/s² and the maximum speed is 5 m/s, or even up to 10 m/s upon request.

Precision machining
With the IMS-A, position detection takes place very close to the tool center point, an important prerequisite for high precision, and thus surface quality in machining. The position resolution of the IMS-A is up to 0.025 µm. This extremely low value creates the conditions for excellent control loop dynamics and thus short cycle times. The system accuracy of +/- 4 µm/m lies within that of glass scales. This means that repeatability of +/- 0.25 µm is possible.

Integrated functions
The functional integration of guiding and measuring in an assembly minimizes installation times. No adjustment of the measuring system is necessary. With the IMS-A, engineers can use several runner blocks on an up to 4,500 mm long profile rail independently and without any accuracy limitations. All components, i.e. rail, runner block with adapter plate and scanner, are individually replaceable in the event of servicing. This reduces servicing costs. The interchangeable construction offered by Rexroth ensures even less effort. All runner blocks of the same size fit onto the profile rails of the respective size without any restrictions. The measuring system transmits the data via HIPERFACE© (*) interfaces, as well as via SSI/1Vp-p to the intelligent drives or controller. DRIVE-CLiQ (**) and FANUC interfaces are to follow.

Prepared for Industry 4.0
The integration of additional temperature and motion sensors makes this measuring system prepared for the future requirements of Industry 4.0. The additional sensors allow machine designers, for example, to read out the temperature and the actual dynamics. The sensor data also forms the basis for future approaches to predictive maintenance. The user can record and evaluate operating states online. If the accelerometers detect changes, such as increasing vibrations, then this is an indication of wear or other problems. Scheduled maintenance can then intervene before the machine needs to be shut down.

Intelligent sensor automation system also launches on Leitz PMM-C coordinate measuring machines

Hexagon Manufacturing Intelligence has announced new functionality for the SENMATION universal sensor interface as the system rolls out to Leitz PMM-C coordinate measuring machines (CMMs). SENMATION enables users to overcome complex measurement challenges on a single CMM by deploying the right sensor at the right time.

Enabling the fully-automatic exchange of sensors within part programs, SENMATION is designed to make programming easier while maximising machine uptime and productivity. The upgraded version adds the HP-S-X5 HD heavy-duty analogue scanning probe to the SENMATION toolset in addition to the existing offering of scanning, optical and vision sensors. Accepting styli of up to 800 mm and 650 g, HP-S-X5 HD offers better part accessibility. It will also enable SENMATION to handle the PROFILER R tactile roughness sensor in the near future, further extending the functionality of the CMM.

Based on a universal sensor switch and intelligent sensor module and directly integrated into the CMM quill, SENMATION uses a mechanical loading system to engage the sensor without operator intervention. A built-in probe identification system recognises the sensor immediately and checks its status, so there is no need to recalibrate between exchanges. The data gathered by each sensor is contained within the same software session, enabling users to gather a comprehensive overview of the workpiece using the best sensor available for every aspect and feature.

“SENMATION gives customers real flexibility, enabling them to work at speed and with confidence in their results. We are very excited to introduce this outstanding technology on the Leitz PMM-C.” said Micha Neininger, Sensors Product Manager at Hexagon Manufacturing Intelligence.

The Leitz PMM-C line of high-performance CMMs combines ultra-high accuracy with unmatched machine dynamics. Fast data gathering and advanced high-speed scanning results in extremely short cycle times and high throughput for efficient process control, and SENMATION adds a new level of adaptability to these CMMs.

As well as HP-S-X5 HD, SENMATION accepts the motorised indexing probe head HH-AS-2.5 with HP-S-X1 scanning sensor, the HP-S-X5 3D scanning probe, and the PRECITEC LR optical sensor for non-contact measurements on matte, reflective, glass or transparent material. Initially launched on the Leitz PMM-Xi, the system is now also available with new orders of the Leitz PMM-C placed via local Hexagon Manufacturing Intelligence commercial operations and dealers.

