CORE-DS: Optical Scan speeds up the Inspection of Turbine Blades

Clamp the turbine blade, push a button and start the non-contact measure-ment. That’s it. – The latest development CORE-DS of WENZEL ScanTec, a subsidiary of WENZEL Group makes it possible: A robust and compact desk-top version for the production environment. Contactless and with high dy-namics and integrated software. That is the result of years of experience in the field of optical measurements of turbine blades.

In recent years, the aerospace and energy industry sectors have recorded signifi-cant growth rates; this trend is expected to continue in the coming years, albeit with a slight delay due to the economic crisis. One of the main manufacturing objectives is to maintain high quality standards while time cycles for inspection and quality control have to be reduced due to growing production volumes.

Optical non-contact solutions have increasingly gained importance in this sector, as they have often a huge speed advantage compared to current tactile solutions. Many optical measurement techniques require however a matt and therefore opti-cally cooperative surface to allow accurate inspection. Shiny or reflective surfaces are therefore to be prepared with a fine chalk powder; an application, which is seen as an inconvenient but necessary process step. "Many of our customers have expressed the desire to eliminate this working step. We at WENZEL ScanTec have in the recent years incorporated this requirement into the development of our tech-nology and can now offer with our system a significant process optimisation” said Klaus Mühlberger, managing director of WENZEL ScanTec GmbH. The optical measurement of shiny surfaces without the described preliminary step is one of the greatest strength of our blade inspection solution.

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METROLOGY: INSPECTION AT THE SPEED OF LIGHT

Industry leaders frustrated with high cost of inspection: Push for speed in the quality department without sacrificing accuracy or adding complexity.

These days, equipment is only as good as the software that runs it. According to Erik Adams, of George Products Company, “Customers don’t want a collection of parts; they want a turn-key solution to their inspection problems that includes powerful software to drive the system.”

The OASIS Inspection System is driven by its own proprietary software that powers the system to operate at very high inspection speeds. New to the system is a strobe light source that creates the part shadow to be measured, and is controlled by the OASIS software to pulse light in micro-second bursts that effectively stops action. Couple that with a strobe rate of 6 bursts per second, synchronized with the shutter on the digital camera, and the result is the OASIS’ ability to measure all external dimensions in under a second - all without the part every needing to stop.

In yet another newly released feature geared toward speed, one-click reporting now instantly takes all measurements and exports them to SPC programs or the OASIS report spreadsheet.

"The speed of the Oasis has reduced our inspection time to seconds per component; reducing the need for a dedicated inspector doing audits and allowing the operator to inspect each component 100%. This has resulted in real-time data acquisition that helps manage tool wear and keeps the process stable during operation. The Oasis is the perfect inspection system to reduce inspection labor and is a great tool to monitor process operations."

Daniel Proveaux, Quality Assurance Manager
Certified Six Sigma Black Belt, COQE Certified Quality Manager
Goodrich Corporation - Bamberg, South Carolina

Founded in 1951 and located in Middletown, Delaware, George Products Company is the manufacturer of the OASIS Inspection System. The OASIS is a full-featured machine vision inspection system designed to measure multiple profile dimensions on parts, accurate to +/- 0.0001”, with all the measurements done in less than a second.

For more information, contact Erik Adams at (302) 449-0199, email info@georgeproducts.com, or visit our web site at www.georgeproducts.com

The First Scanner That “Actually” Measures

Werth Messtechnik GmbH presents its new scanner, the Werth FlatScope, for fast, precise, and reliable inspection of flat work pieces and extrusion profiles in a production environment. The main area of application is in the measurement of complex profiles (e.g. rubber, plastic, or aluminium profiles) as well as stamped parts, laser cut profiles, and circuit boards.

The exceptional features of the scanner, currently the most exact in the world, are based upon proven designs in its mechanical construction. This enables workpieces to be measured with the smallest uncertainty. The measuring range of this reasonably priced series of machines is up to 650 mm. Larger measuring ranges can be supplied upon request.

The Werth FlatScope is equipped with an Image Processing Sensor with telecentric or zoom optics as required. By using the unique Werth Zoom, constructed with linear guideways, an accuracy can be achieved which is unprecedented within the scope of the scanner. The magnification can be set via CNC controls. Powerful image processing, which goes far beyond the capabilities of common edge detector systems, makes the previous, time-consuming preparation of test pieces superfluous. The versatility of numerous available filters eliminates the need for extensive deburring. Even parts with profiles of 100 mm thickness can be measured with ease.

Completely automatic measurement of complicated, extremely low-contrast work pieces in Backlight and Surface Illumination can also be easily achieved. In Grid Scanning mode, the entire measuring area can be scanned quickly and all geometrical characteristics recorded and evaluated.

The WinWerth Measuring Software combines modern, intuitive user operation with exceptional features, making measuring with the Werth FlatScope particularly simple, thus enabling the machine to be used by untrained operators.

Metris Laser Radar maximizes power generation productivity of parabolic solar panels

By Metrology Solutions Provider

Solar Cell Inspection

The geometric integrity of parabolic solar mirrors is a critical factor in reaching maximum productivity for industrial power generation. Deployed to inspect parabolic solar mirrors, Metris Laser Radar has proven its capability to trace incorrect bending and alignment of individual mirror panels. Metris Laser Radar is fit for the large-scale inspection job because it is portable, fast and accurate and offers automatic single-user operation. By using inspection results to tune the geometry of parabolic mirrors, solar thermal power plants increase power generation output and profit.

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NVision to Host Webinar on Reverse Engineering

(September 22, 2009) - NVision Inc., a leader in 3D non-contact optical scanning for over 19 years, will host a Webinar on reverse engineering. The hour-long event will take place on Wednesday, September 30, 2009. Those wishing to attend this Webinar can sign up at http://webinars.qualitymag.com.

