REACHING THE PEAK OF VIDEO MEASUREMENT · nikon metrology i vision beyond precision reaching the...

NIKON METROLOGY I VISION BEYOND PRECISION

REACHING THE PEAK OF VIDEO MEASUREMENT

QUALITY MANUFACTURING TODAY

www.qmtmag.comMarch/April 2015

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March/April 2015

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CONTENTS

QMT March/April 2015 www.qmtmag.com 3

QMT App: download Quality Manufactory Today app for iPad and Android tablets

EditorAndy SandfordEmail: [email protected]

Director/PublisherDawn WisbeyEmail: [email protected]: +44 (0)20 8289 7011Mob: +44 (0)7974 640371

Design and Production ManagerRob TremainEmail: [email protected]

IT DirectorPat CoyneEmail: [email protected]

Website: www.qmtmag.com

Media [email protected] Magazine is a multi-media business magazine for the quality, measurement, inspection and test industries, supported with a fully searchable interactive website www.qmtmag.com.QMT Mobile: website is available in mobile-optimised form. Log on with your phone and you will be directed automatically to the mobile pages.

Front cover:Nikon Metrology

Website: www.nikonmetrology.com

Email: [email protected]

News and comment 4

Events 5

Cover story: Measuring 60 times faster 6Microtec EDM speeds up inspection processes by a factor of 60 by

using an iNEXIV video measuring system.

Quality know-how on show 12We look at what’s new at Control 2015

Experience another dimension 18QMT and Olympus have teamed up to offer readers the chance to

use state-of-the-art opto-digital technology

A race against time 20CMMs and cut measuring time by up to 80% at Pankl Racing Systems

Height gauges keep Xtrac on-track 24Transmission specialist uses shop-fl oor digital technology

How to meet your measurement needs 26First in a series of practical guides from NPL

Firing on all cylinders 28Measuring Audi’s advanced Valvelift System

Cast iron certainty 32Reverse engineering complex castings

NDT landscape unfolds 34The BINDT looks to encourage the better use of NDT

A clear difference 36A scientifi c instrument maker sees the benefi ts of high-end metrology

Spirax Sarco steams ahead on calibration 38Keeping on top of calibration management

Products 40



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4 www.qmtmag.com QMT March/April 2015

NEWS

Ready for ControlWelcome to our bumper Control 2015 issue of QMT. In this issue, as well as look-ing at some of the cutting edge new products you can see in Stuttgart we have some great case studies and feature arti-cles for you.

Our cover story takes a look at how a UK sub-contractor has speeded inspection times by up to 60 times on components for space missions, a hy-personic plane and a new UK-built wristwatch.

We also have the fi rst in a series of articles from NPL that aim to help readers fi ne tune their day-to-day metrology practices.

No issue would be com-plete without a couple of cutting edge automo-tive stories, and we have a couple of crackers this time.

First of all we take a look at challenging metrology requirements in the manu-facture of advanced Audi engines, and then we home in on a leading Aus-trian make of engines for Formula One.

We also launch our 2015 Technology Grant com-petition, organised in con-junction with Olympus.

So I hope you enjoy the issue and come and see us at Control on Stand 7000.

Andy SandfordEditor QMT

UK compliance openingQualtrax Inc, which supplies compliance management software, has opened its Eu-ropean Offi ce, Qualtrax Eu-rope Ltd, in Milton Keynes, United Kingdom.

Qualtrax Europe will pro-vide European sales, con-sultancy and support ser-vices for the management of documents, business processes and training for existing and new customers who need to comply with legislative, industry, trading partner & internal compli-ance standards such as those in the forensics, life sciences, manufacturing and food safety sectors.

Jake Bishop, Managing Director of Qualtrax Eu-rope MD, said: “By the use of cost-effective Qualtrax products, meeting industry and customer requirements has never been so simple. Our easy-to-use software package offers electronic document control and pro-cess management that de-livers impressive error reduc-tions and much increased effi ciencies. Gap analysis and reporting tools allow customers to focus fewer resources on preparing for audits and to concentra-tion more on quality initia-tives in the workplace.”

www.qualtrax.co.uk

Aberlink appoints Mantech GeometricsAberlink Innovative Metrol-ogy has appointed Man-tech Geometrics Ltd as the company’s UK representa-tive for the Midlands and Eastern Counties.

Mantech currently sup-plies a wide range of meas-uring solutions, including multi-sensor measuring ma-chines and X-Ray tomog-raphy systems. Both parties see that that the Aberlink range will represent a per-

fect fi t with these existing products.

Mantech Geometrics Di-rector, Ian Vaughan said: “We are delighted to have been appointed as a repre-sentative for Aberlink. Aber-link products are famous for their accuracy, ease of use, value for money and low cost of ownership. We look forward to supplying the company’s high quality sys-tems to our customers and to continuing to provide the exceptional levels of ser-vice Aberlink is renowned for.”

www.aberlink.co.ukwww.mantechgeometrics.

co.uk

Materials Testing 2015Materials Testing 2015, the leading exhibition for the NDT, condition monitoring and diagnostic engineering industries will take place at Telford International Centre from 8-10 September 2015.

Quality Manufacturing Today is proud to be a me-dia partner of the event, which is organised by the British Institute of Non-De-structive Testing (NDT). NDT is a key area for QMT and

this will be refl ected in edi-torial coverage throughout the year.

Non-destructive testing plays a critical role in en-suring quality and safety in many manufacturing indus-tries and techniques are im-proving all the time. Materi-als Testing 2015 gives visitors from the UK and Europe the opportunity to see the lat-est developments free of charge.

Materials Testing 2015 will feature around 60 exhibi-tors – many of whom will be demonstrating products and equipment for the fi rst time – along with a pro-gramme of seminars includ-ing talks ranging from NDT for 3D printing and using phased array ultrasound, to corrosion analysis in pipe-lines. There will also be a demonstration area, where

manufacturers can bring along samples for testing and discuss their particular inspection problems.

www.bindt.org

Calibration expansion UKAS accredited calibra-tion service for electrical and electronic test and measurement equipment, Calibrationhouse has ex-panded its operations to meet growing demand.

The investment has ena-bled the company to ex-pand its activities into new electronic instrumentation sectors by broadening its calibration service capa-bility to include infra-red thermometry and thermal imaging cameras, as well as luminance (lux) meters and specialist audiology and other types of medical electronic equipment.

These complement the range of multimeters, 17th edition test equipment, PAT testers, high voltage test equipment, production line testers, oscilloscopes and high spec electronic instru-mentation already includ-ed in the company’s cali-bration and repair service.www.calibrationhouse.com

CMSC open for registration The 2015 Coordinate Me-trology Systems Confer-ence will be held from 20

to 24 July in Hollywood, Florida.

Organised by the Coor-dinate Metrology Society (CMS), the eminent mem-bership association for measurement professionals, the 31st annual CMSC will be held from July 20 – 24 at the Diplomat Resort and Spa in Hollywood, Florida.

The CMSC is a week-long technology conference for



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users of portable 3D meas-urement solutions applied by manufacturers and sci-ence laboratories. This inter-nationally respected gath-ering attracts leading OEMs and service providers, as well as expert speakers de-livering fresh perspectives on trends, best practices, R&D, successful applica-tions and innovations in the fi eld of metrology.

Fulfi lling its educational mandate, the CMSC will host a Measurement Zone with an eLearning centre, metrology challenges, edu-cational workshops, indus-try updates, and network-ing events, in addition to technical paper sessions.

The CMSC Exhibition Hall will feature the latest in me-trology products and servic-es including industrial pho-togrammetry, laser trackers, laser radars, articulating arms, laser scanners, laser projection systems, indoor GPS, theodolites, inspection software, and accessories.

During the conference, the Coordinate Metrol-ogy Society will also offer the CMS Level-One and Level-Two Certifi cation ex-aminations. The Level-One Certifi cation examination is a proctored, online as-sessment covering founda-tional theory and practice common to most portable 3D Metrology devices.

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New UKIVA chairIan Alderton from Alrad Im-aging is the new chairman of UKIVA (The UK Industrial Vision Association) with Paul Wilson from Scorpion Vision becoming Vice Chairman. This new structure establish-es a succession plan for the committee, as the Chair and Vice-Chair are now both elected for a two-year tenure, with a view to the Vice-Chair succeeding the Chair, leading to a 4-year cycle.

www.ukiva.org

Engine partnershipZEISS has expanded its agreement with NASCAR engine company ECR En-

gines. It will provide ana-lytical microscopes for con-ducting analyses of various engine components.

ECR is using the latest ZEISS EVO MA25 scanning elec-tron microscope (SEM) for material analysis studies, the ZEISS SteREO Discovery.V20 stereo microscope and the ZEISS Smartzoom 5 digi-tal microscope for imaging larger parts, and a confo-cal light microscope for measuring surface rough-ness and 3D-topographical characterization.

www.zeiss.com

QMT March/April 2015

5 – 8 MayControl • Landesmesse Stuttgart, Germany

www.control-messe.de1 – 4 JuneHxGN Live 2015 •MGM Grand, Las Vegas, NV

www.hxgnlive.com2 – 4 JuneSubcon •NEC, Birmingham

www.subconshow.co.uk20 – 24 JulyCMSC •Hollywood, Florida, USA

www.cmsc.org26 – 28 AugustControl China •Shanghai, China

www.control-china.cn18 – 20 NovemberHxGN Live 2015 •Hong Kong

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EVENTS

• QMT is a media partner• QMT is a media sponsor• QMT is a headline media partner

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COVER STORY

Measuring 60times faster

Nikon Metrology CNC video measuring system helps a subcontractor to speedy AS9100 accreditation

What does an orbiting telescope currently mapping the Milky Way have in common with the fi rst all-English wristwatch to

be produced in half a century? UK subcontractor Microtec EDM, Basildon, supplied prototypes and components for both ventures, as well as for a host of other innovative and high profi le projects. The company recently raised the capability of its metrology department signifi cantly by purchasing a powerful CNC video measuring system, an iNEXIV VMA-4540 from Nikon Metrology.

Until the machine was installed at the end of 2014, Microtec relied on manual video measuring using another make of instrument. Owner and managing director, Graham Cranfi eld said: “We are currently seven years into an 18-year contract involving electro discharge machining (EDM) and centreless grinding of nickel-copper alloy tube to produce a decoy missile component.