The automotive industry is fiercely competitive. Tier-one car manufacturers are constantly looking for breakthroughs in areas such as performance, safety and innovative design, all of which places ever stricter requirements on the processing of metal components.SuperAlloy Industrial Company Ltd. (SAI) is a supplier of high-quality lightweight forged metal products. The forged wheel and car chassis components SAI produce are used by the world’s top car manufacturers, thanks to the company’s insistence on premium quality and precision manufacturing. Renishaw machine tool probe systems, including the OLP40, RMP60, OMP60, and the NC4, are a perfect match for SAI, allowing SAI, assisted by Renishaw, to make great progress on the route to high end precision manufacturing.

SAI’s relationship with Renishaw began with CMM measurement. Dr Henry Shih, CEO of SAI, explains: “When we entered the European market in 2008, we realised that our high-end car manufacturer clients’ quality, dimensional stability and precision requirements for metal products were extremely high. While our equipment at the time was able to meet their volume requirements, we needed to enhance product quality and reduce the amount of rework and corrections during processing so as to achieve high quality levels.

Through Renishaw, we discovered machine tool probe measurement solutions that could deliver in-process measurement control and real-time data feedback on our existing CNC machines, thereby providing effective precision manufacturing control. This was a massive help in terms of increasing production efficiency and precision.”

SAI is currently focused on supplying high-quality forged metal products. SAI’s customers are all high-end automobile manufacturers that demand specialised technologies and services, including some of the world’s top-tier car makers such as BMW, Mercedes-Benz, VW, Porsche, Ferrari, Ducati, Bentley, Audi, Rolls Royce, Jaguar, Land Rover, Ford, Chrysler, Toyota, GM and Honda.

The production of aluminium forged wheel rims

The forged wheel production process is complex, particularly for low-volume, high-diversity production. SAI produces more than 200 types of wheel which requires the utmost production flexibility. Strict standards are applied to workpiece setting, reference measurements and key dimension detection during metal processing, as the precision requirements for machining wheel mounting surfaces exceed the requirements of even the aerospace industry. SAI currently has 600 CNC machine tools working on wheel rim production, including 150 Victor Taichung lathes and 450 YCM milling machines. All these machine tools are engaged in production on a three shift process five days per week. So how does SAI ensure that the precision and stability of 600 machine tools remains consistent?

In order to increase production precision and reduce scrap, SAI equipped the relevant lathes with Renishaw OLP40 touch probes, which use optical signal transmission and are adapted for turning processes. The CNC milling machines were equipped with RMP60 machine tool probes which use wireless radio transmission to measure workpiece position and reference height, as well as providing in-line key dimension detection, thereby increasing production performance.

Mr. Y. C. Kao, Senior Manager of SAI’s Wheel Production Department, explains: “The automated workpiece setup enabled by Renishaw machine tool probes allows us to ensure that the cutting dimensions remain stable and consistent when we are producing wheel rims, as well as effectively reducing human error. For example, the air valve hole cutting thickness Process Capability Index (CPK) rose from 0.71-1.13 to 1.35-1.43 when using Renishaw machine tool probes.”

3D appearance modelling for forged wheel

Wheel styling design has moved from flatter surfaces towards more 3D effects in recent years, causing wheel rims to become ever larger, and placing increasingly stringent demands on processing precision. Until 2011, SAI’s acceptable tolerances for wheel rim production (with the flatter designs used at the time) were 0.05-0.10mm. However, the tighter tolerance requirements of the current 3D designs has gradually increased cutting times and processing; wheel rim appearance processing takes as long as 180 to 240 minutes, with the result that any rework imposes considerable pressures in terms of both production time and cost.

OLP40 probes allow SAI to carry out in-process measurement control to achieve tolerance of less than .0.02 mm, and can replace human measurements and updates to workpiece coordinates. This greatly improves cutting and efficiency for surface precision processing after coating. Even more importantly, it reduces rework by 80%, as before the introduction of in-line measurement systems wheel production generally had to be processed twice to achieve the necessary precision. When combined with Renishaw software, the probes not only play a role in guidance during production, but also provide in-process control and real-time feedback, immediately updating and correcting data during metal cutting, and efficiently monitoring and controlling dimensions and deformations.