About the Webinar:

Today’s optical scanning technologies offer manufacturers unheard-of levels of accuracy and speed in reverse engineering and inspection of parts and assemblies - regardless of their size, geometric complexity or surface finish. Many of those who could benefit from optical scanning are often not aware of the latest technological advancements and their potential for significantly reducing production time and costs – key competitive factors in today’s tough economic environment. This Webinar will show attendees how NVision’s cutting-edge scanning technology can not only produce a higher-quality product – but do it while significantly shaving costs and time-to-market.

Attendees will find out how:

• Soft Air USA®, Inc. reduced the time to market for its replica guns by four weeks.
• A major turbine manufacturer reduced inspection time by 83%.
• The Air Force reduced simulated jet ejector seats costs by 75%.
• and many other real-world examples.

The scanning technologies to be discussed include:

• The MAXOS, a new system that uses a concentrated light to make measurements rather than a touch probe, which allows users to measure complex geometry - even if it has a shiny surface - without the need for spraying. The MAXOS is also unaffected by the limitations of ball radius compensation from which traditional CMMs suffer. It can measure radii down to 0.1 mm with an accuracy of +/- 2 microns.

• The MobileScan, a laser system that is automatically controlled to follow a pre-defined measurement strategy. This means that the scanner can be left alone to scan production items without the constant attention that is required by a handheld device. MobileScan connects easily to a standard notebook computer via USB or Firewire and comes integrated with computer-aided inspection software that automatically processes scan data from a physical part to generate highly accurate polygon and parametric surface models.

• The HandHeld scanner, a powerful portable scanning device that captures 3D geometry. The scanner is attached to a mechanical arm that moves about the object, freeing the user to capture data rapidly and with high resolution. An optional tripod provides complete portability in the field. Intuitive software allows full model editing, polygon reduction, and data output to all standard 3D packages.

Go to http://webinars.qualitymag.com to sign up for this event, or contact NVision, Inc. for more information: Ph: 972.393.8000, E-mail: sales@nvision3d.com, Web site: http://www.nvision3d.com.


About NVision
NVision, Inc. (www.nvision3d.com) was established in 1990 with one goal in mind: to provide customers with the highest accuracy non-contact optical measurement systems and services for Reverse Engineering and Inspection. Focusing our expertise on the aerospace, power generation, and oil/gas industries, NVision provides both contract scanning services and systems sales to companies throughout North America. Our elite team of engineers provides customers with an unmatchable level of experience and is able to advise and assist with the most difficult engineering challenges.

NVision’s clients include industry leaders such as Alstom, Boeing, GE, Lockheed, Lear, NASA, Porsche, Raytheon, Siemens, Toyota, and every branch of the U.S. military.

NVision Scanner Ensures Accuracy of Crash Dummies Used to Check Rollover Performance

(August 6, 2009) -- First Technology Safety Systems, Inc. (FTSS) uses the NVision HandHeld laser scanner to ensure the accuracy of crash dummies, which are crucial in evaluating the performance of side curtain airbags in a rollover. FTSS is the world's leading provider of crash test dummies and computer crash simulation models for automotive, military and aerospace applications.

The need for scanning arose when a mathematical formula was developed to define the geometry of a dummy, which, like many others, was originally based on a physical mold. “Crash dummies have been developed over the years largely as physical molds,” said FTSS Engineer Steve Goldner. “The geometry of the dummy has a major impact on crash test results but it has become essential to convert the original designs to mathematical models in order to enable improvements in manufacturing technology. It also helps avoid damage to the original mold.”

FTSS engineers designed a new dummy based on the mathematical model. Since physical measurement methods could not provide the level of accuracy needed to confirm that the new design matched dummies built from the original mold, they used laser scanning to measure the new dummy. FTSS selected the NVision HandHeld scanner for this task because of its wide-stripe laser, speed, accuracy, and ease of use. The scan data is quickly converted to an STL file, which can be easily compared to a computer aided design (CAD) model.

A key advantage of the HandHeld Scanner is that it is mounted on a mechanical arm so it can move freely around parts of any size. The mechanical arm keeps track of the scanner’s location so all data is collected within the same coordinate system. As FTSS technicians scanned the dummy, the scanner generated a point cloud consisting of the coordinates of individual points. FTSS technicians used integrated software that comes with the scanner to convert the point cloud to an STL polygon mesh. Reverse engineering software then converted the STL data to a surface model. Then they overlaid both the scanned model and the CAD geometry based on the mathematical formula to see how closely they matched.

They used this process to fine-tune the mathematical formulae until they were able to create a new dummy and confirm it exactly reproduced the original mold designs. To date, FTSS has reverse-engineered between 30 and 40 dummies with the NVision HandHeld scanner. This process ensures that current test dummies are consistent with those used in the past, which in turn ensures the accuracy of the crash tests that are used to evaluate automobile safety.

For more information, contact NVision, Inc., 440 Wrangler Dr., Suite 200, Coppell TX 75019. Ph: 972.393.8000, Fax: 972.393.8002. E-mail: sales@nvision3d.com. Visit NVision's Web site at www.nvision3d.com.

ComScan - The Next Generation CMM - Reduces Inspection Times by a Factor of 6

BATAVIA, Ill.--Gaspardo & Associates announces the launch of the ComScan system capable of reducing 3D inspection times by a factor of 5 to 10X. Using a patented semi-spherical gantry, the ComScan system is able to quickly move a 3D scanner and part to be scanned to provide high-speed high resolution automated 3D data collection.

Today, in order to ensure final product quality, many manufacturing plants must inspect the dimensional quality of the components before they go into higher-value assemblies. Dimensional inspection occurs every time a line is restarted or the tooling is changed, and on a sub-sampled set of full production parts. Case studies have shown that on a cylinder head, a CMM can take up to 90 minutes to complete a scan and with the ComScan system this is < 15 minutes.

“The Gaspardo team has designed an excellent product to meet the growing needs of North American manufacturers for 3D scanning automation to better exploit the benefits of white-light scanning technology such as the Steinbichler COMET. The overall package will provide our customers with improved repeatability and less need for user intervention for quality inspection and other critical 3D scanning needs.” Robert Bell, President of Applied Precision, North American Distributor for Steinbichler 3D digitizing systems.