“A complete inspection of the part using our manual video measuring system used to take 20 minutes. Now that the job has been programmed on our new Nikon machine, the same inspection cycle is completed automatically in just 20 seconds. We fi nd that time savings of this magnitude are typical and have revolutionised the productivity of our metrology department.”

He explained that it took them only a few hours to create the inspection cycle for this fairly complex job, based on a CAD model of the part. The process will become even shorter as company employees become more familiar with programming. For contracts that frequently repeat, the automated measuring approach saves a lot of time in the long term. Even after measuring a dozen of the missile tubes, the programming time had been justifi ed. The component is actually required in quantities of a few thousand every year and even though only one in 12 needs to be inspected, the saving in measuring

time during 2015 alone will be more than double the programming time.

By the same reasoning, prototypes and components needed in small batches are more productively inspected manually on the pre-existing video measuring machine, or indeed on the iNEXIV VMA-4540 operated in manual mode.

Wide range of component sizesWork carried out by Microtec for space missions

includes making parts for the joint ESA / JAXA (Japan Aerospace Exploration Agency) BepiColombo mission to Mercury, which will set off in July 2016 on a seven and a half year journey to the smallest terrestrial planet in our solar system. Another project involves the manufacture of prototypes and components for an orbiting telescope.

In both cases, the telescope parts are relatively large. Many other components that the Basildon subcontractor produces go down to 20 microns in size, however, placing the fi rm in very select group of such specialist providers of wire-cut EDM and spark-erosion services in the UK.

A current project in the micro area entails sparking 30-micron wide slots 3 mm deep into

Dawn Carter inspecting a

spark eroded nickel-copper

alloy component for a decoy

missile on the Nikon iNEXIV

VMA-4540 CNC video meas-

uring system at Microtec

Close-up of the wire-eroded,

molybdenum grid for an elec-

tron beam gun on the table of

the iNEXIV.



• Direct hardware and software support from Renishaw

• Unparalleled choice of 3 and 5-axis sensor systems

• Rapid exchange service on all system elements

• UKAS accredited calibration

• Renishaw scales, readers, thermal compensation & reference sphere

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A new




COVER STORY

copper for Reaction Engines, Oxford, which is designing a multi-use, Mach 5 engine for launching satellites. A further project is the wire-erosion of 70-micron wide vanes in copper and molybdenum grids, required in quantities of 50 per year for an electron beam gun.

Somewhere between these extremes in size lie the components Microtec machines for Charles Frodsham & Co, clockmaker to the British Royal family. In 2015, managing director Philip Whyte plans to launch the fi rst all-English-made wristwatch to be produced on a production basis in half a century. It will be manufactured from start to fi nish under one roof at the company’s workshop near Heathfi eld, East Sussex.

Close associationCharles Frodsham has a longstanding business

relationship with Microtec. The subcontractor regularly wire-erodes gold watch cases and produces springs for the clockmaker, which in turn carries out micro-scale turning, milling and drilling that is beyond the capabilities of Microtec’s production equipment.

A smaller Nikon Metrology CNC video measuring machine has been in use at Charles Frodsham’s Hastings workshop for about fi ve years. Mr Whyte recommended this make of instrument to Microtec due to its reliability and precision, as well as the strength of after-sales support.

Mr Cranfi eld benchmarked other potential suppliers’ equipment but could not see a better option. In the process, he discovered that some other makes of machine on the market for video metrology actually incorporate Nikon’s

apochromatic lens, which has better correction of chromatic and spherical aberration than conventional achromatic lenses. It helped him to come to the conclusion that the Nikon Metrology offering was optimal.

Multiple target markets led by aerospaceAerospace and defence contracts are the mainstay

of Microtec’s business, Rolls-Royce, BAE Systems, Selex Galileo and Astrium being regular clients. It is the principal reason for Microtec seeking AS9100 accreditation, a process that will be assisted by the purchase of the Nikon Metrology iNEXIV machine. It will be especially important for speeding production of fi rst article inspection reports. The Nikon Metrology VMA AutoMeasure software automatically compares measured results against CAD models and allows such reports to be produced quickly and in standardised format.

Motorsport, closely related technologically with aerospace,

is becoming an increasingly important

Microtec’s managing director,

Graham Cranfi eld inspecting a

steel mould cavity ring.



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COVER STORY

target market for the subcontractor. Medical and dental industry work, which is often defi ned by complex machining in diffi cult materials, is another specialism. A current contract involves producing very small tweezers with serrations that are eroded with 20 μm wire, fi ve times thinner than an average human hair.

Another medical job requires a plastic fi lter mould to be produced with 0.25 mm ribs. Mould and tool manufacture in the 1990s accounted for 80 per cent of Microtec’s turnover, dropping to 20 per cent in subsequent years as China absorbed much of the business. Recently, however, the percentage is increasing as mouldmaking is reshored due to an increase in the cost of production overseas as well as problems with quality and logistics.

Non-contact 2D and 3D measuringMost wire-cut EDM work requires 2D inspection,

for which video measuring is ideal. However, some spark eroded components need to be measured in 3D and one of the advantages of iNEXIV video inspection is the ability to measure heights using the instrument’s generous 73.5 mm working distance.

Inspection in 3D extends to mouldmaking. Early in January 2015, Microtec was tasked with refurbishing a plastic injection mould for producing electrical plug sockets for the British manufacturer, MK. No drawings or CAD model were available, so the mould’s broken upstands were remanufactured in tool steel by measuring the height and width of the relevant sections on the iNEXIV.

A similar procedure allows reverse engineering of legacy components for which no data exists, such as parts for classic cars. In this case, after the data has been collected, a DXF fi le is output that can be used directly in a machine tool’s CNC or in a CAD/CAM system to generate the cutter paths. Nikon Metrology’s part-to-CAD software provides the capability to compare the machined component with the DXF fi le to ensure that it is within tolerance.

Touch probing capabilitySome features on components, such as sloping

faces and undercuts, do not lend themselves to optical measurement. In such cases, the iNEXIV VMA-4540 has the facility to accept a Renishaw TP20 or TP200 touch probe to capture the point data. The probe is offset from the optical axis but works in the same 450 x 400 x 200 mm coordinate space, with only slightly reduced operating range. A stylus changer is provided.

Mr Cranfi eld continued: “We always use vision if we can, as in general it is quicker and more accurate. However, if parts are not the right shape or not scrupulously clean, touch probing is the better option.

“On the other hand, some features would be diffi cult to inspect with a touch probe, such as the curved surface of a dome, as calculations to compensate for the stylus tip diameter at each measurement point across the surface would be impractical.

“Using the auto focus (AF) feature of the iNEXIV, we can accurately capture heights very quickly. There is also a laser AF option that we are thinking of retrofi tting that is very good at highly repeatable Z-axis measurements on fl at surfaces.”

It is even possible to mix optical and tactile measurements in the same cycle, which is another option that Microtec will be using. For example, the BepiColombo telescope parts require mainly 2D optical inspection of apertures, but there are arrays of 2 mm diameter tapped holes whose positions will need to be probed during the same program.

This job will benefi t from image stitching within the Nikon Metrology software, as the aluminium components are 550 mm in diameter and will need to be scanned in four quadrants under the 450 x 400 mm X / Y travels of the iNEXIV’s moving column. Additionally, stitching of multiple images at different Z-axis heights allows deep components to be rendered all-in-focus.

The instrument’s versatility is further enhanced by a variety of illumination options. It has episcopic, diascopic and eight-segment ring LEDs. Combining these enables accurate detection of low-contrast edges.

Even when a workpiece is misaligned, an intelligent search feature automatically locks on to it based on a target image recorded in a teaching fi le. Detection is assisted by the wide fi eld of view, measuring 13.3 x 10 mm at 0.35x magnifi cation, while zooming in to 3.5x in fi ve steps delivers accurate measurements as well as high resolution images.

www.nikonmetrology.com

The iNEXIV VMA-4540’s PC

screen shows an image of the

area of the component under

inspection, current point co-

ordinates, a list of the features

inspected, any that are out of

tolerance, and more.

Close-up of a mould cavity

ring. Inspection is possible by

video measurement or tactile

probe.



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Control 2015, the leading international showcase for measurement and quality assurance takes place in Stuttgart from 5 to 8 May.

The show brings together users from all over the world with the international market leaders and innovative suppliers of all QA related technologies, products, subsystems and complete solutions in hard and software.

Specifi c segments covered by the event include measurement technology, materials testing, analytical equipment, opto-electronics and Quality Assurance systems.

Overall more than 900 exhibitors from 32 countries will be exhibiting at Control 2015, including QMT, which is proud to be a media partner of this world-leading event. Pick up your copy of the latest issue at the entrance to the show and come and see us in hall 7 on stand 7000.

www.control-messe.de/en

Shop fl oor vision measurementAberlink Innovative Metrology will be

launching an advanced new shop-fl oor vision measuring system at Control 2015 (Hall 7, stand 7207). Featuring Aberlink’s

powerful vision software and easy-to-use inspection tools,

the new machine is designed to deliver high levels of accuracy, faster component throughput and enhanced

ease of use.Also making a Control debut will be the

latest iteration of Aberlink’s inspection software. In addition to discrete point touch-probe and vision measurement Aberlink 3D Mk IV enables extremely accurate, rapid scanning of features and profi les. It has an improved CAD Comparison software module and an easy-to-use ‘Off-line Programming from CAD’ software module.

The scanning capabilities enabled by the new software will be demonstrated on an Aberlink Zenith Too CMM, fi tted with a PH10M motorised indexing head and SP25M scanning probe.

Aberlink will also demonstrate the extent of its CMM range by showing its largest ever machine. With a 1200mm X-axis, 1000-3000mm

CONTROL 2015

Quality know-how on show

Over 900 exhibitors will be showcasing the latest hardware and software at Control 2015



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Y-axis and 1000mm Z-axis, Aberlink claims that the innovative Azimuth will deliver extended measuring capacity, high accuracy, excellent ease-of-use and exceptional speed, at a very cost effective price.

