necsa opens up South African research opportunities with microfocus Nikon Metrology x-ray and CT system

September 6, 2011

A brand new Nikon Metrology inspection system is now in use at the microfocus X-ray radiography/tomography facility (MIXRAD) of the South African Nuclear Energy Corporation (Necsa). It is the first high-precision microfocus X-ray/CT system made available to South African researchers, engineers and students who can use this advanced technology free-of-charge. High-precision 2D radiography and 3D tomography renderings help them investigate diverse natural and industrial samples in a non-destructive fashion. With the microfocus X-ray/CT system readily available and upgraded Neutron and new Gamma radiation radiography/tomography laboratories underway, Necsa offers the edge in non-destructive inspection on micron level. These investments greatly advance research on mineral deposits in South Africa, or help motivate the application for beam time at nano-level Synchrotron facilities abroad if needed.

One system characterizing many different samples

Necsa recently took delivery of a new 225kV microfocus X-ray/CT system from Nikon Metrology. The instrument has been acquired through South Africa’s National Research Fund – Research Infrastructure Support Programme (NRF-RISP). “Our new system helps academic and industrial researchers in South Africa study mineral deposit samples and advance paleontology, archaeology, geology, biology, energy as well as numerous industrial applications including mechanical and chemical engineering,” says Frikkie de Beer, Necsa’s radiography/tomography chief scientist. “Making complementary advanced imaging methods accessible triggers more active cooperation with universities, research institutions and companies in South Africa and abroad.”

The Nikon Metrology system allows users to literally navigate through the 3D volumes of their samples. Pinpoint sharp magnified 3D volume renderings make the difference in evaluating internal surfaces, material densities and other valuable material characteristics that otherwise remain invisible. It is also possible to calculate the volumetric fraction and size distribution for any specific mineral material found in the sample.

Developing high-level research expertise

The application reach of researchers and scientists using the system is impressive. To suit different user requirements, the Nikon Metrology XT H system can be adapted to characterize samples of different size, material and weight. For future upgrade of the current system delivered to Necsa, Nikon Metrology offers the quite unique capability of the system to have the X-ray source equipped with a rotating reflection target. This X-ray source setup provides much better cooling performance, allowing increased X-ray flux to be generated in order to penetrate larger or denser samples.

Using the same electron beam, the machine can be set up to produce small focal spot sizes, such as spot sizes between 3 and 5 micron for reflection targets (as delivered to Necsa), 10 micron on rotating targets and 1 micron on transmission targets (two options considered by Necsa). This enables researchers to detect inclusions, voids or material properties in resolution of about the spot size, highlighting the machine’s versatility.

The microfocus X-ray instrument in the MIXRAD facility places South African capabilities on par with international standards,” De Beer concludes. “The South African research community benefits from this by developing high-level research expertise and changing the country’s socio-economic situation.”

A geology sample CT slice highlighting 2 types of mineral deposits (pseudo-colored), each measuring approximately 20 micron.

 

 

 

 

 

 

 

 

 

Necsa instrument scientists posing in front of the Nikon Metrology microfocus X-ray and CT inspection system. Back: Mr. Lunga Bam, Mr. Robert Nshimirimana, Mr. Evens Moraba, Mr. Jacob Radebe and Mr. Frikkie de Beer (Section Head). Front: Mr. Paul Keanly (Nikon Representative) and Mr. Kobus Hoffman.

 

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Search Your Engines: NASCAR Engineers Zoom In on Motor Problems with Powerful Microscope

August 12, 2011

Article written by Larry Greenemeier

Joe Gibbs Racing is using a powerful Nikon microscope to help solve the mystery of engine failures that have cost the team several races.

Sunday’s NASCAR race was bittersweet for Joe Gibbs Racing (JGR). After dominating the early part of the 200-lap Good Sam RV Insurance 500 at Pennsylvania’s Pocono Raceway, only one of JGR’s drivers—Kyle Busch—managed to finish in the top 10, thanks to a long rain delay and problems in the pits. Yet even more important than Busch’s second-place finish (and the 15th- and 26th-place finishes of teammates Denny Hamlin and Joey Logano, respectively) was the absence of engine problems that have plagued JGR all season.

ZOOMING IN ON THE PROBLEM: JGR engineers used a Nikon AZ100 microscope to capture and analyze images of failed rocker arms. These arms, designed to help the cars accelerate to high speeds without damaging the engine, were experiencing excessive wear and tear even though they were coated with lubricant to prevent just that type of problem.