To see this ComScan system in action, come by Gaspardo & Associates’ booth # 706 at CMSC 2009, the Coordinate Metrology Systems Conference, July 21st to 24th in Louisville KY or go to http://www.youtube.com/watch?v=sEpZxaVFXxQ.

About Gaspardo & Associates: Since its founding in 1996, Gaspardo & Associates has been offering 3D metrology services to North American manufacturers for high accuracy computer aided measurement, inspection, verification and reverse engineering. After recognizing the potential for automation, Gaspardo and Associates started developing the ComScan system. The ComScan system is destined to impact the CMM market much like CAD systems made the drafting machine obsolete.

About Applied Precision: Established in 1999, Applied Precision is a leading provider of 3D digitizing systems and services for new product development, quality inspection and CAD updating solutions to numerous manufacturing industries across North America. These include automotive, recreational products, aerospace, medical device, power generation and various consumer products manufacturers. Applied Precision Inc. is ISO9001:2000 Certified with a proven commitment to quality in all aspects of its systems & services businesses, including technical support & training programs.

PTB develops micro and nano coordinate measuring instrument for 3D objects

From the motion sensor to the computer chip - in many products of daily life components are used whose functioning is based on smallest structures of the size of thousandths - or even millionths - of millimetres. These micro and nano structures must be manufactured and assembled with the highest precision so that in the end, the overall system will function smoothly. Thereby, details are important - and therefore scientists at the Physikalisch-Technische Bundesanstalt (PTB) have developed a metrological scanning probe microscope into a micro and nano coordinate measuring instrument. This now allows dimensional quantities with nanometer resolution also to be measured on three-dimensional objects in an extraordinarily large measurement range of 25 mm x 25 mm x 5 mm. The new device is already extensively being used at PTB - to a large part for calibration orders from industry and research.

The micro probe used in the micro-nano CMM measures the form and the spacing of two reference spheres with diameters of two millimetres each. The figure shows a survey of the system and the proportions of measuring probe and measurement object in detail.

Often, such small dimensions can be grasped only when they are transferred to everyday life. If we assume, for example, that someone lost a cube of sugar within an area of 25 square kilometres - the new micro and nano coordinate measuring instrument would not only be able to find it, but it would also be able to determine its exact position and shape. This does not only apply to plane surfaces, but also to three-dimensional landscapes, for example if the cube of sugar were stuck to a steep wall.

As increasingly, components with structures in the micro- and nanometer range are being used in industry, dimensional metrology on such structures is becoming increasingly important. To meet the increasing requirements for 3D measurements of micro and nano structures, 3D measuring probes newly developed at PTB were incorporated in a metrological scanning probe microscope based on a commercial nano-positioning system with integrated laser displacement sensors of the company SIOS Messtechnik GmbH. The new functionalities given by the measuring probe and the software extend the scanning probe microscope to a metrological micro/nano coordinate measuring machine (CMM) which also allows 3D measurements conforming to standards to be performed on micro and nano structures.

International intercomparisons on step-height standards and lattice structures have shown that the measuring system is worldwide one of the most precise of its kind. For step heights, measurement uncertainties in the subnanometer range - and for measurements of the mean structure spacing on extensive lattice standards even in the range of 10 picometers - have been achieved and confirmed in comparison with optical diffraction measurements.

The new measuring instrument is available for dimensional precision measurements with nm resolution on 3D micro and nano structures such as micro gears, micro balls, hardness indenters and nano lattice standards as well as for comparisons of measures; moreover, it serves as a platform for research and development tasks. It is an important link between nano, micro and macro coordinate metrology.

Source: PTB

With laser scan, Mount Rushmore to get virtual tours

MOUNT RUSHMORE -- Mount Rushmore National Memorial is set to get a three-dimensional digital recording, park officials announced Friday.

Laser scans by a partnership will give the National Park Service the ability to develop a digital model for virtual tours of the memorial and its entire park site, memorial superintendent Gerard Baker said.

"We're going to open it up so the citizens of America and the world can see things they've never seen before," Baker said.

CyArk, a U.S.-based nonprofit organization that scans historic cultural sites with the cutting-edge laser technology, will conduct the scanning with the cooperation of several local firms and the Scottish Ministry of Culture. The project will start sometime in late September and wrap up in two weeks.

Wyss Associates in Rapid City and the South Dakota School of Mines & Technology are partners in the scanning effort.

The laser scanning technology has being used to scan and digitally record five historic cultural sites in Scotland, and that country will assist with the scanning of five cultural heritage sites worldwide, starting with Mount Rushmore. The site is one of 500 sites CyArk hopes to scan and preserve a digital record. The company has already digitally preserved two dozen sites around the world, including places in Italy, Egypt, Cambodia and Mexico.

The virtual tours of Mount Rushmore and the surrounding grounds could serve as a way for tourists to view the sites in what Scottish Culture Minister Michael Russell called a "Star-Trekkie" way.

"In those circumstances, you can take some pressure off the places themselves," he said.

The scanning project will provide a three-dimensional digital model capable of re-creating sculpted surfaces with an accuracy of less than 1 centimeter. Both ground and air-based radars will scan the grounds.

"We're hoping we can put the monument and the structures here in the context of the overall park," Ben Kacyra of CyArk said.

The completed scanning data also will be stored in the Hall of Records for posterity and help explain the carving project to future civilizations. The electronic model also could provide guidance, in the event of damage to the sculpture, to replicate carved surfaces.

The Leica Absolute Tracker is now equipped with PowerLock

This vision technology automatically locks onto any moving target without user intervention. Current laser tracker technology requires that the operator pays careful attention that the laser beam between the tracker and the target is not interrupted. Catching the beam requires the operator to find the laser beam, and then physically pass the target through the beam before the tracker can start measuring again. According to some customers this process interruption can account for up to 20% of their total measurement time.

PowerLock prevents from such interruptions. By utilizing a vision system built into the Leica Absolute Tracker the sensor can now determine where a target is without the need for the laser beam to be locked on. The Leica Absolute Tracker locks on to the target automatically as soon as it is within view of the sensor. This allows the operator to focus on the part they need to measure without constantly worrying about the laser tracker and whether or not they have broken the beam. PowerLock works with all standard reflectors and all Leica T-Products.