Variants of Aberlink’s Axiom Too CMMs will be fi tted with PH20 head touch probing systems, PH6M-SP25M scanning probe systems, in addition to advanced interchangeable cameras and collimated light systems. Designed to makes inspection bottlenecks a thing of the past, the recently launched high-specifi cation variant of the Axiom Too, the Axiom Too HS, will demonstrate its greater accuracy, higher acceleration and faster travel.

www.aberlink.co.uk

Wireless gap measurementNextSense will be showing the latest

version of its CALIPRI gap measurement device on stand 5442. The device, which is used worldwide to test gaps and hem edges without the need for mathematical approximations, has now been upgraded to use Wi-Fi instead of cables and has a new ergonomic redesign to allow it to fi t more securely and comfortably into the hand.

Functionality has also been increased by a software update. Derivatives of a car line can now be displayed clearly in one measurement plan, and centrally created plans can be easily distributed between sites and production steps.

Clemens Gasser, Managing Director of NextSense, explains: “CALIPRI is used by premium automotive manufacturers all over the world on a daily basis to assess gaps and evaluate hem edges. Quality engineers often have to test all the different bodies for hours on end. Our innovation of being able to move the sensor head independently from the output unit, i.e. a desktop PC or tablet, will make a huge difference in terms of increasing mobility and therefore also achieve even greater acceptance.”

The key to this new design is the way that data is pre-processed in the sensor head, thus reducing the volume of data that needs to be transmitted so that it can be done via a wireless network.

www.nextsense.at

Explore the product rangeOn its largest ever stand at

Control (Stand 7105), the Bowers Group will feature products from Bowers, Baty, Moore & Wright and CV Instruments.

Bowers Group will be launching the all-new XT3 bore gauging range, including the ‘pistol grip’

Holematic model and digital versions of the XT3-BT

bore gauge. Designed to help operators improve inspection effi ciency,

Bowers’ XT3 range of three-point electronic bore micrometers offers a new ergonomic design – including a larger and clearer LCD display – and bi-directional communication giving greater fl exibility for data acquisition and storage.

Control 2015 will also feature the launch of Bowers’ new XTA Micro to cover the measuring range from 2 to 20mm. The precision engineered XTA Micro incorporates a more compact mechanical controller and Vernier scale for improved resolution.

The redesigned, pocket-sized MicroGauge 2-point bore gauging system will also be on display – featuring interchangeable heads for a variety of applications and has been designed specifi cally for the measurement of small bores between 1.0-10.0mm. It features a completely new digital readout and extremely compact overall dimensions.

Products on display from Baty the VuMaster CNC, which has an innovative absolute 2D scale system; the Venture Touch, an advanced Vision system which combines a manually operated X-Y measuring stage with a motorised Z axis; and the R400 FT2-E, a horizontal projector with Fusion 2D Touchscreen DRO and built-in optical edge detection.

Also on show will be the Venture Plus 6460 – a top end system in which measurements from data points taken using the touch probe can be combined with those taken using Video Edge Detection for optimum speed and reduced inspection times.

Moore & Wright will also be exhibiting a wide range of classic products including both dial and digital callipers, protractors, indicators and micrometers.

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Inspection softwareDelcam will demonstrate the 2015 version

of its PowerINSPECT hardware-independent metrology software on Stand 3108. This latest release includes automatic collision avoidance, faster import of large CAD fi les, quicker preparation of longer inspection reports, and improved display of results from point-cloud data, plus many other customer-requested enhancements.

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CONTROL 2015

when there was a possibility of any collision between the probe and the item being inspected. Until now, the user then had to make the required changes to the probe path to avoid the collision.

With PowerINSPECT 2015, the software adjusts the probe path automatically if a direct move between inspection features could produce a collision. The software will calculate a new motion path that avoids the obstacle, typically by moving up and over the obstruction or around it. As well as preventing collisions, automatic collision checking will save signifi cant programming time, especially when inspecting more complex items.

A number of improvements to PowerINSPECT 2015 have made both data import and report generation much faster. The differences will be particularly apparent when reading large CAD models, such as a complete car body, and when producing longer reports with more graphical images.

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Contact and non-contact systemFARO will be presenting its FARO Edge

ScanArm HD. The Edge ScanArm combines the fl exibility and the functionalities of a

FARO Edge measuring arm with the high-defi nition Laser Line Probe HD,

creating a powerful contact/non-contact portable measurement system for challenging application requirements. The FARO Gage with the barcode scanner and the most accurate FARO Laser Tracker Vantage for large volume measurements will also be demonstrated.

Also on show will be the high speed FARO Focus3D Laser Scanner3D scanner for 3D measurement

and 3D image documentation and the new FARO Freestyle3D. This handheld Laser Scanner is said to be the only industrial-

grade handheld device that allows users to scan almost any kind of surface in almost any kind of environment.

www.faro.com

Microhardness systemAt Control 2014 Buehler showed the fi rst

prototypes of its Wilson VH3300 microhardness test system. This system has now been perfected and is ready to be launched and will be showcased on Stand 5135.

Complementing the Wilson VH3100 system,

the Wilson VH3300 expands the range of automatic Vickers/Knoop hardness testers from Buehler with a solution tailored to measurements with very high and/or very low test loads.

Both systems come equipped with patent-pending collision protection technology, a high-speed sample stage and the DiaMet™ universal testing software. Differences exist with regard to the load range and number of indenters and objectives. Whilst the Wilson VH3100 is optimized for effi cient measurement in the production line, the new VH3300 model with its extensive variety of scales and magnifi cations offers maximum fl exibility for automated hardness testing to ASTM and ISO in the test laboratory, in materials and product development, in clean production environments and in routine quality control.

The Wilson VH3300 microhardness test system features a 6-position test head with up to three indenters and three zoom objectives, an automated X/Y sample stage available in two sizes (180 mm x 180 mm as standard) and a powerful image analysis system.

Depending on the option chosen, the maximum sample height is 105 mm or 150 mm, which combined with test loads from 5 g to 60 kg opens up a wide range of applications.

www.buehler.com

Hardness testing specialistZwick Roell Indentec is the hardness testing

specialist of the Zwick Roell Group. From its Innovations Centre in the West Midlands of



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the UL it develops and manufactures a range of hardness testing machines and hardness reference materials.

On Stand 1307, Zwick Roell Indentec will be exhibiting its new ranges of testing machines including re-designed Rockwell, Micro Vickers and Micro and Macro Vickers testers and a new Closed Loop Universal Hardness Tester.

It is also launching a hardness app which can be downloaded free from i-tunes which offers help with the specifi cation of hardness testers and other helpful tools. Visitors are welcome to bring their hardness testing specimens to the stand.

www.zwick.de

Coating inspection and testElcometer, which offers designs and

manufactures equipment for coatings inspection and testing and for ultrasonic NDT, will show new products for the inspection of industrial coatings and the measurement of material thickness.

The Elcometer 480 Triple Angle Glossmeter aims to offer ease of use with a menu-driven colour display, robust and ergonomic operation, statistics and graphing, as well as USB and Bluetooth data transfer to Android and Apple mobile devices.

The Elcometer 508 Push-Off Hydraulic Adhesion Tester is a versatile adhesion measurement system which can be used to accurately measure the strength of the bond between the coating and the substrate for many adhesion testing requirements. Tests can be made on fl at or curved (concave and convex) surfaces.

Finally, the Elcometer MTG Range of Ultrasonic Material Thickness Gauges is a group of four products from the entry level MTG2 through the MTG4 and MTG6 to the top of the range MTG8.

www.elcometer.com

Automated surface measurementIn addition to conventional 3D microscope

systems, NanoFocus (Stand 7318) also offers surface metrology systems for inline use. With various options for automation they can be fl exibly integrated into production-related control systems.

NanoFocus confocal 3D surface measuring systems suitable for full automation can be

integrated directly into production lines for 100% control. They can also be implemented near the production lines for sample inspection (single or serial measurements).

Customer-specifi c measurement strategies and complex evaluations can be easily confi gured with the NanoFocus automation software μsoft automation. Measurement results can be directly transferred to pre-defi ned evaluation protocols or exported to further relevant software via various data interfaces. Result data is available for nominal/actual comparison or can be exported for further analysis to qs-STAT, Matlab, various data bases or SPC-charts.

Industrial requirements are fulfi lled by functions such as wafer map import or OCR/DDM/Bar Code Reading.

For series measurement no user intervention is required thanks to features such as fi ducial recognition, automated alignment and measurement range tracking. Measurement data and analyses are permanently stored in an analysis library and are available for statistical process control and an optimized documentation.

NanoFocus has successfully supplied automated measurement systems for leading manufacturers across a number of industries. These include systems for fully automated wafer inspection in semi-conductor manufacturing, serial control of joint implants and dental implants in medical technology and the measurement of micro-welding and critical surfaces on automotive components.

www.nanofocus.com

CONTROL 2015



http://www.zwick.de

http://www.elcometer.com

http://www.nanofocus.com


TECHNOLOGY GRANT

Experience another dimensionQMT and Olympus have teamed up to offer readers the chance to use state-of-the-art opto-digital technology on their projectDo you have a cutting-edge precision engineering or materials science inspection project or an idea for one? Would a cutting edge opto-digital microscopes help you stretch the boundaries of your ambitions and achievements? A technology grant could make that possible.

In partnership with QMT, Olympus is inviting short proposals for innovative inspection projects which are technically challenging and require advanced microscopy solutions.

Three successful applications will have the chance to use an advanced digital microscope system for six months, free of charge, with full training installation and support.

The equipment on offer includes the LEXT OLS4100 3D laser scanning microscope for surface inspection and the new DSX510 and DSX510i digital systems, featuring elevated measuring speed and performance, and/or a handheld DELTA Premium X-ray fl uorescence analyser.

The entries will be judged on four criteria:• R&D excellence: the extent to which the project shows new approaches for R&D in the respective area or industry• Application excellence: the extent to which the project supports general trends for further improvement of e.g. production/ product quality, environment, safety, health, etc. • Innovation: the degree of potential for innovation in the proposed project• Relevance of instrument to application: does the instrument provide an effective solution to the measurement task that is being proposed.

The winners will be selected by a judging panel that will include Prof Dr Ing Jörg Seewig, Institute for Measurement and Sensor-Technology, Technical University Kaiserslautern, Markus Fabich, Metrology

Application Specialist, Olympus and Andy Sandford, Editor, QMT magazine.