Renishaw machine tool probe systems have allowed SAI to increase production precision and product quality, while also reducing scrap from 2-3% to 0%, and improving production efficiency.

Precision processing for car chassis

The automotive industry has already evolved from focusing on basic safety requirements and performance towards enhanced driving comfort, improved fuel efficiency and reduced emissions. The safety and stability of lighter vehicles moving at high speed is closely connected to the manufacturing of the car chassis. The higher the precision of chassis produced with aluminium alloys, the safer and more stable the car is when travelling at speeds as high as 200 km/h, and the more comfortable the driving experience. The lighter the chassis, the lower the fuel consumption, and thus the easier it is for the vehicle to meet environmental requirements.

SAI has continually improved its forging and mechanical processing technology. The company moved into the processing and production of precision car chassis in 2011. SAI now has 38 Tongtai high end five-axis CNC machine tools, all of which are equipped with Renishaw OMP60 optical machine tool probes and NC4 non-contact laser tool setters.

Unlike wheel rim production, chassis production tends to involve high volume and lower diversity, but nevertheless still requires high-precision metal cutting and processing. Renishaw OMP60 optical machine tool touch probes use advanced modulated optical transmission to provide 360° signal transmission. The probe simplifies measurement and calibration processes, thereby achieving high-precision measurement for workpieces with complex profiles. The NC4 uses innovative laser technology to perform high-speed, high-precision measurement of cutting tools as small as 0.2 mm, and to perform tool breakage detection on cutting tools as small as 0.1 mm. Its non-contact method avoids the potential for causing wear or damage of cutting tools.

Production times for car chassis are relatively short, and can generally be kept within 20-25 minutes. Renishaw machine tool probe systems provide the operator with turnkey solutions for real-time positioning and measurement, and in-process control measurement, helping to further automate production processes.

Trusted brand, thoughtful service

SAI chose Renishaw because of the company’s trust in the Renishaw brand. Mr Shih explains: “When we choose suppliers, we don’t just look at the price of the product; we also attach a great deal of value to their R&D capabilities and service. Renishaw has an excellent reputation in manufacturing industries, and also provides service for different industries, so it doesn’t just offer a product or a solution, but also shares with us its experience, expertise and the industry’s best practices. Renishaw is also meticulous in terms of its technical support, and the Renishaw team reacts quickly to solve problems; this is particularly impressive to us.”

SAI’s trust in Renishaw began with the use of CMM probes. The company now has 10 CMMs fitted with Renishaw probes. For machine tool performance checks, SAI has also fitted its machining centres with Renishaw QC20-W telescopic ballbar measuring instruments for the most comprehensive diagnostic testing and verification functions.

Global engineering technologies company Renishaw has launched the Primo LTS (length tool setter). The Primo LTS is a single-axis tool setter which allows users to set tool length, check for breakage, and compensate for thermal growth on a CNC machining centre.

The Primo LTS eliminates the need for time-consuming, error-prone manual tool length setting which can lead to scrap, rework, and reduced productivity and profit levels.

Automated on-machine tool length setting with Primo LTS is up to ten times faster than manual methods, resulting in immediate and significant cost savings. It is suitable for use on small to large CNC machining centres and helps guarantee “right first time” parts, reducing waste and increasing profits.

During a machining process, dimensional accuracy is dependent on a number of variables, including tool length and tool breakage. The Primo LTS monitors these variables automatically, enabling users to compensate for variations which may occur and benefitting the overall machining process.

The Primo LTS is a hard-wired product featuring a fully integrated interface for straightforward electrical connection: the hardware can be bolted onto the machine table and is immediately operational, with no additional set-up required. The Primo LTS is designed to operate in the harshest of machining environments, so it is resistant to swarf or coolant ingress and prevents false triggers caused by shocks or vibration. An integrated air blast provides effective swarf removal when necessary.

Easy to install and use, Primo LTS provides an accessible solution for increasing the productivity and profitability of a machine tool.

Advanced ballbar training enables shop to achieve “better than new” machine tool accuracy and extend machine life for unconventional silicon processing. Semiconductor industry supplier now understands its machine tool’s performance better than OEM service technicians. Ballbar data supports TPM and emerging SPC and OEE programs.

