Qc20-w Sales Brochure

7/27/2019 Qc20-w Sales Brochure

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QC20-W ballbar system

The Renishaw QC20-W wireless ballbarfor machine tool performance diagnosis

Reduces down-time & costsReduces machine down-time, scrap andinspection costs

Helps ensure accurate parts,first time, from CNC machines

QA complianceShow compliance with both machineperformance and quality management standards

Predictive maintenanceAllows fact based predictive maintenance


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Production pressures!I you are involved in component machining youdont need telling that machining errors can resultin numerous quality problems and reworked orscrapped components.

The quality o every component produced ona CNC machine is highly dependent on themachines per ormance. Problems with a machineinevitably result in de ective parts. It may becosmetic, out o specifcation, or unft or purpose

but the inspection, investigation and rectifcationwill have an impact on your business:

Wasted time and reduced productivity

Higher piece part costs

Delayed deliveries

Dissatisfed customers

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All too requently, traditional quality andinspection procedures only identi y problems a tercomponents have been produced. Thats too late.

This is especially true i youre working on highcost, complex parts. In combination with theclose tolerances o the parts and high volumemachining there is little or no margin or errors.

Human error and tooling problems can besome o the many reasons or this, but machinepositioning per ormance can o ten be the major

actor.

Modern CNC machine tools have excellentspecifcations, but their per ormance (evenwhen new) can be compromised by inadequate

oundations, poor location and incorrectinstallation. Once in use, they are also subjectto wear and possible damage rom crashes ormisuse.

Thats why it is ESSENTIAL that your machines

per ormance is checked regularly and, justas importantly, checked before you startmanu acturing components.


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De ective machines = de ective partsA typical 3-axis machine tool is subject to21 degrees o reedom (deviations rom theideal including linear positioning, pitch, yaw,straightness, roll and squareness between axes).All o these can have a detrimental e ect on themachines overall positioning accuracy and theaccuracy o machined parts.

Furthermore, the potential or problems increasessignifcantly when you consider the additionaldynamic e ects as the machine moves andthe coordination needed to produce smooth,interpolated motion.

Degradation o machine positioning accuracyis not always apparent until a machine startsto produce reject parts. What is needed isa process to put you back in control o yourmachine tool so you can decide whether aproblem needs immediate attention or canbe tackled later, but in all cases, before youstart machining!

With so many actors involved, any solution has

to be simple to use, quick and deliver easilyunderstood results, with the minimum disruptionand cost to your business. Luckily there is asolution.

In theory i a CNC machines positioningper ormance was per ect then the circle tracedout by the machine would exactly match theprogrammed circular path.

3 axes o motion . . .

Per ect circles in X, Y and Z axis defne a per ect machine

. . . and multiple potential positioning errorson each axis (and between axes)

BacklashReversal spikesLateral play

Cyclic errorStraightnessScale error

Servo mismatch Squareness

In practice any o the errors mentioned abovewill cause the radius o the circle to deviate romthe programmed circle. I you could accuratelymeasure the actual circular path and compareit with the programmed path you would have ameasure o the machines per ormance.

This is the basis o the Renishaw QC20-W ballbar,the industry standard or quick machine toolper ormance diagnosis.

Potential errors on an axis

Potential errors between axes


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The Renishaw ballbar

Renishaws QC20-W ballbar o ers you the per ectsolution. Its the quickest, easiest and moste ective way to monitor machine tool condition.

The heart o the system is the ballbar itsel , avery high accuracy, telescoping linear sensor withprecision balls at each end. In use the balls arekinematically located between precision magneticcups, one attached to the machine table and theother to the machine spindle or spindle housing.

This arrangement enables the ballbar to measureminute variations in radius as the machine ollowsa programmed circular path (see main illustrationbelow).