Last year’s winners can testify to the benefi ts that can come by getting access to cutting-edge microscopy systems. Dr Bijörn Busse, University Medical Center Hamburg-Eppendorf won the chance to use a DSX500i inverted high-resolution motorised opto-digital microscope to fi nd new ways to understand the causes of bone fractures.

He said he would defi nitely apply again, explaining: “It is a great opportunity to test, learn and apply new research tools.”

Another winner was Dr Megan Cordill of the Austrian Academy of Science who was investigating developments in fl exible electronics.

She said that the opportunity to use a LEXT 3D scanning laser microscope gave new insight into the deformation mechanisms in thin fi lms. “The LEXT has been a fantastic addition to my lab not only for the technology grant experiments but for other experiments and analyses we could not perform with our available characterization facilities. The Olympus Technology Grant is simply a great opportunity to try a new technique and dive deeper into one’s own research.”

The deadline for applications is July 31st 2015. Successful applicants will be notifi ed by 30th September 2015 and must agree to have details of their projects published in media including QMT magazine.

Entry is open to applicants from the EMEA region including all European countries including Turkey and Russia, the Middle East and Africa.

Enter now for your chance to experience another dimension with QMT and Olympus

You can apply online on the QMT Website www.qmtmag.com

Offi cial partner

Your chance to win!




Like Humpty Dumpty, it is hard to put the pieces back together once a real world product quality disaster strikes. The ultimate cost of a recall will be far, far greater than any savings from cutting corners or not investing in a quality assurance program in the fi rst place. With our broad spectrum of physical testing machines, software, and technical support, Tinius Olsen can help you assure quality from material to end product. To international standards and your toughest specifi cations. Reputations (yours and ours) depend on it.

Busted!This company’s QA programAND reputation

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AUTOSPORT

A race

Formula 1 engine maker Pankl replaced manual systems with CMMs and cut measuring time by up to 80%, writes Judith Schwarz

When Sebastian Vettel and Fernando Alonso steer their Formula One cars over the track, minute details play a key

role in determining the winner. The battle for every second begins long before they sit behind the wheel – it starts with the manufacturers of engines and drive systems. One of them is Pankl Racing Systems AG. The company develops and builds engine and gearing components for various motorsport teams in all international motorsport classes, including Formula One, the 24 Hours of Le Mans, NASCAR and MotoGP, the pinnacle of motorcycle racing. Pankl Engine Systems manufactures the engine components at its plant in Bruck an der Mur, Austria.

Every gram counts“Lighter, more reliable and better quality,” says

Mario Pichler, Head of Quality Assurance at Pankl Engine Systems, describing the constantly growing demands. Engine components for motorsports repeatedly demand the utmost of manufacturers. In general, it all starts with a specifi cation sheet on which designers note how much stress an engine part is subjected to during a race – how many RPMs, how much ignition pressure and maximum torque, as well as the values for the borehole diameters and idle stroke. The engineers at Pankl are then tasked with designing such parts – be it a titanium connecting rod or an aluminum piston – so that they are as light as possible, yet able to withstand extreme forces on the track: “Our engineers try to get the most out of the part, often a thin line between weight and sustainability,” says Mr Pichler.

Measure, measure, measureMotorsport demands the utmost not only from

design and production, but also the measuring technology. First, precision down to a few micrometers is essential to pushing the limits of the technologically feasible. Second, an enormous

amount of measurements have to be taken. Low quantities of 80 or even 30, as well as constantly changing requirements on parts are commonplace in motorsport. Therefore, the engineers in Bruck often face 15 initial sample approvals for new parts in a single day.

Pankl measures each of these samples several times before downstream production can start. This is supplemented by random samples and 100% measurements during running production. 10-15 machine processes cover the production of a connecting rod for motorsports, for example – and measurements are made following every single step.

Until a few years ago, Pankl relied primarily on manual measuring equipment for these in-process measurements – from slide gauges, quick tests and height gauges to micrometers and contour measuring systems. “This took a lot of time and was largely dependent on the skills of the employees,” remembers Mr Pichler. The results obtained with manual measuring equipment fl uctuate from colleague to colleague due to minimal differences in how it is used. Management and Quality Assurance considered the use of an automatic measuring machine with the primary goal of automating in-process measurements to accelerate them and make them reproducible.

Plug & playPankl decided to test the DuraMax 3D coordinate

measuring machine from ZEISS. The compact measuring machine is specially designed to replace manual measuring equipment in a production setting. It is also oblivious to mechanical vibrations and temperature fl uctuations between 18-30 degrees Celsius, and has a footprint of just one square meter.

With accuracy down to 2.4 μm, it is also considerably more precise than manual measurements – even if it is not quite as accurate as the ZEISS PRISMO SACC coordinate measuring

Mario Pichler, Head of Quality

Assurance at Pankl

Pankl Racing Systems

Pankl Racing Systems AG headquartered in Kapfen-burg, Austria, specializes in lightweight components designed to withstand extreme mechanical stress. The company has around 1150 employees around the world who develop, produce and distribute engine and drive systems, as well as chassis parts for motorsport, luxury cars and helicopters. Pankl manufactured its fi rst con-necting rods for motor-sport back in 1985. Today, the company‘s racing division is the market-leading supplier of engine and drive systems. The engine systems are built in Bruck an der Mur, Austria, and Irvine, California, while the drive systems are put together in Kapfenburg, Austria, and Bicester, UK.

against time




AUTOSPORT

In-process measurements

with DuraMax are made on

site in the production hall.

Connecting rods in motor-

sport: As part of the crank

drive in an engine, a connect-

ing rod transfers the linear

motion of the piston into the

torque of the crankshaft. It is

usually made of two com-

ponents screwed together.

It may sound simple, but in

motorsport it is highly com-

plex: the production process

at Pankl involves 10-15 steps.

And the workpiece is meas-

ured after every single one.

machines that Pankl uses in its measuring lab. The DuraMax can also be operated with ZEISS CALYPSO measuring software, which eight measuring technicians in Bruck are already familiar with thanks to their experience with the other ZEISS machines. “DuraMax was simply a plug & play option for us,” says Mr Pichler.

The measuring technicians transferred existing measuring programs to the machine, measured the fi rst workpieces and began test operations. Many production employees, of course, had to be convinced that it was time to replace their trusted manual equipment with an automatic measuring machine. “However, within two weeks, they no longer wanted to do without the measuring machine. The decision had been made: we were keeping it,” says Mr Pichler.

80% reduction in measuring timeHe says Pankl was able to reach its goal of

automating in-process measurements and all measurements that it did by hand in the past can now be made on the DuraMax. This allows Pankl to reduce its measuring time by 80% for certain tasks.

According to the measurement plan, for example, around 80 characteristics must be measured following the milling of contours on a connecting rod.

As Mr Pichler says, “Before DuraMax, we needed six different gauges and an altimeter with fi ve different fi xtures to reach everything.” This process took one hour and twenty minutes. Now, an employee can clamp the workpiece on a single measuring machine, the ZEISS DuraMax. At the press of a button, the stylus automatically measures the part, thus recording all necessary values – this takes just 15 minutes. Projected on to the numerous process steps and initial sample inspections in motorsport, this results in considerable savings at the production level for Pankl.

The introduction of DuraMax brought another benefi t to Pankl: the results obtained in the

measuring lab, as well as production, are now reproducible. Until now, Pankl only made in-process measurements on coordinate measuring machines in the measuring lab for certain critical dimensions. The rest were manually documented and thus subject to numerous factors such as the individual methods of the production worker. In extreme cases, the deviations from the ideal dimensions were only discovered in the fi nal checks after a lot of time and money had already been invested in downstream production.

Today, DuraMax provides Pankl with a high amount of security regarding the quality of its products at an early stage. This was only possible because the coordinate measuring machine, like the gauges, was ideal for use in a production environment.

Measuring on the production line“This is not an earthquake, but rather our




AUTOSPORT

demagnetization system for the connecting rod,” Mr Pichler tells visitors to Bruck when the building shakes a bit. A measuring machine designed to withstand mechanical vibrations was therefore required to replace manual measuring equipment: “It was absolutely necessary for the in-process measurements to take place in the production hall,” he explains. Prior to this, waiting times in the measuring lab were on the agenda because manual measuring equipment was not accurate enough for some random sample measurements. Now, there are very few in-process measurements that have to be made in the measuring lab.

”Today, we use DuraMax to measure everything we can. As a result, we have much less traffi c in Quality Assurance and the waiting times have been eliminated.”

This also necessitated a few preparations and a clear distribution of responsibilities amongst

measuring technicians and machine operators. Today, the measuring technicians prepare the fi xtures to clamp the workpieces so that the machine operators know exactly how they have

to position their workpieces on the coordinate measuring machine. The measuring technicians generate the measuring programs using offl ine measuring stations.

On this basis, production employees can make many of the in-process measurements themselves – they simply have to select the program and press start. The good experiences with ZEISS DuraMax led Pankl to buy four of these compact measuring machines. Two of them are used for connecting rod production alone. In addition to small batches for motorsport, Pankl recently began manufacturing an increasing number of connecting rods and other components in large quantities for luxury cars such as Ferrari, Porsche, McLaren and Mercedes. They also place considerable demands on design, production and measuring technology – even if the drivers won‘t be facing off against Vettel and Alonso.

www.zeiss.com

Mario Pichler’s goal was to

automate in-process meas-

urements.

The coordinate measuring

machine allows Pankl to

reduce its measuring times

by up to 80% . Photo: Mario

Pichler and René Hautz

All the measurements that we

did by hand in the past can

now be made on DuraMax,”

says Mario Pichler, Head of

Quality Assurance at Pankl

Engine Systems.



http://www.zeiss.com

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SHOP FLOOR

Height gauges keep Xtrac on-track

Trimos VL Series digital height gauges achieve laboratory levels of precision on the show fl oor at transmission specialist Xtrac

Established in 1984, Xtrac is widely recognised as the worldwide leader in the design and manufacture of transmission systems. The company supports a wide client base covering top level motorsport, transportation, defence and marine.

Xtrac remains a privately owned company and is dedicated to a policy of continuous improvement; this is supported by personal development plans for key staff members and a well-funded capital expenditure programme. The close relationship between design, production engineering and manufacturing ensures that Xtrac is able to manufacture even the most complex components, whilst a continuing commitment to researching new processes and

manufacturing techniques has enabled the development of enhanced product designs.