Ballbar testing is nothing new to those who use fleets of machine tools, including people like Wayne Ross and Jacob Hebbeler of Silfex Inc based at Eaton, Ohio, USA. Both have used ballbar analysis to maintain and enhance the accuracy of the plant’s 50+ machines for more than a decade. But, it turns out that experienced ballbar users can still learn a few new tricks that can be transformational to a business. After upgrading to a QC20-W wireless ballbar and taking Renishaw Advanced Ballbar course, TPM manager Ross and machine operator Hebbeler now use captured ballbar data to evaluate machines, “super tune” them to better-than-factory accuracy and get longer life out of machine components. They have also changed the way the company proves out machines, schedules maintenance and evaluates the need for new machines. “We’ve done ballbar testing for years, but until we took the advanced ballbar course we weren’t making full use of the results,” said Ross. “Now we’re using the ballbar to qualify metrology, time our maintenance decisions, implement TPM and SPC, and even forecast machine life. It’s helping us make operational and capital equipment decisions in ways we never thought possible.”

Unconventional processing with conventional equipment

Silfex’s machining application is like a military proving ground for machine tools, so machine diagnostics are a way of life. Its lathes and VMCs – primarily Haas and Mazak – use diamond tooling to grind and polish silicon and quartz for the semiconductor industry, resulting in glass-like debris and diamond particles forming an abrasive compound that wears out components in months. The 290 employee company is a rapidly growing division of Lam Research Corporation and has built a reputation as a premier single-source supplier of electrodes and silicon fixturing for Lam plasma etching chambers. These consumable parts support the etching process in the manufacture of computer chips, and part values can be as high as $30,000.

“We are one of the few companies in the world that can grow defect-free, single-crystal silicon to a diameter of 460 mm,” Ross explained. “We do start to finish manufacturing under one roof, which is important because the semi conductor industry requires 100 percent traceability on everything from the material source to the machined parts, and we have all of that under direct control,” added Ross. “For our customers’ requirements, this is a purchasing manager’s dream.”

The plant is environmentally controlled and equipped with multiple clean rooms from class 10,000 to 100. “One speck of contamination can wipe out a lot of computer chips,” Ross stressed.  Processing the silicon includes wire sawing, waterjet cutting, milling, drilling, grinding and lap polishing before inspection in metrology rooms with CMM and VCMM equipment. Parts then go to an on-site clean room for packaging. Production runs range from five to 100 pieces per setup and the required tolerances are typically ±0.001″, with some requiring ±0.0005″.

Grinding silicon creates an extremely harsh machining environment. “We’re using conventional machines to do unconventional processing, and using ballbar diagnostics to stay on top of our machine capability in a high-wear application,” said Ross. “We use the ballbar to diagnose ballscrew wear every six months, but usually get called to test machines before that. The advanced ballbar training showed us how to determine if we can make machine adjustments or if it’s time to replace the ballscrews. This allows us to control downtime scheduling and maintain our accuracy as machine components wear out, rather than judging machine capability from the quality of finished parts. We run these machines hard, three shifts, five days a week, with quite a few long runs, and the grinding environment is tough on the equipment. I’m amazed at how accurate we can make these machines considering how rapidly the machining environment changes. Our VMCs are hitting accuracies comparable to much higher-end machines. And, while high-end machines are faster, we can only grind so fast. So, we don’t need ‘faster,’ just accurate.”

Advanced ballbar training raises the bar for company’s machining capability

Ross and Hebbeler came away from Renishaw advanced training with a much better understanding of their ballbar data and how to use it. Conducted at Renishaw in Hoffman Estates, Illinois, USA, the hands-on course lets participants practice setting up and running ballbar analysis on a variety of different machine tools in a learning lab. “I’ve been working with ballbars for 13 years and thought I knew my stuff,” said Hebbeler. “But after 10 minutes, I was learning new tricks. Among other things, we learned how to troubleshoot scale mismatch, which has helped us super tune our circular interpolation and extend the useful life of the mechanical parts of our machines. We also look at lateral play to gauge the condition of our linear guides.”