The PowerLock technology will be released to the market in summer 2009. Any Leica Absolute Tracker purchased from today on will be upgraded to this functionality free of charge at release. All Leica Absolute Trackers in the market will be able to be upgraded to this technology for a small charge in a local Hexagon Metrology service center.

Video: http://metrology.leica-geosystems.com/en/Downloads_6843.htm?cid=6393

Leica Geosystems Metrology Products

Whether building the fastest car, the biggest plane, or the most precise tooling, you need exact measurements to improve quality and productivity. So when it has to be right, professionals trust Leica Geosystems Metrology to help collect, analyze, and present 3-dimensional (3D) data for industrial measurement. Leica Geosystems Metrology is best known for its broad array of control and industrial measurement products including laser trackers, Local Positioning Technology (LPT) based systems, hand-held scanners, 3D software and high-precision total stations. Those who use Leica Geosystems Metrology products every day trust them for their dependability, the value they deliver, and the world-class service & support that’s second to none.

Precision, reliability and service from Leica Geosystems Metrology.

Hexagon Metrology

Hexagon Metrology is part of the Hexagon AB Group and includes leading metrology brands such as Brown & Sharpe, CE Johansson, CimCore, CogniTens, DEA, Leica Geosystems (Metrology Division), Leitz, m&h Inprocess Messtechnik, PC-DMIS, QUINDOS, ROMER, Sheffield, Standard Gage and TESA. Hexagon Metrology brands represent an unrivaled global installed base of millions of Coordinate Measuring Machines (CMMs), portable measuring systems and handheld instruments, and tens of thousands of metrology software licenses. Hexagon Metrology empowers its customers to fully control manufacturing processes that rely on dimensional precision, ensuring that products manufactured precisely conform to the original product design. The company offering of machines, systems and software is complemented by a wide range of product support, aftermarket and value-added services.

Laser 3D Scanning Technology Widely Used for Military Defense Contract Inspection

From the Space Shuttle to high tech military jets, 3D laser scanning inspection has reached every level of military defense contract inspection. A few years ago, laser technology was instituted to scan the Space Shuttle for potential errors and flaws, allowing difficult-to-inspect areas to be accurately measured and compiled for analysis.

Since then, 3D laser scanning technology has been implemented in all levels of military defense inspection, allowing accurate measurements in a 3 dimensional form that eliminates all guess work by presenting the data as it is accurately depicted. This allows equipment, parts and tools to be accurately measured and compared to as-designed CAD models, allowing flaws to be instantly identified so they can be repaired.

The accuracy and precision that military technology requires demands that the laser scanning and contract inspection company be ITAR certified. Without that certification, there’s no guarantee the inspection will meet the rigorous demands of military applications. (This was the paragraph added to put in the requirements they wanted)

When implemented for contract inspection, laser technology improves the safety, reliability, and useful life of high valued equipment where lives may indeed be at stake. It provides the accurate data necessary in the field of defense, leaving no room for guess work by projecting data that accurately fits the status of the equipment being scanned.

What’s ideal about the new developments in 3d laser scanning technology is its increasing portability, allowing the equipment to be taken anywhere so that equipment can be checked in the field. Installments of any size can be scanned, from a Humvee to a fighter jet, right there in the field. This allows for the kind of detailed-specific quality inspection that’s so essential when lives are at stake.

Laser scanning scans the equipment as is, not just how it’s designed to be. This helps identify flaws to be fixed before they become a problem where lives are put on the line.

Laser technology can even be used to accurately access the hulls of ships while still in the water, no matter how big. Ship hulls can involve complicated geometric shapes, especially when they involve the complexity and scope of military design. 3D laser scanning produces an exact model of the ship’s hull while still in the water, identifying any flaws or weakness for potential repair.

The safety an accuracy of military infrastructure has been greatly improved through the development of laser technology when used for product inspection, improving the safety of the equipment as well as the lives of the personnel who operate them.

Renishaw launches CMM retrofit service

Renishaw announced a series of major new initiatives at Control 2009, including its first CMM retrofit service, and MODUS™ its first metrology software. There was also strong interest in a new probe that allows surface finish inspection within a standard CMM programme, plus the latest linear magnetic encoder technology and a new true absolute optical encoder for rotary and linear applications.

There was a very positive reaction to the new products and services, with many visitors especially pleased that Renishaw is now able to offer a complete CMM measurement package for the first time.

Cost-effective CMM upgrades

The Control show took place from 5th to 8th May in Stuttgart, Germany, and Renishaw's key message was aimed at manufacturers who are suffering from inspection bottlenecks that tie up staff and expensive machines whilst waiting for vital measurement results.

Vistors to the stand saw examples of cost-effective CMM retrofits carried out by Renishaw on a DEA Mistral and Tesa CMM, illustrating the huge productivity gains that can be made by upgrading existing machines. Engineers at the Renishaw stand gave advice about retrofitting a CMM and many visitors, including those with old CMMs, were surprised at the results that can be achieved with a retrofit carried out by a company with expertise in all relevant technologies.

A Renishaw CMM retrofit is available for all budgets and applications, from touch trigger probing and 3-axis scanning, through to the latest ultra-fast REVO® 5-axis measurement system. The company offers a 'one-stop shop' upgrade solution, from its new MODUS metrology software and universal CMM controller, through to sensors and machine calibration.

New surface finish probe

Also demonstrated at Control 2009 was a new probe option for Renishaw's revolutionary REVO® five-axis measurement system, which for the first time, allows surface finish inspection to be fully integrated with CMM measurement routines.

With a measurement capability of 6.3 to 0.05 Ra, the SFP1 surface finish probe provides a unique single platform capability that will eliminate the need for hand-held sensors, or the necessity to move parts to costly dedicated measuring machines, reducing labour costs and inspection lead times.