The nature of the company’s customers means that demands for short lead times and unmatched quality standards are everyday Xtrac challenges, whilst the ability to manufacture and inspect components entirely in-house is vital in satisfying both challenging demands.

Neil Warwick, Xtrac Inspection Manager explained: ‘The consequences of failure in the fi eld of Xtrac’s manufactured components means that quality permeates every aspect of the business, from administration systems, through the development of our advanced manufacturing techniques, to the company’s state of the art product inspection facilities.

“To guarantee the delivery of premium quality products, in addition to operating several coordinate measuring machines and many other advanced inspection aids in our fi nal inspection department, each of our production operators takes responsibility for the quality of their own work. To ensure that production personnel are able to achieve the required levels of accuracy, and that they are able to undertake the necessary range of inspection tasks, we supply them with the best available inspection equipment.

“Although we ensure that our shop-fl oor conditions are kept in a pristine condition, given the presence of machine tools and other equipment, we have a challenging requirement for inspection aids that can stand-up to the demands of continued shop-fl oor use, yet provide inspection department levels of precision.

“Some time ago, we undertook a search for an easy to use, multi-functional, accurate height gauge that could be used with confi dence within our manufacturing areas. We found the answer in a Trimos VL300 from Bowers Group. As the robust height gauge proved to be ideal for achieving high precision results on the shop-fl oor and was also popular with our production operatives, we soon ordered a second Trimos VL300.

“The reliable nature and the outstanding accuracy of our original Trimos height gauges has resulted in the purchase of further models over several years. Our most recent Trimos height gauge purchase was prompted by a substantial increase in production and our need for a series of smaller capacity, relatively



SHOP FLOOR

simple, yet accurate, shop-fl oor height gauges.

“Having had a demonstration of a Trimos VL300 model we found that, compared to our multi-functional Trimos height gauges, the smaller, simpler model provided us with the limited range of functions that we needed, yet adhered to our demanding accuracy needs. Having recently purchased 4 x VL300 gauges, they are now located throughout our shop-fl oor and are helping us to guarantee the continued quality of our output.”

Trimos VL Series Digital Height Gauges provide laboratory standards of precision to the shop fl oor and are ideal for use in close proximity to machine tools. The height gauges’ logical operating system and speed of use guarantees a short operator learning curve and ensures that new users are able to perform all required measuring tasks within the cycle times of machine tools. Ease of use is further aided by the gauges’ use of a rechargeable battery pack.

An ingenious Trimos measurement activator ensures excellent standards of accuracy and repeatability and also provides outstanding reproducibility of measuring results from

operator to operator. A simple VL300 built-in keypad gives access to all functions, whilst a large digital display shows the achieved measured values. If required all measured values can be downloaded via an RS232C data output.

Amongst the numerous precise measuring tasks, the VL Series height gauges are able to perform in a metric or inch mode are - step heights, internal / external diameters, surface and centreline distance measurements and zero setting to a preset value.

Neil Warwick concluded: “To help meet all of our quality aims, Xtrac is totally committed to developing our employees, customer relationships, technical capability and continually improving the effectiveness of our quality management systems in line with the requirements of ISO 9001:2008. We regard our suppliers as a vital part of our business and constantly strive to promote and improve relationships with our suppliers. This policy is typifi ed by the excellent relationship we have established with Bowers and our outstanding experience we have had with our many Trimos height gauges.”

www.bowersgroup.co.uk

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TRAINING

The fi rst of a series of articles designed to help QMT readers in their everyday measurement needs from Keith Bevan, the Delivery Manager for Training at the National Physical Laboratory (NPL).We are working with QMT to help readers understand the value of metrology, and particularly dimensional metrology to their daily lives. Over a series of articles we will help you to meet your metrology needs in 2015, to evaluate where the need is, and provide you with the good practice approach to make the right measurements in the correct way.

We want to share the expertise developed over many years at NPL, to pass on the type of measurement good practice that we encourage through our written publications and training courses. Much is made of measurement good practice but how do we defi ne this term? The guiding principles that we use to defi ne measurement good practice are:

The right measurements - measurements should only be made to satisfy agreed and well-specifi ed requirements.

The right tools - measurements should be made using equipment and methods that have been demonstrated to be fi t for purpose.

The right people - measurement staff should be competent, properly qualifi ed and well informed.

Regular review - there should be both internal and independent assessment of the technical performance of all measurement facilities and procedures.

Demonstrable consistency - measurements made in one location should be consistent with those made elsewhere.

The right procedures - well-defi ned procedures consistent with national or international standards

should be in place for all measurements.These principles underpin our training

programmes and form the basis of our measurement good practice guides. There are now more than 130 guides and over ten percent of them relate to dimensional measurement, providing a valued professional tool to those working in quality and assurance. These are very popular with hundreds of copies being downloaded every month. In November 2014 ‘Fundamental Good Practice in Dimensional Metrology’ was downloaded 195 times, ‘Callipers and Micrometers’ 187 times, ‘CMM Measurement Strategies’ 162 times and ‘Dimensional Measurement Using Vision Systems’ 128 times.

The guiding principles behind the guides and training programmes will also be at the heart of this series of articles, passing on the basics of a sound approach to measurement that will help you to improve your quality management processes. The aim is to encourage you to make a difference within your workplaces, to give you the skills and confi dence to make small improvements to operational procedures that could deliver a return for your employers and improve your own job satisfaction.

The articles will be designed to prompt you to ask the right questions before, during, and after a measurement. It does not provide the answers to those questions, but will offer enough to ensure you know where to look for them in the context of your measurement need. By doing this, it will help you make better measurements in your workplaces.

Keith Bevan (right) is the Deliv-

ery Manager for Training at the

National Physical Laboratory

(NPL) Image ‘Courtesy of NPL’

How to meet your measurement needs in 2015



TRAINING

The advice and tips we share will be based on the fundamentals that lie behind NPL’s established training programme and good practice guides. These guides have been regularly updated over years to ensure they contain the latest thinking, knowledge and research.

The aim of the articles will be a snapshot of our basic introduction to metrology course, which aims to introduce measurement to delegates and show them its value to industry and society, and how it can underpin quality assurance.

A recent learner to complete the course was Nathanael Turner, an Engineering Doctorate student on a four-year placement at the Manufacturing Technology Centre. Nathanael took the course as an e- training module, making it easier to be fl exible around his work and study. “I had a reasonable understanding of measurement in terms of dimensional measurement before the course, but wasn’t aware of the wider aspects to metrology

or NPL,” he said. “It [the course] taught me things about the history of metrology and its importance to wider society and the economy that I had never thought of before.”

Over fi ve articles we will help you to understand what you need to establish a culture of good practice and continuous improvement within your organisation. Ultimately this understanding will lead to a decrease in errors and an increase in productivity, less need for technical support, reduced waste and re-works, better quality and accuracy and improved decision-making, questioning and planning culture.

The series of articles can be collated to become a checklist that you can refer back to when thinking about a measurement need. The fi rst article, to be published in our next issue, will examine the preliminary actions you need to consider before you plan any measurement task.

www.npl.co.uk

Updated good practice guidesNPL has recently updated the following fi ve dimensional good practice guides: ‘The Measurement of Surface Texture Using Stylus Instru-ments’ • ‘Dimensional Measurement Using Vision Systems’ • ‘Callipers and Micrometers’ • ‘CMM Measurement Strategies’

• ‘CMM Probing’ These and all other guides are free to download. Visit the NPL website at http://www.npl.co.uk/publications/guides/dimensional-good-practice-guides to register and receive the free guides relevant to you. Future plansNPL has plans for more guides in the future. The need has been identifi ed for more advanced guides on vision systems

and an enhanced probing strategies guide.NPL is also looking at making the guides available in other formats, for instance e-books. NPL measurement good practice guides supplement other forms of learning such as the NPL Dimensional Measurement e-learning course and more traditional classroom based learning provided by NPL’s training framework. Details of all these forms of learning can be found on the NPL website.We would also like you to tell us about your needs for dimensional metrology guides and training coursesNPL aims to continuously improve its good practice guides. We are looking into future requirements for dimensional good practice guidance and training courses and would like your view. To have an infl uence on future good practice guides, please complete our survey at website:www.surveymonkey.com/s/Dimensional

e-Learning TrainingExcellence in measurement training: online, on-demand

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Firing on all cylindersWhen a brand reputation is built on construction quality and technological prowess, quality inspection is a major part of day-to-day processes. Fred Buschina* explains the unique solution used to measure the highly-sophisticated Audi Valvelift System (AVS).Automotive applications perhaps rank among the most challenging for metrologists. The sheer range of component parts involved – the freeform surfaces of the bodywork, the complex multi-featured engine elements, the diverse material types – all present different challenges for inspection. For top manufacturers, teams of engineers are not only tasked with fi nding the most effi cient new ways to design and build innovative vehicles, but also with ensuring their quality and optimising manufacturing processes.

World renowned for its technology, creativity and innovation, Audi has a proud reputation to uphold. But it also recognises the responsibility it has to customers and to the industry as a whole to continue to develop better, more effi cient technologies that will have long-lasting benefi ts in future. Like most automotive industry leaders, Audi’s engine designers strive to increase power and torque while reducing fuel consumption. And with the Audi Valvelift System (AVS), they are getting closer.

AVS is an innovative variable valve control

system that represents the most recent generation of camshaft technology. It regulates the lift of the valves in two stages depending on load and engine speed. It can be used on the intake valves to regulate the amount of air drawn through, or on the exhaust valves where it can reduce fl ushing losses in the combustion chamber and ensure the correct fl ow of exhaust gas to a turbocharger. The overall

Right and below right, The

Gyõr plant in Hungary makes

the full range of Audi engines,

including V6, V8, V10 and V12

versions and their variants.

*Fred Buschina is the

Managing Director of

Hexagon Metrology PTS



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AUTOMOTIVE

result is a sizable drop in fuel consumption, with particular effi ciency in the mid-load range.

Simple design, complex metrology tasksIn automotive industry terms, AVS has a relatively

simple design, with a lower mass of moving parts than in older camshaft systems which use levers or cups between the camshaft and valves. However, camshafts are a notoriously diffi cult technology to manufacture and inspect, with gearing, cams, mountings and axial control grooves all found on a single unit. Yet Audi can manufacture up to 28,000 sliding cam units and 7,000 spline shafts per day, so high-accuracy, high-throughput dimensional metrology solutions are essential.