“After the advanced class we concentrated on interpreting our numbers to see if there were more details we could control,” Ross explained. “Jacob has gotten really good at adjusting the backlash and reversal spikes, so we can get more life out of the ballscrews, which is our edge until we can get a service technician in. Sometimes we can do two or three adjustments and that buys us a lot of productive time to schedule when to take the machine offline for repair.”

Accuracy now starts at ground level

Silfex uses ballbar diagnostics to determine a machine’s squareness, which is the prerequisite for analyzing backlash and reversal spikes. “Many machine shops overlook the effects of the floor, as we were, on machine level,” said Ross. “We are lucky our concrete is substantial enough to support all the weight we put on it, and we check and adjust the machine level upon installation. Once we set the level we can diagnose reversal spikes, backlash and scaling mismatch, which we didn’t know how to do before the class.”

Ross and Hebbeler now handle machine levelling, largely because they can hit specs that some technicians have trouble achieving. “The two-tenths bubble servicemen can meet our requirements, but the five-tenths bubble guys can’t,” said Hebbeler. “Our levelling is so precise today that we often wish the levelling screws had a finer pitch on them.”

After the training Ross and Hebbeler used their new knowledge to push the boundaries of machine accuracy. “Our goal on squareness was 0.000050″/inch, and I decided we would try for 0.000025″/inch,” said Ross. “When I told Jacob he expressed doubt, but I showed him data that proved he had already achieved it three times prior.”

Based on their success with the ballbar, Ross and Hebbeler are expanding their machine diagnostics. “The ballbar tells us about the foundation: the linear guides, the ballscrews and the truss bearings – the bottom end of the machine – that’s where mechanical tolerances are established and it also confirms our metrology,” said Ross. “We’ve also started using some vibration analysis, and that tells us about the top-end of the machine which dictates finish. So, between the two, we are analyzing all the factors that affect our size and finish. We’d like to get into volumetric compensation testing with the ballbar. We currently test X and Y on VMCs, and X and Z on the lathes and have done full Y-Z testing in the past on a few machines but with volumetric testing we’ll also hit X-Z and I think we’ll be able to get what we need in the 220-degree sweep the ballbar is capable of performing.”

No wire, no worry

Upgrading to the wireless ballbar simplified data collection, and made it safer, Hebbeler explained. “With the wired ballbar, I spent a lot of time babysitting a machine under test,” said Hebbeler. “I had to feed wire in through the back of the machine, and if I walked away for a few minutes I often came back to a twisted wire. I always had a nagging thought that any little tug on a wire during a test might skew the results. We don’t have those issues with wireless operation. I can set it up and go do something else until the test is complete. It’s also safer now that we’ve eliminated open-door testing.”

Ballbar data opens doors for new programs

Silfex is now using ballbar data to establish thresholds in relation to its various processes and determine process capability. “We now have diagnostics to back up what we think is happening with our machines,” said Ross. “This data is being used for our TPM program, implementation of SPC and our future OEE (Overall Equipment Effectiveness) monitoring. Full SPC will allow us to move away from 100 percent inspection. We are also working to determine what will be the useful life of a machine based on capability, maintenance costs and consistent quality.”

Even machine tool technicians are impressed with the expertise demonstrated at Silfex. “Some of them will say, ‘well, this machine is now as good as new,’ and we tell them we need it better,” said Hebbeler. “Their response is, ‘well then tell us what to do,’ and when we show them they ask how we did it. The advanced training provided us with knowledge that is tech-level and, in some cases beyond, so we have data to backup our thinking.”

The data generated through ballbar analysis has even found its way to the company’s C-suite. “The executives at corporate now want to see a ballbar report every time a machine is qualified,” said Hebbeler. “This is filed with the machine documentation as part of our regular procedures between here and headquarters. Manufacturing keeps raising the bar and ballbar analysis helps us reach higher.”  Ross added, “The world revolves around numbers and ballbar analysis is our magnifying glass to help make good business decisions.”