The data collected is used to calculate overallmeasures o positioning accuracy (circularity,circular deviation) in accordance with internationalstandards such as ISO 230-4 and ASME B5.54,or Renishaws own analysis reports. Data isdisplayed graphically as well as in numeric ormatto aid and support diagnosis.

Supplied as a complete kit-in-a-case, the ballbarkit provides a power ul and portable solution

just add a PC and youre ready to start testing.

Renishaw ballbar testingTypically, a quick 10 minute test is all that isrequired.

Ballbar 20 so tware guides you through thecircular test described above, with clearin ormation and guidance throughout the simple

our step process

1. Set-up

Quick and easy, the QC20-W ballbar is

mounted between two repeatablemagnetic joints.

2. Capture

The machine per orms two consecutivecircular arcs (clockwise and counter-clockwise) in any one o the machines testplanes (XY, YZ, ZX) and very accuratelymeasures any variations in the test circleradius traced by the machine during the test.

3. Analyse

Renishaws Ballbar 20 so tware thenanalyses the measured data to give resultsin accordance with various internationalstandards (eg. ISO 230-4, ASME B5.54).

4. Diagnose

Renishaws own and uniquely comprehensive diagnostic report also gives you an overallassessment o machine per ormance(circularity) but in addition provides anautomatic diagnosis o up to 15 specifcmachine positioning errors. Each error isranked according to its signifcance to overallmachine per ormance alongside the errorvalue. Even non-experts can get expertresults.

It is such a power ul diagnosis that manyo the worlds leading machine tool buildersand manu acturing companies choose it astheir standard test report ormat.

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Fixing your machineThe Renishaw diagnosis report (a) not onlyranks individual machine errors but using the hotlinks to the system manual you can see typicalmachining aults (b) related to these, and evensome possible fxes.

Even with this diagnosis you can be aced withmany alternative strategies to get your machinewithin the required specifcation. Your choice will

depend on the machine confguration and whatresources you have available. However, usingan integrated simulator package you can use theresults fle to see what combination o error fxeswill produce what overall improvement in machineper ormance.

This allows you to make an in ormed decisionon the best course o action, whether that isin-house correction, contracted-in machinemaintenance, or even moving production to an

alternative machine.

Advanced diagnosisThe QC20-W and Ballbar 20 so tware allowsyou, or the frst time, to carry out testing in threeorthogonal planes with only a single set-up. Thisgives much quicker testing and allows or a truevolumetric analysis o your machine.

Checking trendsRegular, repeatable testing is the key toe ectively tracking changes in machine error

sources over time. Ballbar 20 uses customerdefned test templates to ensure repeatabletesting. A comprehensive machine history

unction (c) then gives you a quick and simpleway to examine the data. You can see i problemsare developing and so schedule preventativemaintenance (PM) i necessary in a targeted andtimely way. Fixing problems be ore they becomecritical minimises downtime and maintenancecosts.

As simple as A-B-C

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(a)

(b)

(c)


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Whatever your jobThe ability to quickly veri y machine per ormanceis o beneft across nearly all job unctions.

Production Understand your machines true capabilities,

choosing the right machine or each job. Achieve manu acturing tolerances, reducing

or avoiding scrap, rework and time-consuming set up and inspection processes.

Maintenance Identi y problems quickly; no need to strip

down machines just to see i something iswrong.

Evaluate repair strategies and their resultsbe ore you start.

Implement predictive maintenanceprograms by regularly tracking a machinesper ormance.

Minimise specialist call outs and check thatcontractors have fxed the problem be orethey leave.

Purchasing Evaluate new machines prior to purchase.

Evaluate a ter installation, be ore fnal sign-o .

Field service All the benefts as or Maintenance plus .. Reduced warranty costs due to improved

diagnosis. Increased service team productivity due

to reduced time on site (due to quickerdiagnosis).

Increased customer satis action, test reportsprovide tangible proo o service.

Quality Comply with standards or quality

management (eg ISO 9000). Equipment calibrations traceable to national

standards.