The Audi Hungaria Motor plant in Gyõr, Hungary produces nearly two million engines a year for various models of Audi cars supplied to customers around the world. It is also home to a number of Leitz ultra-high accuracy coordinate measuring machines supplied by Hexagon Metrology, which are employed three shifts a day, seven days a week to ensure that every part meets the rigorous standards required for both safety and build quality. Eleven of these CMMs are dedicated to quality control for the AVS camshaft, measuring complex geometric features including involute gears, step gears and cams.

Measuring camshaft components on CMMsOn the basic shafts, gearing parameters including

pitches, fl ank direction and profi le form must be checked along with various control geometries. For cam units, the key is measuring not just the shape, but the cam angle too. Audi uses Leitz Reference series CMMs to inspect all these components, gathering accurate dimensional data and turning it into actionable information using the QUINDOS metrology software.

Part of the appeal of the Leitz Reference range for this application was the option of having an integrated rotary table on one of the machines. This feature signifi cantly speeds up the AVS camshaft measurements to give Audi an economical one part, one program solution. As well as enabling reliable and accurate dimensional inspection of the components, the rotary table adds the potential to test parts with large measuring volumes.

Along with the rotary table, the CMM in question has a 1500 mm x 900 mm x 700 mm measurement stroke, which is important for the fl exibility of measurement programs. It enables the basic shaft to be measured horizontally as well as vertically, while the various types of fi xtures in use may also require a large measurement range. During inspection of the internal gears of the cams, the rotary table fi xtures are used. But for some applications, such as the measurements of the more delicate pump cam, special fi xtures are required to ensure that the part is not deformed by the inspection process.

Right, Various fi xturing meth-

ods are used to mount engine

components for measurement

on this Leitz Reference series

machine, far right, The main

attraction of the Leitz Refer-

ence for the measurement of

cam units and basic shafts

is the rotary table, which can

also be used to measure very

small internal gearing and

control geometries.

Each car that rolls off the pro-

duction line may have subtle

differences in equipment or

engine specifi cation, adding to

the metrology challenge.




AUTOMOTIVE

Parameter programs for all types and variations

Another challenge for automotive industry metrology is the variation within ranges. With consumers more than willing to pay a premium to customise their vehicle, manufacturers now offer a bewildering array of options within their models and ranges. Any number of seemingly identical cars might be slightly different under the bonnet, and engine specifi cation is no exception to this trend.

AVS has core component types which exist in every engine system it is integrated into. However, as AVS is used on a number of models and engine sizes, there can be subtle differences between these components. For example, depending on the engine type, a different sliding cam unit may be required.

To manage these variations, the CAD data is used to produce an Excel fi le with the required camshaft data and parameters. QUINDOS can then import the nominals and generate the part program, while operators can select different programs through an easy-to-use graphical user interface.

Offl ine programming to improve productivityBecause of the exceptionally high demands of

the plant, Audi cannot afford to waste equipment time. This is why part programming is now conducted 100% offl ine using Hexagon Metrology I++ Simulator. With I++ Simulator, operators can work in a virtual reality environment to produce real programs using identical controls to those they would use to programme the actual CMM.

The benefi ts of this tool are particularly important for intricate and varied parts like the components of the AVS. Machine downtime is minimised, as are the costs of programming and operator training. Collision protection warnings within the simulation minimise the risk of machine damage when the program is implemented in reality. For new users or even experienced operators programming new or complex part types, it offers the chance to verify part clearance and accessibility prior to use, while tool and fi xture use can also be checked and optimised. I++ Simulator can also work directly from the CAD data to construct inspection programs for newly-designed parts where a physical prototype does not yet exist – helping to support Audi’s research and development testing needs.

Interpreting data to improve output qualityAt the heart of the quality control equipment

at Audi is the Hexagon Metrology dimensional analysis software, QUINDOS. With specialist modules for a huge range of applications including powertrain and gearing system measurements, QUINDOS is multi-faceted option which adapts seamlessly for Audi’s varying needs.

Even challenging geometries like the tapered main bearing of a crankshaft can be inspected using a specialised QUINDOS evaluation program. Once the measurement process is complete, QUINDOS compares measurement data to the applicable standards and outputs it to the Q-DAS qs-STAT statistical software package for process analysis. Quick and easily interpretable information output ensures that Audi can quickly identify any quality issues and take corrective action, minimising wastage and downtime.

Integrating technology around the factoryAs well as the Leitz Reference series CMMs

used for inspection of the AVS components, Audi has several other Hexagon Metrology ultra-high accuracy CMMs installed around the factory. These include a Leitz PMM-C lab machine for traceability to the national laboratory, SIRIO shop-fl oor machines and a large-format Leitz PMM-F, which has high-speed scanning capabilities that have halved the time required to conduct complex cylinder bore analyses.

Because all of these measurement systems run QUINDOS, inspection results from different areas of the engine build process can be easily interpreted and compared, building a complete picture of production to minimise assembly issues and ensure that the components come together as a complete high performance engine.

Audi has also made use of the manufacturer-independent functionality of QUINDOS to integrate equipment from suppliers other than Hexagon Metrology, saving the costs of training operators on multiple software packages and or unnecessarily replacing older equipment. Upward compatibility also ensures that all existing programs are retained at upgrade to minimise reprogramming.

Progress through speed and accuracyEven though AVS is designed to simplify engine

dynamics, it still relies on complex component parts to function correctly and actively improve overall vehicle performance. Precision measurement is vital to the build, both in terms of process productivity and output quality. Measuring high volumes of complete component parts quickly and accurately enables Audi to maintain its reputation for quality while pushing the boundaries of what is technically possible. Like AVS, new systems and techniques will continue to drive progress, and with its Hexagon Metrology equipment, Audi will be able to measure this progress with absolute precision.

www.hexagonmetrology.com

The plant also has a Leitz

SIRIO machine which offers

speed and fl exibility to meas-

ure complex parts like this

engine cylinder head.



http://www.hexagonmetrology.com


SCANNING

Cast iron certaintyInnovative scanning technology allows the inspection of complex castings at Benninger Guss

Sometimes the original documentation of parts that need to be cast is not available – a problem that many businesses now solve using modern scanning technology. Indeed, even when a drawing is available, 3D scanning technology can be used to validate potential geometric and dimensional deviation between the manufactured component and the original documentation. These results can then be used in consultation with the customer to defi ne which geometry is correct.

In March 2013 Swiss foundry Benninger Guss AG started producing sand moulds on a 3D printer to use in the manufacture of castings for prototypes, replacement parts and production parts with specifi c geometrical requirements. In order to complete the manufacturing chain for replacement parts the investment also included the purchase of a Creaform’s HandySCAN 3D portable 3D scanner and software to carry out quality control on the reverse engineered castings and sand cores.

This software allowed Benninger Guss to generate a completely parametric CAD data record of the part. This was important as it is necessary to simulate the casting process on this type of work as the pouring of the replacement part must be successful on the fi rst attempt. Otherwise time delays and costs would not make this a viable solution.

The HandySCAN 3D from Creaform was

chosen for a number of reasons including accuracy, maximum handling fl exibility and the ability to scan on the move in a production environment. Also decisive were the fast starting up of the system and possibility of measuring a range of component sizes.

Mr.Jans, who is the team leader of Technical Model Assembly and in charge of the digital castings section at Benninger Guss AG, explains: “For the application mentioned above there is, in our view, no suitable alternative available on the market that meets our requirements.

“It is the purchase of a 3D scanner together with a 3D printer for sand casting that has made it possible for us to generate more turnovers in the replacement parts business for the. The advantage is quite obvious. Now we can handle tasks quickly that we would not have been able to carry out before by ourselves. As we inevitably have to work very closely with the customer when making replacement parts, an outsourcing solution was not advantageous.”

Mobile and Accurate 3D MeasurementsInspections for casting and forging require

the acquisition of dimensions on parts of various shapes and complexity, potentially performed in any kind of environment. Due to its portability and versatility, the HandySCAN 3D can perform the acquisition of any part

When dealing with some com-

plex components, it is almost

impossible to obtain exact

results from conventional

geometry. In these cases, In-

spection is only possible with

scanning technology.



SCANNING

Digital model of the casting

not only directly at foundry, but also at the customer’s premises, on the production fl oor or at the supplier’s location.

Quality inspectors or operators usually need to evaluate the physical part themselves using its corresponding digital model. Because of that, acquisition data must be accurate and the 3D model must include all the information needed for a complete inspection.

In casting and forging, raw parts are usually machined in particularly critical areas to produce the fi nal component. So it is also important to carry out dimensional checks on the raw casting to make sure that there is enough metal to machine. A 3D scan allows operators to align the raw part on the machine and orient it so as to guarantee enough material for the operation. Moreover, time and money are saved because unqualifi ed cast and forged parts will not be machined.

Creaform says that thanks to the integrated TRUaccuracy technology, the portable and

self-positioning HandySCAN 3D Scanner delivers complete and accurate mesh fi les (.stl format) regardless of environmental conditions (e.g. instabilities, vibration, heat differences or suboptimal user skill).

It says that compared to traditional measurement methods, the HandySCAN 3D solution also helps save a considerable amount of time. The scanned data is documented in real time and is reproduced more easily than data resulting from visual inspection and manual testing devices.

www.creaform3d.com

METROLOGY SOLUTIONS

+49 711 1856 8030 www.creaform3d.com

Visit us at Control

Hall 5, Booth 5108

Experience Creaform’s portable CMM and

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- Save time

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http://www.creaform3d.com

http://www.creaform3d.com


http://www.or3d.co.uk


NDT

NDT landscape unfoldsThe British Institute of Non Destructive Testing looks to encourage the better use of NDT

The 2014 report ‘A landscape for the future of NDT in the UK economy’ identifi es the fundamental opportunities and challenges for the NDT community in the UK and recommends key enabling actions in order to support economic growth and increase the public’s awareness of and safety through NDT. These actions are listed in four primary sectors and cover: new business engagement, people, technology and R&D.

‘New business engagement’ is summarised in the report as the need to “demonstrate the value of NDT through the life of a facility or structure. Engage insurance companies and regulators to maximise the benefi ts of NDT.”