As tool manufacturing standards and testing methods continue to improve, the welding industry now requires highly accurate and reliable inspection checks in every part of the process. This includes inspections for fixture frames and supporting tools such as check fixtures and molds.

Since implementing several measurement solutions from FARO, Chinese systems integrator MH Robot & Automation Co., Ltd. (MH Robot & Automation), has managed to enhance the precision and stability of its welding and assembly equipment systems, as well as improve the overall precision of its production line and conveyor systems.

More than a Decade of Trust: High Accuracy and Reliability of FaroArm

Renishaw, the global engineering technology company will once again be exhibiting at the Advanced Manufacturing show, which runs alongside Subcon and the Design and Innovation Show, from the 2nd to 4th June 2015 at the NEC, Birmingham, UK.

Renishaw will be exhibiting a broad range of its innovative metrology and additive manufacturing products including the Equator gauge, AM250 – the only UK manufactured metal based additive manufacturing machine, the PH20 5 axis touch-trigger system for CMMs, a range of machine tool probe systems including the SPRINT scanning probe, as well as variety of styli and fixturing options.

Visitors to Hall 4 stand A125 will be able to see Equator, Renishaw’s lightweight, fast and highly accurate versatile gauge that operators can use with ‘push-button’ simplicity. Equator’s innovative flexible gauging technology is based for the comparison of production parts to a reference master part. Users can greatly increase throughput and reduce scrap rates at a fraction of the cost of an equivalent custom gauging system. New for Advanced Manufacturing is INTUO software, which simplifies and automates the gauging of a wide variety of parts, removing dependence on the skill of manual gauge users.

Also exhibited will be Renishaw’s AM250 laser melting machine. This system utilises a pioneering process capable of producing complex fully dense metal components direct from 3D CAD using a high-powered ytterbium laser. Parts are built from a range of metal powders that are fully melted in a tightly controlled atmosphere in a layer thickness ranging from 20 -100 microns.

5 axis touch-trigger measurement will be demonstrated by Renishaw’s PH20 system for co-ordinate measuring machines (CMMs). PH20 increases touch-trigger CMM throughput by up to three times, using fast, infinite rotary positioning and unique “head touch” capability for high-speed point capture with minimal CMM movement.

Visitors interested in process control for machine tools will also be able to discuss Renishaw’s game-changing machine tool probe system, SPRINT. The system incorporates a new generation of on-machine scanning technology that will deliver a step-change in the benefits of process control, enabling fast and accurate form and profile data capture from both prismatic and complex 3D components.

Coordinate measuring machines gain surface inspection capability with new PROFILER R solution

Hexagon Metrology has announced the addition of a new sensor for its Leitz ultra-high accuracy coordinate measuring machines (CMMs). The PROFILER R miniature roughness sensor offers an alternative to manual roughness measurement devices, allowing quick and easy surface checks within a quality inspection program.

The PROFILER R miniature roughness sensor can be automatically swapped on to several Hexagon Metrology and Leitz range scanning sensors using a standard probe changer. Supporting all common roughness parameter measurements, it removes the operator variances that limit the reliability of manual measurements. An integrated pivoting rotary axis gives good part accessibility for simple programming, helping users to optimise alignment without the need to reclamp the workpiece. Setup and changeover times are also reduced, enabling greater efficiency in the quality assurance process.

“With increasingly demanding tolerance requirements across the industrial spectrum, the texture of the workpiece surface is more important than ever,” said Micha Neininger, Sensor Product Manager at Hexagon Metrology. “PROFILER R gives customers the option to make roughness measurements part of their regular inspection routines. Where previously this was a manual process which added the complication of reconciling reports, this new sensor enables surface measurements to be packaged with other quality data in the CMM software.”

Currently compatible with the Leitz PMM-C and Leitz Reference CMMs from Hexagon Metrology, the PROFILER R is available to order from 4 May 2015 through local Hexagon Metrology commercial operations and dealers.