As a fully integrated option for the REVO 5-axis measurement system, users of the SFP1 surface finish probe will benefit from a range of powerful features including infinite rotational adjustment that will allow the probe to be orientated to allow the measurement of a surface at any angle.

True absolute optical encoder

There was also strong interest in Renishaw’s true absolute optical encoder system that has excellent dirt immunity, and an impressive specification that breaks new ground in position feedback. RESOLUTE™ is the world’s first absolute encoder capable of 27-bit resolution at 36,000 rpm, giving an astonishing market-leading resolution of just 1 nanometre at 100 m/s for both linear and angle encoder applications. Large set-up tolerances enable easy installation and high reliability, whilst low jitter and SDE (Sub-Divisional Error) meet the demands of high precision stages.

Also shown was TONiC™, a new super-compact optical encoder, offering speeds up to 10 m/s and resolutions down to 5 nm for both linear and rotary applications.

http://www.renishaw.com/

Supersizing opens doors for Kristek

Less than a week after installing an ‘extra large’ XYZ CNC lathe Kristek Precision Ltd secured an ongoing order for large stainless steel seal rings which could not have been made on its existing machines.

The investment in the XYZ XL1500 ‘extra large’ CNC lathe – a 50hp/1500 mm swing over bed lathe equipped with Siemens 840D ShopTurn conversational control – highlights the Melksham subcontractor’s progression to larger, more complex machining. It is also in sharp contrast to the ISO 9001-accredited company’s beginnings, when the original 2000 sq. ft. workshop housed various small manual lathes, turret mills, capstan lathes and pillar drills.

Prior to establishing KPL in 1987, the directors had minimal experience of CNC machining. However, as the business grew year on year, with KPL demonstrating its expertise in the machining of prototypes and small to medium batches to tight tolerances and a high standard, the company began to invest in CNC turning machines, machining centres and CADCAM software.

Today the company’s 15-strong team provides a ‘one stop’ machining service, supplying precision CNC machined components to customers in a wide range of industries, including power generation, automotive testing, and oil and gas. Any additional requirements such as plating, painting and heat treatment are project managed by KPL, the primary objective being to deliver consistent high quality work at competitive prices.

“We are a skills-based company,” says Kelvin Stone, Director, “and this, in combination with a comprehensive range of CNC machine tools, means we are very flexible. We can CNC turn components up to 1500 mm diameter by 1000 mm long and CNC mill up to 2000 mm by 750 mm by 700 mm in most materials. These materials include plastics as well as ferrous and non-ferrous metals, with particular emphasis on difficult-to-machine materials such as stainless steels, titanium, Inconel and Hastelloy.”

KPL already had two large facing lathes, but machining of the 1350 mm OD stainless steel seal rings has been allocated to the new XL 1500 because the machine is more efficient and provides pinpoint accuracy. The machining sequence involves skimming the front face and machining several grooves, then machining the bore some five thou under size to allow for expansion and parting-off through to a depth of up to 30 mm.

The key dimensions of the machined ring are checked in situ using a portable co-ordinate measuring arm before parting-off takes place. This is the final stage of the machining sequence, as parting-off provides a finish machined rear face to the component, eliminating the need for a second machining set-up. However, because of the unpredictability of the expansion of the machined component, off-machine inspection is used to confirm the crucial bore/outside measurements of the first-off and any program adjustment, if required, is then made on the XL 1500 CNC lathe prior to machining successive components. The final 100 percent inspection of the machined component is then carried out on a large co-ordinate measuring machine.

As for new opportunities resulting from its installation, a company in Edinburgh already using KPL for large milling work has decided that the Melksham subcontractor should now take on its large turning work as well.

http://www.kristek.co.uk/

KREON TECHNOLOGIES announces new partnership in the USA

KREON TECHNOLOGIES, the French specialist in 3D scanning solutions for reverse engineering and quality control applications announces the creation of a new partnership, with GoMeasure3d, for the distribution of its products in North America

A strategic alliance

KREON TECHNOLOGIES is pleased to announce its new partnership with GoMeasure 3D, an American company specializing in sales of 3D measurement solutions for reverse engineering and quality control. For KREON, this is the opportunity to develop its activity in the US market and to have a local intermediary. " This agreement will enable us to provide the American market with our products in addition to a local customer service, which is one of KREON main values" explains Thierry Rebillard, the manager of KREON TECHNOLOGIES. GoMeasure 3D will provide the Northern American market with the overall KREON range of laser scanners. "This partnership will bring options of precision nerver before available in this market at such an affordable price" declares Darryl Motley, CEO of GoMeasure 3D.

Today, KREON presents a wide range of scanning solutions designed to address specific challenges in non contact measurement so as to meet the largest number of customers' needs. "The advantage are the high quality for the price and the range of options for the customer available in the KREON line. We believe we will be able to provide the highest quality portable CMM an laser solutions to industry" says Darryl Motley.

About GoMeasure 3D

GoMeasure 3D has been in the digitizing, reverse engineering and inspection business for over a decade. It provides measurement solutions for an array of customers including manufacturing engineers, graphic artists, the medical field, universities and more. The company is famous for supplying the customer with a complete solution of hardware, software and training that allows them to simplify their tasks and to increase productivity as well. "The experience of GoMeasure 3D in the 3D measurement solutions field is very important for KREON. That is why we are very confident in working with them" explains Thierry Rebillard. Regarding his new KREON distributor status, Darryl Motley declares "we chose to work with KREON because of its excellent reputation in the worldwide marketplace and we wanted to bring those quality products to the US market. KREON will give us the tools we need to make our customers successful".

To know more about GoMeasure 3D, email at info@gomeasure3d.com

www.gomeasure3d.com

Hexagon Metrology Ships CMM Arm-Scanner System

NORTH KINGSTOWN, RI - Hexagon Metrology, Inc, announces the immediate availability of a combination laser scanning metrology package, which combines a Brown & Sharpe Global Performance bridge CMM with a ROMER INFINITE 2.0 7-axis portable arm with a ScanShark V4ix laser scanner that is plug-and-play swappable between both systems. The key to the inter-compatibility is the TESA kinematic joint that is shared between all ROMER scanning arms and TESASTAR-m equipped bridge machines. Companies can invest in a single scanner that can be leveraged to the strengths of two different types of measuring platforms.