Engaging with insurance and regulatory sectors will help to encourage better use of NDT. This is closely connected to the need to build closer links with the structural integrity community through networks, businesses and professional bodies. Tony Dunhill, current President of the British Institute of Non-Destructive Testing (BINDT) and chair of the NDT working group, says: “Ideally, I would like us all to end up in a safer place; that is the be all and end all. I would like the breadth of the infl uence of the NDT industry to be appreciated, and I want people and companies to consider that whenever they are looking at the development of a new material or manufacturing process, they ought to be thinking ‘Has this process generated any defects?’.”

The links with the structural integrity community are not only required for the improvement of structural integrity management solutions but to also prevent acute failures – ensuring public safety – and to secure on-going cost-effective operation in the future. In order to achieve this, the preparation of a series of case studies and demonstrator schemes covering technical feasibility are advised to help

demonstrate how NDT can be used to increase safety. These case studies will also play a major role in endorsing NDT and showing how it can be used to secure business, as well as encouraging an increased take-up of new NDT technology and the use of existing technology in new applications.

By implementing a solid PR programme, these case studies can be used as promotional tools to target businesses that are not currently engaged in NDT through seminars, business publications and other media channels. These actions all require stable funding methods. Keith Newton, Director of RCNDE and co-editor of the Landscape report, says: “This report provides the foundation for developing opportunities within NDT, for which we now need to try and secure funding. There are many more people who could do with smart NDT. Having the report helps to set the scene for potential investors and the fact it has been written by a cross-sector group should also give it validity.” There could even be scope for a Structural Integrity Catapult Centre acting as an international facility to develop the knowledge base for understanding duty cycles, material properties, inspection capabilities and acceptable risk.

The NDT industry needs to be reinforced with solid methods of funding in order to carry out the key enabling actions detailed in the report, to continue to contribute towards the growth of the UK economy and to impact on the UK government’s plans for future development in priority technology areas. By securing such funding, the NDT industry will be free to demonstrate its true value within the UK economy, which will inevitably lead to new business opportunities for companies throughout the UK and beyond.

www.BINDT.org

Report co-author and BINDT

Immediate Past President

Tony Dunhill discusses the

fi ndings with BINDT CEO

Cameron Sinclair



http://www.BINDT.org

The international exhibition for all concerned with NDT, testing for quality, materials testing,

condition monitoring and diagnostic engineering.

The Institute’s Annual Conference, NDT 2015, is to run alongside the Materials Testing Exhibition, giving delegates many opportunities to visit the show.

Cost-effective participation packages are available.

Materials Testing 2015 will present companies with a major forum for promoting their products and services and interfacing with their markets; a unique opportunity to:

Review the latest technologies Source new contacts Meet industry colleagues Keep up-to-date Get new business Participate in the development of the industry.

Organised by The British Institute of NDT

Newton Building, St George’s Avenue, Northampton NN2 6JB, UK. Tel: +44 (0)1604 89 3811; Fax: +44 (0)1604 89 3861; Email: [email protected]

w w w . m a t e r i a l s t e s t i n g . o r g

Materials Testing 2015 8 - 10 September 2015 | The International Centre, Telford, UK

The place to meet and do business

The Advanced Engineering UK 2015 group of events

Visit 5 of the UK's leading advancedengineering events under 1 roof4th - 5th November, NEC Birmingham UKOnce again, the Advanced Engineering UK group of events brings together OEMs, primes and allsupply chain tiers, to meet and do business across some of the UK's highest-growth advancedengineering sectors. Whether attending as an exhibitor or a visitor, each of the 5 co locatingadvanced engineering shows provides you with a business forum and supply chain showcasewithin its own sector, and those of its co-locating sister events.

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INSTRUMENTS

Scientifi c instrument maker Waters sees the benefi t of high-end metrologyMore than a decade ago Waters Corporation, the scientifi c laboratory instrument and software manufacturer, started introducing high-end metrology equipment to its several sites in the South Manchester area to help cope with the increasing demands of advanced product development and manufacture.

The results over the next few years provided that this was the right investment philosophy, particularly with regard to the production of leading-edge mass spectrometers.

Recently the company enhanced this capability with major Vision/Coordinate Measuring Machine acquisitions from Mitutoyo UK, the company’s long-time metrology partner.

Speaking at the company’s new mass-spectrometry headquarters in Wilmslow, Cheshire, where product development and manufacture have been brought together under one roof, Six Sigma and Metrology Engineer Dr. Kevin Rogers explained that: “The information and knowledge extracted in the fi rst few years served to prove how useful high-end metrology can be in terms of

product quality and development. The use of metrology within Waters has expanded considerably since that time and is now a key part of all aspects of manufacturing within the organization.”

Mass spectrometers are very complex systems relying on tight-tolerance components to achieve very fi nely controlled manipulation of ion beams for the qualitative and quantitative analysis

of biological samples. The need for high-precision dimensional inspection, as an aid to determine performance limiting tolerances within critical sub-assemblies, was identifi ed. These assemblies required non-contact measurement of some key components.

Dr. Rogers continued: “Use of Mitutoyo metrology equipment has led to improved product yield and by turn an increase in productivity and quality. The fi nancial outlay on Mitutoyo equipment within Waters has never been questioned and the use of high-performance metrological tools is seen as an ongoing and expanding force for good.

“The equipment has proven itself invaluable in terms of delivering previously unachievable answers. Mitutoyo’s support system from sales through to service has been excellent. Mitutoyo are a very easy company to deal with and one which I feel, as a user, places the customer foremost.”

Three high-performance Mitutoyo QV Series CNC Vision Measuring Systems were acquired recently to support expanded production of smaller parts, together with a Crysta Apex C122010 CMM for measuring larger components up to 2 metres in length.

Apart from the established relationship between the companies, the Mitutoyo QV machines were chosen based on demonstrated capability, which has proven more than adequate in production and development operations.

“The use of metrology has had manifold benefi ts but has also led to the need, as our own product complexity has expanded, to measure more and more challenging features and dimensions within our product range for even greater product knowledge. This has led us to challenge metrology OEMs to provide even more capable solutions and placed us at the leading edge of metrology requirements”, Dr. Rogers concluded.

www.mitutoyo.co.uk

A clear difference



http://www.mitutoyo.co.uk

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CALIBRATION

Spirax Sarco steams ahead on calibration

IndySoft helps Spirax Sarco keep on top of calibration management for its extensive inventory of gauges

Cheltenham based Spirax Sarco is a global leader in the design and manufacture of steam technologies, offering a comprehensive range of steam solutions to a variety of industries and processes.

Steam is widely acknowledged as the most cost effective way of distributing energy in the form of heat, around a plant or institution for use in a variety of processes. As a leader in the fi eld, Spirax Sarco is able to provide an industry leading product range, combined with the support services and expertise needed to enable its customers to optimise their manufacturing processes through effective use of steam. In addition to designing, installing and commissioning new facilities, Spirax Sarco helps its customers to optimise existing steam systems, upgrade steam plants and to maintain performance through scheduled maintenance routines.

The BS EN ISO 9001:2008 registered company’s impressive integrated fabrication facility is able to deliver pre-assembled packages of products, from simple valve train units through to complex steam systems.

To enable the effective operation of Spirax Sarco’s quality system the company employs a multitude of instruments and gauges that need to be calibrated monitored and traced to their locations.

Amanda Shakespeare of Spirax Sarco,

Cheltenham explained. “Given both the health and safety and commercial implications of the failure in the fi eld of our products, Spirax Sarco administers a strict quality regime. Our exacting quality standards are a major reason for the excellent reputation Spirax Sarco now enjoys throughout the world.

“To enable a multitude of different checks and inspection routines to be carried-out, we currently have more than 12,000 instruments in active service, all of which need to be calibrated, the vast majority of this work takes place on-site. In addition to numerous analogue and digital dimensional gauges, such as micrometers, calipers and bore gauges, we also use countless specialised instruments across a broad range of diverse disciplines, such as pressure, material analysis, mass and electrical testing. Not only do we need to adhere to each individual instrument’s calibration schedule, we need to analyse its wear rate and track its location throughout our sites.

“As the volume of instruments being sent to commercial calibration laboratories reached a critical level some time ago it was decided that a fi rst-class, on-site calibration facility, with results traceable to UKAS (The United Kingdom Accreditation Service).should be established. Now fully operational, in addition to making commercial

A multitude of instruments

and gauges need to be cali-

brated, monitored and traced

to their locations




CALIBRATION

Each working day, the

IndySoft system provides a

comprehensive list of gauges

to be calibrated

sense, the facility’s ability to calibrate and return critical instrument to production in hours, as opposed to days, and sometimes weeks when sent for external calibration, aids the company’s overall effi ciency.

“Having previously used a fairly limited DOS based gauge management software system in our calibration facility, to help improve our effi ciency we undertook a search for a more up to date product. After narrowing our search and arranging demonstrations of the four most suitable systems, impressed by its advanced capabilities, we purchased IndySoft’s calibration and asset management software.

“As well as having all of the features that we were looking for, IndySoft software proved extremely fl exible, fast, easy to use and it had an excellent reporting function. In addition, the company were able to guarantee high levels of after sales back-up.

“Not only did IndySoft’s staff provide excellent initial training and help us to confi gure the software to suit our specifi c needs, on the rare occasion that we experience a diffi culty, IndySoft provide an instant response.

“As our gauge inventory has expanded and our calibration work-load has grown, had we persevered with our previously used DOS based software system, the administration of our calibration system would now be a logistical nightmare. The speed and ease of use of the IndySoft system has helped us to ensure the continued effective administration of our busy calibration function. In addition, the availability of IndySoft software up-dates makes our system future proof.

“Each working day, the IndySoft system provides a comprehensive list of gauges to be calibrated, and importantly for us, their locations. Once calibrated, the system up-dates the gauges history, provide a fail/pass decision and gives us access to analysis tools. It really helps that all relevant information is displayed in a logical way with excellent graphics.”

IndySoft users benefi t from the system’s continuous evolution. Many years of real-world software development and rigorous testing by true professionals has ensured that IndySoft is now an acknowledged leader in the fi eld of Calibration and Asset Management Software.