Ensure equipment meets recognisedstandards be ore shipment (machine toolOEMs).

Management/Sales and Marketing Reduce component costs, increase capacity

and demonstrate your confdence andcapability to your customers.

Whatever the type o company you work or

End user

Machine OEM

Distributor

Service and maintenance contractor

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The Renishaw QC20-W ballbar helps you do your job better and saves you money


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The system comes in a sel contained kit including almosteverything you need to begin ballbar testing. Just add adesktop, laptop or even a netbook PC. Every kit includes aGetting started with QC20-W ballbar DVD which introducesthe system, takes you step-by-step through the equipment,set-up, installation and use o the system, and shows you howto carry out a test and review the results.

Accessories are available to extend capability to many lathesand two-axis machines (e.g. vertical turning lathes). As with

any Renishaw product you have the support o our salesengineers, optional training courses and the back up o aworld class service network.

Implementing Renishaw ballbar

Why walk away rom success?The Renishaw ballbar is unique, simple to useand delivers real benefts or your business.I you own CNC machine tools you need theassurance o running regular ballbar checks.And now, with QC20-W, theres even morereasons to try one yoursel .Why walk away. ?

QC20-W ballbar kit with ballbar calibrator

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Proven in useThe Renishaw telescoping ballbar has been inuse or over 20 years and is the most widelyaccepted tool or machine tool per ormancemeasurement. With thousands o ballbarsin use worldwide, companies o all sizes andtypes have ound them to be a cost-e ectivesolution to improving their business. Whetherits a one man service operator or the largest omachine tool OEMs, the result is the same.

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Mori Seiki uses Renishaw ballbar to givehighest standard o customer service

Mori Seiki Group is acknowledged asone o the worlds leading designersand manu acturers o high specifcationmachine tools,having delivered morethan 185,000 units worldwide since its

oundation in 1948.MoriSeiki recognises, however, that simply o eringmachine tools does not provide customers with the

ullsupport or their production activities that theyare looking or. In order to provide support serviceto the same high level, MoriSeiki has established aworldwide support system with over 400 dedicatedemployeeslocated around the globe.

With an established reputation or o ering thehighest possible levelo service Mori Seikihas 2parts &service centres in Japan, another 5 locatedin Europe and USA, and 3 in Asia.These provide

ullsupport to the 44 technicalcentres in Japan

and a urther 57 around the world, where highlytrained service sta are on callto ensure immediatecustomer response.

For itslatest business strategycalled Global One , to improve the service levelto customerseven urther, MoriSeikiis putting added emphasison ensuring and maintaining greater machineaccuracy. A vitalelement in achieving this goaliswidespread use o the RenishawQC10 ballbar.

The QC10 ballbar is an internationally recognisedsystem or diagnosing the positioning per ormanceo machine tools.Be ore MoriSeikistarted usingthe QC10 ballbar, machine per ormance wasverifed bymeasuring a test component machinedbyeach machine. This was a valid test but onethat required considerable time and experienceto interpret the results (mis-diagnoses were notuncommon).

The QC10 ballbar is nowthe chosen tool or useboth at the MoriSeiki actoryand by service andtechnicalcentres around the world. It is a highlyportable system, simple to use and with a quicktest providing very power ulin ormation about themachines per ormance.

QC10 ballbar test on NMVvertical turning centre

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Title

Dave Wigmore,a ormer time-servedengineer at Mazak,runs a CNCmaintenance service company andconsiders a ballbar critical to operations.When Renishaw introduced the QC20-Wtelescoping ballbar system he wasdetermined to be the frst UK user.

Dave Wigmore set up his maintenance company,Wigmore CNC, in 1992 so he knows CNCmachines inside out. For years he used theRenishawQC10 ballbar to per orm tests o machineper ormance but there has always been somethingthat he knewcould be improved the wire. NowI dont have to worry about someone catchingthe wire and knocking the ballbar o during a testor working out howthe wire willwind around. Iam much more willing to do a quick test on anymachine which I can do with no extra preparation;that smallelement o hassle has been taken awayand the set-up is much aster.