“This package leverages several existing Hexagon brands and technologies into one complete package offering,” said Eric Bennett, Product Manager for bridge products. “There are definitely times when scanning with an arm is the fastest and most effective technique, for example, when the part is large and must be measured in place. Conversely, if you have lots of smaller identical products you would like to scan repeatedly, then it is useful to set up a program to scan batches of them automatically. With this package, you don’t have to choose between one or the other.”

Dave Armstrong, Product Manager for portable products, added, “There was a time when the substantial investment in a laser scanner meant it came down to buying either the bridge machine or the arm. With our offering, you don’t have to choose, you can have both. Other systems where the scanner is integrated or the connectors are incompatible simply don’t have this flexibility.”

Shared systems can do double duty as inspection systems as well as performing reverse engineering and 3D point cloud gathering tasks Either machine is also capable of performing point-to-point inspection on its own without the scanner being attached, so both machines can be used simultaneously, regardless of which one happens to be using the laser scanner.

A shared scanner package comes complete with a Brown & Sharpe Global Performance bridge CMM (there are nine standard sizes available), a ROMER INFINITE 2.0 7-axis arm (there are six standard sizes available), a ScanShark V4ix probe, complete cabling, software and control boxes for each system, plus application software and a computer for each system. The packages are available for immediate shipment.

About Hexagon Metrology

Hexagon Metrology is part of the Hexagon AB Group and includes leading metrology brands such as Brown & Sharpe, CE Johansson, CimCore, CogniTens, DEA, Leica Geosystems (Metrology Division), Leitz, m&h, PC-DMIS, QUINDOS, ROMER, Sheffield and TESA. Hexagon Metrology brands represent an unrivaled global installed base of millions of CMMs, portable measuring systems and handheld instruments, and tens of thousands of metrology software licenses. Hexagon Metrology empowers its customers to fully control manufacturing processes that rely on dimensional precision, ensuring that products manufactured precisely conform to the original product design. The company offering of machines, systems and software is complemented by a wide range of product support, aftermarket and value-added services.

For more information, visit http://www.hexagonmetrology.us/

Body Geometry Verification at Volvo Speeded Up Using Metris Scanner

The innovative Metris Cross Scanner is used at Volvo Cars Gent to further accelerate the design-through-manufacturing process for its brand new Volvo XC60 crossover vehicle. By digitising physical sheet metal and plastic body parts and virtually assembling vehicle bodies in software, Volvo engineers completed pre-production geometry verification nearly twice as fast. 3D laser scanning technology, point cloud processing and virtual assembly shortened physical evaluation of prototypes and eliminates the need for costly specialised verification tooling.

Body assembly on the critical vehicle development path

Volvo Cars built up a solid reputation in terms of vehicle safety, environment and design. Recently, the Swedish car maker released the brand new Volvo XC60, which currently stirs up the new crossover vehicle segment. The vehicle body of this innovative car required the coordination of many different groups to design and manufacture. Sheet metal stamping and welding in combination with the use of new materials and joining technologies set ever-tougher geometric challenges. Process and product tolerances, as well as material and equipment behaviour, can influence body geometry, when shifting from vehicle body CAD model to physical nominal model and finally to serial-produced car. The position of edges, holes and other geometric features plays an essential role in correctly assembling the different body parts of a passenger vehicle.

In 2005, Belgium-based Volvo Cars Gent and Metris (Leuven) participated in a project that aimed to streamline the pre-production phases by simplifying the geometric body verification process. Both companies joined forces to develop a new geometric verification method for vehicle bodies, which builds on a digital inspection process using 3D scanning and virtual assembly. This method provides better insight and effectiveness compared to traditional body tuning, which involves extensive tactile inspection, physical part conflict analysis and complex verification tooling.

Ground-breaking 3D cross laser scanner technology
In close collaboration with Volvo Cars, Metris optimised its existing cross scanner to match the performance level required to drive the new geometric verification method. “We jointly integrated the laser scanner for use on horizontal-arm CMMs, and increased the scanner’s field-of-view depth. The increased scanning standoff distance range offers higher measuring flexibility and better access to clamped body components. The cross scanner incorporates three laser beam/digital camera sets, each shifted 120 degrees in position. This allows the laser scanner to capture slots, sleeves, holes and other features in a single scan. Although inherently designed for scanning geometric features, the cross scanner is also suitable for digitising 3D surfaces and edges. The positions of features and edges are imperative to correctly mate parts and assemble car bodies.

The development work also impacted laser optics technology and digital data processing. The cross scanner design has been enhanced to flexibly deal with all material types and colors without the use of spray. Now, reflective sheet metal as well as painted surfaces can be captured quickly and reliably. Laser scanning generates point cloud data at high scan rates, which by far outperform tactile point-by-point acquisition technology. Furthermore, it is much easier to define the linear and polygon scanner travel paths than to specify individual touch sensor points for a tactile inspection job.

Faster and better Volvo XC60 body geometry verification
In the pre-production stage at Volvo Cars, metrology engineers scan sheet metal and castings (steel and aluminum) as well as composite and plastic body parts. After acquiring data at approximately 20 micron accuracy, they filter the resulting point cloud, and analyse geometry against nominal CAD data. Volvo Cars relies on digital graphic reports to evaluate the parts, and streamline supplier interaction with regards to adjusting moulding and stamping equipment. Digital component verification only requires standard holding fixtures, whereas traditional inspection methods demand costly dedicated positioning and fixation tooling.

After digitising individual parts, engineers align and virtually assemble sheet metal, interior, exterior and chassis components in software in order to build a complete virtual vehicle body. Even before body parts are physically assembled, the new geometric verification approach gives already information about potential part fitting issues. To run specialised investigations, virtual body assembly models are loaded into dedicated software for reverse engineering, variation analysis, and spring-back prediction, for example. Analysis between scanned and numerical vehicle body models enables us to efficiently tune component geometry to fall within the assembly processing window.