Founded in 1991, FAW-Volkswagen Automotive Co., Ltd (FAW-VW) is a Chinese joint venture between FAW Group Corporation and the Volkswagen Group. The company is headquartered in Changchun, Jilin, and it has a registered capital of RMB 7.81billion (US$1.22 billion). As China’s first modern passenger sedan industrial base of considerable economic scale, FAW-VW produced more than one million vehicles in 2011 alone, with annual sales adding up to more than RMB 170 billion (US$ 26.9 billion).

FAW-VW’s sound foundations and strategies enabled the company to grow continuously. Its strong corporate culture and commitment to technological leadership are some of its key success factors. In addition, FAW-VW considers the pursuit of quality extremely important, as is evident in the safety and environmental-friendliness of FAW-VW sedans.

Maintenance of Assembly Line
Checking the Anchor Points on the Conveyor Trolley Over in its Chengdu plant, FAW-VW specializes in the production and assembly of the Jetta and Sagitar car models. A large component of the assembly line is the conveyor system on which all the vehicles are transported. Any failure in this system would effectively cripple all other departments within the facility. In order to ensure that each plant operates at its optimum, the company put in place a number of processes to minimize downtime on its shop floor.

Similar to a majority of automotive manufacturers, FAW-VW utilizes an overhead conveyor to move vehicles around the plant. The way that FAW-VW chose to avoid system failure was to specially dedicate space and staff to conduct regular maintenance on the shop floor. “It is our department’s responsibility to make sure that the all our equipment functions properly, so that production is carried out smoothly,” said Mr. Song Jiashan, Head of Assembly Shop Maintenance. “This includes making sure that different automation systems interface well with one another, enabling us to uphold our quality promise to customers.”

Mr. Song’s department plays a pivotal role in supporting plant operations. Regular inspection and alignment checks on the equipment are necessary to ensure optimal performance. Common areas of interest requiring inspection include anchor points on the cradle support structure, corresponding anchor points on the conveyor trolley, and relative distances between work piece and center axis. These measurements vary in nature, and range anywhere between 2 to 4m in length.

Traditionally, the technicians rely on hand tools such as tape measures, gauges, micrometers and spirit levels to get the job done. However, these traditional methods were not ideal in more ways than one. “To begin with, accuracy levels achieved are lower with hand tools,” shared Mr. Zhou Tingzhi, an engineer from the Assembly Shop Maintenance department. “At times, complex measurements would require several procedures, and these would accumulate large error margins. It would also take us a long time to perform the measurements and calculations manually.”

Enhancing Capabilities
FAW-VW’s measurement needs prompted the search for a better alternative to replace existing methods. In 2011, the company came into contact with FARO and found that the FaroArm® Platinum was a suitable solution for its metrology needs. The FaroArm is a portable coordinate measuring machine (CMM) that performs highly accurate measurements. Taking the form of an articulating arm, the device has multiple rotating axes, which allows maximum versatility. Data acquired by the device is then fed directly to a computer, where it can be further manipulated.

FAW-VW deploys a 12-ft FaroArm on the maintenance platform, located right next to the assembly line. Whenever a glitch occurs on the production line, the team would use the device to pinpoint the precise problem area before zooming into it. “On average, problems occur only three to five times a month,” stated Mr. Song. “While we don’t need it every day, its presence on the shop floor has made all the difference to our work, and the quality of our products.”

Since acquiring the portable CMM from FARO, FAW-VW’s inspection and alignment checks on its manufacturing systems have become much more precise and simple. This, in turn, has kept the plant operating at its best. The arm’s versatility and accuracy meant that the FAW-VW team could confidently rely on the device to meet its variety of measurement needs. Mr. Zhou revealed, “Now, equipment alignment and inspection of check fixtures can all be done with just one tool. With the FaroArm, we can now accomplish our measurement task which is having volumetric size of 4m and below, at an accuracy of up to 0.02mm. We have eliminated the possibility of human error, and greatly increased the precision levels by switching to FARO.”

Aside from precision levels, FARO also addressed FAW-VW’s concern for efficiency while performing measurements. Mr. Song stated, “Complex measurements that required several tools and procedures in the past can now be completed quickly and simply! Instead of having to make calculations manually, the software does that automatically and gives us the final figures. Being able to pre-program the measurements also saves us a lot of time.”