Mr Wigmore, who did indeed receive the frstQC20-Wballbar to be supplied in the UK, continues,I pushed Renishawto supply me with a QC20-Wballbar as soon as I heard they were intendingto launch a wireless version o the QC10 ballbarusing Bluetooth wireless technology. Having useda QC10 ballbar system daily or years, I know ithas separated me rom other CNCmaintenancecompanies. It is an independent traceablemeasure o the servicing I have done, critical in theaerospace industry, where I do most o my business.

I willalways per orm three ballbar tests to establishthe per ormance o the machine in the X, Yand Zaxes, testing 2 planes with each check. That givesme a ull analysis o up to 23 di erent machineerrors. This is what I have always done with QC10ballbar and I can do exactly the same with thenewQC20-Wballbar. I then always put the testresults on the machine, using the stickers Renishawprovide.Its a simple visualdisplay but it isundeniable proo the machine has been tested andiscapable o producing the parts. I put the machineinto a state where the customer only has to worryabout the tooling, fxturing and programming.

I you are serious about CNC machinetool maintenance then using QC20-Wballbar is the only option

Dave Wigmore receiving hisnew QC20-W telescoping ballbar system

QC20-Wtelescoping ballbar performing test on CNClathe


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*H-8014-158

Renishaw plc

New Mills, Wotton-under-Edge,Gloucestershire GL12 8JRUnited Kingdom

T +44 (0) 1453 524524F +44 (0) 1453 524901E [email protected]

www.renishaw.com

Issued: 0413 Part no. H-8014-1589-04 A

2009-2013 Renishaw plc. All rights reserved.Renishaw reserves the right to change speci ications without noticeRENISHAW and the probe symbol used in the RENISHAW logo are registered trade marks o Renishaw plc in the United Kingdom and other countries.apply innovation and names and designations o o ther Renishaw products and technologies are trade marks o Renishaw plc or its subsidiaries.All other brand names and product names used in this document are trade names, trade marks or registered trade marks o their respective owners.

RENISHAW HAS MADE CONSIDERABLE EFFORTS TO ENSURE THE CONTENT OF THIS DOCUMENT IS CORRECT AT THE DATE OFPUBLICATION BUT MAKES NO WARRANTIES OR REPRESENTATIONS REGARDING THE CONTENT. RENISHAW EXCLUDES LIABILITY,HOWSOEVER ARISING, FOR ANY INACCURACIES IN THIS DOCUMENT.

For worldwide contact details, please visit our main website at www.renishaw.com/contact

About Renishaw

Renishaw is an established world leader in engineering technologies, with a strong history o innovation in product developmentand manu acturing. Since its ormation in 1973, the company has supplied leading-edge products that increase processproductivity, improve product quality and deliver cost-e ective automation solutions.

A worldwide network o subsidiary companies and distributors provides exceptional service and support or its customers.

Products include: Additive manu acturing, vacuum casting, and injection moulding technologies or design, prototyping, and production applications

Advanced material technologies with a variety o applications in multiple ields

Dental CAD/CAM scanning and milling systems and supply o dental structures

Encoder systems or high accuracy linear, angle and rotary position eedback

Fixturing or CMMs (co-ordinate measuring machines) and gauging systems

Gauging systems or comparative measurement o machined parts

High speed laser measurement and surveying systems or use in extreme environments

Laser and ballbar systems or per ormance measurement and calibration o machines

Medical devices or neurosurgical applications

Probe systems and so tware or job set-up, tool setting and inspection on CNC machine tools

Raman spectroscopy systems or non-destruct ive material analysis

Sensor systems and so tware or measurement on CMMs Styli or CMM and machine tool probe applications

Qc20-w Sales Brochure

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