Verifying surfaces and features using handheld laser scanners
The collaboration project with Volvo Cars also contributed to the development of K-Scan, a handheld laser scanner with a single laser stripe for in-situ inspection. An optical CMM continuously tracks the scanner so that the operator can freely walk around and take scans in an area that spans an entire vehicle. Volvo engineers use K-Scan to verify flush & gap, body deformation and static/dynamic geometry on prototype or early production vehicles. Colour-coded visual inspection reports illustrate how flush and gap evolves along complete spines in between hood and front fender, for example. Optical handheld verification also includes special cases where manual methods fall short, such as zero gaps, or in case an urgent issue comes up that needs fast troubleshooting.

In summary, the new process reduces times for matching loops, and realizes an important cost reduction for test materials and screwed body, nominal blue bucks and dedicated fixtures. Virtual verification on the basis of 3D scanning is a major step forward. This project received the Henry Ford Technology Award in Detroit. 3D scanning covers reverse engineering of clay models, virtual geometry verification of vehicle body structures, and geometric feedback data collection on finished cars.

Reduction in number of geometry iteration loops When preparing production rollout for the Volvo C30 in 2006, the virtual body geometry method has been applied and evaluated for the first time. In parallel, traditional tactile verification methods were performed to set benchmarks in terms of inspection precision and throughput. When ramping up Volvo XC60 production in 2008, it was actually managed to reduce geometry iteration loops and the lead-time of individual loops. Fewer physical evaluation prototypes also reduce material scrap and decreases expenditure of complex verification tooling, such as body-in-white cubing.

3D scanning technologies are already well accepted at Volvo Cars where they are used in different stages of the car manufacturing process. Non-contact metrology is systematically applied in the early design stages when engineering styling by digitising clay models. In pre-production, engineering intensively digitises body parts and body-in-white structures to optimize part manufacturing and assembly. After kicking off serial production, specific aspects of car components or full cars are scanned to serve as SPC samples for quality monitoring and product audit purposes. For the future, an important role for laser scanning is seen as a key enabler of in-line quality control.

Hexagon Metrology Unveils Leica T-Scan TS50A Laser Scanner

NORTH KINGSTOWN, RI, - Hexagon Metrology, Inc. announces the new Leica T-Scan TS50-A hand-held laser scanner, which interfaces with the Leica Absolute Tracker. The new Leica T-Scan delivers improvements that result in a doubling of the data acquisition rate, a fifty percent improvement in scanned point density, and scanner accuracy improved by a third. Together, these changes deliver 6DoF laser scanning performance that makes contact-free measuring faster, more accurate, and more efficient.

The core of the product improvements lie with the unit’s laser and optics system, which result not only in greater scanner accuracy, but also improved data quality, with a reduction in system noise, and an improved ability to scan all types of surfaces, particularly ones that are shiny or dark, under all lighting conditions. The scanner is capable of self-adjustment to lighting conditions, independent of the operator. Combined with the Leica Absolute Tracker system, the new T-Scan has improved system specifications of up to 25%.

“The TS50A is the third generation T-Scan unit, and offers great improvements with absolutely no compromises,” said David Armstrong, product manager, portable products for Hexagon Metrology, Inc. “The increased sampling speed will be of particular interest for the T-Scan’s core applications of digitizing and inspecting very large objects, such as aircraft or portions of aircraft, and the large blades for wind turbines. With usable scanning volumes of 59 feet (medium range system) or 98 feet (long range system) from the base unit, it really is an unbeatable solution for large volume 3D scanning.”

Ergonomic handling, robust design for shop floor and even outdoor environments, and improved accuracy specifications make the T-Scan TS50 scanner an ideal solution for automotive, aerospace, wind power, shipbuilding, defense and heavy equipment applications. The T-Scan TS50a is available for immediate shipment with Leica Absolute Trackers.

About Leica Geosystems Metrology Products

Whether building the fastest car, the biggest plane, or the most precise tooling, you need exact measurements to improve quality and productivity. So when it has to be right, professionals trust Leica Geosystems Metrology to help collect, analyze, and present 3-dimensional (3D) data for industrial measurement. Leica Geosystems Metrology is best known for its broad array of control and industrial measurement products including laser trackers, Local Positioning Technology (LPT) based systems, hand-held scanners, 3D software and high-precision total stations. Those who use Leica Geosystems Metrology products every day trust them for their dependability, the value they deliver, and the world-class service and support that is second to none. Precision, reliability and service from Leica Geosystems Metrology.

About Hexagon Metrology

Hexagon Metrology serves the high precision measurement and inspection needs of worldwide manufacturers with its extensive line of metrology hardware, software, accessories, and customer services. The company's name-brand portfolio of quality assurance products include Brown & Sharpe, CogniTens, Leica Geosystems, ROMER, Sheffield, PC-DMIS, DEA, Leitz, m&h, and TESA. Hexagon Metrology has an unrivaled installed base of more than 1.5 million handheld, stationary and portable measurement devices, and over 30,000 seats of PC-DMIS metrology software.

For more information, visit http://www.hexagonmetrology.us/

Metris rotating reflection target sets new productivity and performance standards for industrial CT

Metris releases a variant for the industrial 225kV micro-focus X-ray source featuring a rotating reflection target that drastically increases overall CT scanning performance. By establishing up to 5 times more X-ray flux, customers can either speed up data acquisition by a similar factor or increase data accuracy by taking more radiographs in the same time.

Traditional X-ray sources using fixed targets can only receive a limited flux of electrons to avoid damaging the target. By introducing a rotating reflection target that yields much better cooling performance, the electron flux on the rotating target radically increases without the risk for permanent damage. This boosts X-ray flux by a large factor, and enables customers to obtain faster CT data acquisition or achieve higher CT data accuracy in the same time span.

Fast pinpoint-sharp volumetric imaging

After becoming mainstream technology in medical CT scanning, the use of rotating targets in industrial CT scanning sets new productivity and performance standards,” comments David Bate, Product Marketing Manager of X-ray and CT solutions, “Fast pinpoint-sharp volumetric imaging often turns out to be the missing link in resolving research, troubleshooting or quality control challenges. Available factory-fit, Metris makes sure that rotating target technology is within reach of new and existing CT customers.”