Over many years, IndySoft has regularly introduced innovative new products feature that have quickly become established as industry standards throughout the sector. IndySoft’s paperless system with full audit trails has recognition of compliance to many quality standards, such as AS9100, QS9000, TS16949, ISO9000, FDA 21CFR Part 11 and ISO17025.”

Calibrations can be performed on a pass/fail basis, test point results or even from embedded Excel or Word documents. A software module is included allowing users to perform studies such as R&R, Linearity, Bias, Stability, Failure Logs etc.

Managing Director of IndySoft Europe, Jake Bishop added. “More often than not we supply IndySoft software to in-house calibration facilities and commercial calibration laboratories that have previously been using manual systems. So it is particularly rewarding when companies such as Spirax Sarco chose to replace their less effi cient,

existing software systems with IndySoft Calibration and Asset Management Software. Invariably, potential customers currently using inferior software packages recognise their inherent limitations and have formulated ‘wish lists’ of features needed in a replacement system. As IndySoft Calibration and Asset Management Software delivers all of the required elements, when given the opportunity to demonstrate, in the vast majority of cases, IndySoft is chosen as the replacement system.

“In addition to its suitability for managing the gauge stocks of smaller concerns, IndySoft software’s un-matched ability to administer extremely large inventories, that include multiple gauge categories with mixed calibration schedules, across multiple sites, renders it ideal for use within the most demanding of situations. These attributes meant that IndySoft was the ideal answer to Spirax Sarco needs.

“Much of IndySoft Europe’s remarkable sales success has been due to satisfi ed customers recommending our software to other potential users. IndySoft Calibration offers the most fl exible and easy to use calibration system. New users are able to calibrate equipment and generate certifi cates of calibration ‘Out of the box’.

“Through the use of an exclusive process modelling engine, IndySoft users can confi gure their own, event driven systems with checkpoints and rules set at every point along the equipment path. This fl exibility ensures that assets are handled according to company’s existing work-fl ow and procedures. Users are able to track all equipment as it moves about their businesses, manage schedules such as preventative maintenance, calibration, service/repair, and create user defi ned timetables.”

www.indysoft.co.uk



http://www.indysoft.co.uk


PRODUCTS

Metered dose testingWorking with a leading pharmaceutical manufacturer, AMETEK Test & Calibration Instruments has developed a semi-automated system for testing the fi ring mechanisms used in one-shot pressurized metered dose inhaler (MDI) canisters.

The company says that there was previously no known dedicated testing solution for testing MDIs to protect patient safety by ensuring that the correct dosage of a drug is delivered with every release. The MDI Test System is said to give signifi cantly faster turnaround than conventional testing systems. It is suitable for use in production, quality control, educational and research applications.

The tester detects the fi ring load and valve breakdown load of one-shot, pressurized MDI canisters. The breakdown test is carried out at a predefi ned load and tolerance to check that inhaler operation is at a consistent pressure to ensure correct dosages. A safety discharge port allows canister contents to safely vent to a collection vessel.

The test jig that holds the canister is custom designed to user requirements and is easy to remove, allowing the test machine to be used to perform other functions such as tension, compression, tear and peel, friction and cycling tests.

The MDI system is supplied complete with inhaler testing jig, interlocking safety shield, a 50N and a 1kN load cell, hand-held remote control and NEXYGENPlus software.

www.lloyd-instruments.com

High-precision height gaugeMitutoyo’s QM-Height Digimatic height gauge offers accuracy of 3.6/4.5μm over the measuring range (350/600mm) and signifi cant improvements in design and capability. High accuracy/resolution Mitutoyo ABSOLUTE linear encoders ensure precision and dependability. A large display panel with user friendly icon-based control keys and GO/NG LED indicator provides excellent useability.

Enhanced measurement and memory capabilities of the new QM-Height allow the capture of complex dimensional data. Measurements include height, step, inside/outside width, inside/outside diameter, pitch circle and free-form surface maximum/minimum heights by scanning measurement. The QM-Height remembers the preceding measurement (height component) and can display the difference (pitch) between results.

The new QM-Height models offer pneumatic fl otation as standard and an ergonomically designed grip, enabling the gauge to be moved easily over the surface plate and the probe precisely positioned on the workpiece.

Battery power, provided by four AA cells, provides autonomous operation – up to 300 hours is possible between battery replacement, or 80 hours with regular use of the pneumatic fl otation function. Alternatively, the

AC power adapter supplied provides uninterrupted use.

Full compatibility with existing Mitutoyo Digimatic peripherals and USB output enables measurement result storage and documentation, SPC analysis and straightforward integration into networked measurement systems with the ability to use, if required, Mitutoyo’s U-WAVE wireless data communication system for the ultimate in fl exibility.

www.mitutoyo.co.uk

Cutwel measures upWest Yorkshire-based tooling supplier Cutwel has announced an expanded range of new measuring tools for 2015, with catalogues from leading metrology suppliers Mahr and Insize

available on request.Cutwel says that one of the

highlights of the extended Insize range is the new Ultrasonic Hardness Tester (ISHU-460 Series). This gives the ability to test surface hardening layers and plating for steel, non-ferrous metal and alloys.

Large work pieces can be tested in any direction and the tester is also suitable for rough surfaces. The test time is just 2 seconds and the test force applied is independent of the operator.

The hardness tester has a memory for 1000 test results, pictures can be taken of the workpiece and and you can get a report of the testing results which can be sent to a computer via a USB connection.

A highlight of the Mahr range is the Self-Centering Dial-Bore Gage MaraMeter. Cutwel says this is ideal for measuring diffi cult to reach bore diameters, grooves and recesses. It is universally applicable and extremely versatile as every instrument spans a broad measuring range, within this series it is quick and easy to adjust to any size.

The measuring head consists of a carbide-tipped moving anvil and interchangeable stationary anvil which has a carbide ball.

www.cutwel.co.uk



http://www.lloyd-instruments.com

http://3.6/4.5�m

http://www.mitutoyo.co.uk

http://www.cutwel.co.uk

29th Control – International trade fair for quality assurance

Measuring technology . Material testing . Analysis apparatus

Optoelectronics . Quality assurance systems

05. – 08. MAY 2015 . STUTTGART

www.control-messe.de


http://www.control-messe.de


PRODUCTS

High-accuracy range extendedHexagon Metrology has announced a new frame size for its high-accuracy coordinate measuring machine (CMM) range. The Leitz Reference HP 7.7.5 offers a compact solution ideal for measuring small workpieces with tight tolerances.

Using the proven design of the Leitz Reference line and with a measurement range of 700 x 700 x 500 mm, the Leitz Reference HP 7.7.5 provides the low levels of measuring uncertainty required by precision manufacturers. Equipped with the Hexagon Metrology HP-S-X3 Scanning Probe Head as standard, it can carry stylus confi gurations of up to 360 mm in length and 150 g in weight.

“The Leitz Reference HP 7.7.5 features all the technology that gives this range its characteristic accuracy, versatility and throughput,” explains Ingo Lindner, stationary CMM Product Line Manager at Hexagon Metrology. “This compact size has a small footprint but huge application potential across a number of industries.”

Designed as a universal measurement system with scope to adapt to a number of jobs throughout the production process, Leitz Reference line machines offer customers an effi cient multipurpose solution without compromising on accuracy. Available with PC-DMIS

or QUINDOS metrology software, they can also be confi gured as gear inspection centres.

The new Leitz Reference HP 7.7.5 is available to order immediately through local Hexagon Metrology commercial operations with shipments beginning in May 2015.

www.hexagon.com

Seal gap measurementThird Dimension has developed a solution to the challenges of measuring automotive seal gaps. The system has been tested with a leading luxury automotive manufacturer, accurately measuring gaps from 0mm to 50mm controlling tolerance bands of +/-0.5mm (+/-0.02”), with R&R scores better than 15%.

Automotive closures are a complex area of engineering, with tight geometries to ensure that performance remains consistent over what can be a very demanding product life. As well as external, visible gaps, it is also important to measure the internal closure gap dimensions where the door seals will ultimately be fi tted.

GapGun offers the capability to measure both external body gaps and inside (seal) gaps with just one instrument. Working with a premium car manufacturer in the UK, Third Dimension has developed a technique to accurately achieve this measurement having designed two patented fi xtures; a door stop striker plate and a f riction block.

John Kane, Third Dimension’s Chief Business Development Offi cer, said: “We have been designing and manufacturing industrial measurement systems for many years. Our real value is the innovation we introduce and our experience in industrial metrology.

“We have been able to apply the lessons we have learned and incorporated the views of customers into our manufacturing and

development process. We strive to ensure that we are providing the best solution to our customers’ most diffi cult measurement problems.”

GapGun can be easily integrated in the manufacturing process for quality inspection with minimal training. The method of measurement is quick and easy, requiring no additional specialist training. With results collected in seconds by the same system as external gaps, there’s no need to collate the results from multiple systems, saving time and reducing the risk of error.

www.third.com/products.

Infra-red and radio touch probesDesigned for use on machining centres, milling, drilling and boring machines and B-axis lathes with automatic tool change, a new generation of touch probes has been introduced by Heidenhain for aligning and measuring workpieces, tool setting and detecting cutter wear and breakage.

New features include the ability to feed signals back to the control via an infrared (IR) or radio link. This means that the same unit can be swapped between different machine tools on a shop fl oor, irrespective of whether they are equipped with IR or radio communication, saving the cost of buying extra probes.

A further advantage, mainly applicable to larger machines, is mixed operation using both forms of data communication. It allows the long range of radio transmission to reach the tool changer so that a workpiece probe can be activated, ready for use. Subsequently switching to IR during probing exploits the increased speed and accuracy of data transmission at infrared frequencies.

www.heidenhain.co.uk



http://www.hexagon.com

http://www.third.com/products

http://www.heidenhain.co.uk

Onsite and offsite training on all faro

arm gauges and laser trackers

Manchester Metrology Ltd, Unit 12 Greenside Lane Industrial EstateGreenside Lane, Droylsden, Manchester, M43 7AJ

TEL- 0161 6378744 • FAX- 0161 [email protected]

Onsite inspection services using the

latest faro arm gauge and laser

trackers

Hiring and leasing of laser trackers arms and gauges with all

software options long term and short term

hiring available

Onsite and offsite calibration of your faro equipment accessories available for arms and gauges including probes probe extension kits magnetic chucks

and leapfrog cones

Laser tracker accessories and

adapters



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