Serving a broad range of industries

Metris is a worldwide metrology leader that provides a wide range of 3D scanning technologies, including X-ray and CT scanning solutions. Metris industrial CT scanners serve many industry sectors, including automotive, aerospace, pharmaceutical, medical, geology, and paleontology.

Faster and more in-depth material research

One of the first XT H 225 variants equipped with a rotating reflection target is used at ACCESS e.V. Material researchers working for this organization are associated to the renowned Rheinisch-Westfälische Technische Hochschule (RWTH) in Aachen, Germany. ACCESS material researchers use CT inspection for process optimization of metal castings or for in-situ observation of solidification experiments. Faster CT scanning and improved CT image quality are essential in economically capturing and visualizing 3D material concentrations in castings, such as silicon in automotive pistons or carbon globulites in iron castings. For the in-situ solidification experiments, the emphasis is more on high frame rates to keep up with the rapid processes of the phase formation.

Toshiba GE Turbine Components Purchases Second MAXOS Measurement System

NVision, Inc. is pleased to announce the purchase of a second MAXOS non-contact measurement system by Toshiba GE Turbine Components (TGTC). In 2008, TGTC purchased its first MAXOS, which helped the company reduce the time needed to inspect and measure turbine blades by 83%, from 280 minutes to 45 minutes. "The MAXOS provides the best possible accuracy, eliminates the need for matt coating, and easily integrates with our engineering and production processes," said Tomio Kubota, President of TGTC. "It is also significantly faster than any of the other systems we had originally considered."

TGTC is a joint venture that combines the cutting-edge production expertise of Toshiba and General Electric to produce large blades ranging from 26 to 52 inches (660 to 1320 mm) for steam turbines. The company's annual production of blades is sufficient to generate the equivalent of eight to ten gigawatts of electricity. TGTC is sited within Toshiba's Works in Yokohama, Japan and produces long blades. A turbine bucket is comprised of an airfoil and a root. The long blades built at Yokohama have mid-span geometry that provides support for the midsection of the airfoil. The complex geometry of these blades means that many cross-sections must be examined.

TGTC previously used a coordinate measuring machine (CMM) to inspect the blades but found that it was too slow and often unable to access hard-to-reach areas such as dovetail hooks and fillets. As a result, it typically took longer to inspect the blades than to make them.

The MAXOS uses a proprietary non-contact probe consisting of a concentrated light that collects individual points at a rate of 100 per second, many times faster than a CMM. Unlike laser or white light fringe scanners, the MAXOS can inspect turbine blades without having to apply a matt coating that introduces dimensional inaccuracy. The MAXOS uses five axes to reach every point on the blades and also generates specific and accurate measurements of critical areas. Resulting measurements are reported instantly and the need for additional manual inspection is eliminated.

The MAXOS provides accuracy of +/- 0.0004" and a resolution between measured points down to 0.0002" on this project. The system can be provided with a resolution as low as 0.0001". The MAXOS software is configured with an overall best fit of the measured geometry to allow a part with some error to fit within the overall tolerance envelope of the reference data. Win3DS Blade inspection software is configured to give fast results and different kinds of evaluations on mid-span, fillets, gaps and airfoils. Different best-fits are available, including Gauss and Chebyshev.

TGTC is extremely happy with the results delivered by the MAXOS and are in the process of implementing the system at their other facilities around the world.

For more information, visit www.nvision3d.com.

SOURCE: NVision, Inc.

Five Axis CMM Inspection System Halves Measurement Times

Leader in five-axis turbomachinery production quickly adopts new five-axis Renishaw inspection system, gains faster throughput, greater CMM utilization, and programming reductions from days to hours.

Constantly changing surface geometries, pin-wheeling shapes and tight, intricate features make turbomachinery components - impellers, blades and blisks - some of industry's most complex and exacting shapes. TURBOCAM International achieved leadership in this specialized field by mastery of five-axis machining and five-axis programming software. However, efficient inspection of ever increasing numbers of complex parts was frustrated by slow, tedious, stop-and-go measurement inspection on a legacy 3+2 axis coordinate measuring machine (CMM).

Early adopter of revolutionary CMM scanning technology

Changing 3-D part geometries required many different probe orientations, plus frequent stylus and tip changes for difficult to reach features, explains Dave Romaine, Quality Assurance Manager. "We would have to stop the CMM and calibrate each re-orientation of the probe. That was compounded as we inspected multiple blades around a part."

As five-axis experts, TURBOCAM staff were quick to see the potential of a revolutionary scanning system from Renishaw that makes possible automated, programmable five-axis measurement at speeds and accuracies never before possible by CMMs. The Renscan5 scanning system offered the capability for continuous five-axis interpolated motion, comparable to TURBOCAM's five-axis machine tools.

In January 2007 TURBOCAM became one of the first adopters of the new Renscan5 continuous five-axis inspection capability. Installed on a new Wenzel LH8.10.7 bridge-type CMM at the company's Dover, New Hampshire, USA plant, Renscan5 transformed part measurement and inspection from a bottleneck to an enabler.

CMM measurement times reduced by at least 50 percent

High-speed continuous probing routines are reducing programming time, set-up time and measurement time by 50 percent and more. Besides faster throughput, Renscan5 time-savings allows the taking of many more data points for greater measurement precision and frees up CMM time for qualification of turned blanks and in-process checks before final machining passes.

Those powerful advantages led TURBOCAM in early 2008 to become the first company worldwide to add a second Renscan5 CMM, a larger Wenzel LH10.12.8, this time at a new facility in nearby Barrington. In this new facility, Renscan5 is an "essential resource" says Romaine, that is being developed to support higher-throughput production generated by around-the-clock, reduced-staff manufacturing.

XSpect Solutions, now part of Wenzel, did the installation of Renscan5 on both the new CMMs.


Posted Jun 10, 2009