NASCAR racers cover hundreds of kilometers at any given event at speeds at times exceeding 300 kilometers per hour. Tires, suspension and hundreds of other components must work together flawlessly to keep a driver in contention, but without an engine reliably delivering upward of 700 horsepower, that driver will struggle to keep up with the pack. Whereas many problems can be addressed in the pit area during a race, major engine failure—the result of a cracked engine block, broken valve, damaged piston or any of a dozen other causes—is not one of them. Once the race starts a “blown” engine cannot be replaced, although a problematic engine may be replaced prior to a race.

Hamlin, ranked 11th in the NASCAR standings this year going into this weekend’s race, has had to swap out engines before two of his past three races, including the Brickyard 400 in late July. JGR, which won more  Sprint Cup races last season than any other, has experienced nine engine failures so far this season prior to races. In the past two seasons, bad engines have cost the team five DNFs (did not finish). These problems put the team’s engineers on the spot to diagnose the issue and devise a solution.

With the season well past the halfway point, JGR engineers are hoping upgrades in their lab have helped them turn the corner. Foremost among the new equipment is a high-power Nikon AZ100 Multizoom microscope more likely to be used by scientists to examine biological specimens than by mechanics conducting forensic investigations of car engines and other equipment.

Following an engine failure, JGR engineers thoroughly examine the motor’s major internal components—this could be a lifter, a piston or any number of small parts. Precise engineering is crucial to performing well in NASCAR races. “This has been a particularly challenging year as no two failures have been related,” JGR Quality Control Engineer Richard Miller says.

In 2010 JGR engineers built 322 motors at $80,000 a piece. “Our target is plus or minus two horsepower at 875 horsepower, and last year we hit it every time but twice,” says Mark Bringle, JGR technical sponsor manager. “We’re getting 875 horsepower out of 358-cubic-inch motors. If you know anything about motors, that’s not supposed to happen. There’s really, really violent conditions taking place inside these motors so not only do we look at the parts before assembly, we also look at the parts under a microscope after assembly for stress, cracks and things like that.”

To provide some context, a 2012 Chevy Corvette with a 6.2-liter V-8 engine delivers about 430 horsepower. Your, ahem, “friend’s” Chrysler Town and Country V-6 minivan gets about 280 horsepower, whereas your neighbor’s four-cylinder Toyota Prius maxes out at about 135 horsepower.

JGR began using the Nikon microscope early last season to diagnose problems with their engines’ rocker arms, which are reciprocating levers that convey radial movement from the camshaft into linear movement. These arms, designed to help the cars accelerate to high speeds without damaging the engine, were experiencing excessive wear and tear even though they were coated with lubricant to prevent just that type of problem.

After being contacted by the racing team, Nikon shipped JGR an AZ100, which combines the wide-field-of-view advantages of a stereoscopic zoom microscope (from 5x to 400x) with those of a metallographic microscope typically used by materials scientists. JGR engineers used the microscope, with its high-resolution lens and the digital imaging system, to capture and analyze images of failed rocker arms. Through video conferencing and image sharing with the manufacturer of the rocker arms, it took the two groups only 90 minutes to determine that “inclusion and discoloration in the coating were responsible for the rocker arms’ damage—and that the excessive stress and heat placed on these parts were not being properly deflected,” according to Nikon.

Since then, JGR engineers have used the microscope to zoom in on other problem areas in engines, take digital snapshots and send them to parts-makers. Previously, JGR had used a crude microscope that could not take photos, which meant engineers had to describe what they were seeing to engine part–makers. Most car owners, NASCAR or otherwise, can relate to this: “That was the problem. When you’re trying to describe something to someone as abnormal, it’s very difficult a lot of times to describe,” Bringle says.

This season, the AZ100 has been instrumental in helping JGR diagnose issues related to valve-train components, among others. “We were able to very quickly identify an issue with our valve springs and with [the] coating on our valve stems,” Miller says. “As you can imagine, the quicker we can identify an issue, the quicker we can implement a corrective action internally and convey our findings to the vendor.”

JGR attributes this fast turnaround to helping the team stay in contention this year, despite its engine issues. The team’s next shot to test its progress comes at this weekend’s race in Watkins Glen, N.Y.

Visit www.scientificamerican.com to read similar articles.

Visit www.nikonmetrology.com to learn more about Nikon Metrology Microscopes.

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Philips Lighting Turnhout pushes innovation using Nikon Metrology X-ray and CT

June 1, 2011

Radiography imaging and metrology drives research, quality, productivity and a reduced ecological footprint

Philips Lighting in Turnhout, Belgium, recently took delivery of a Nikon Metrology XT V system for X-ray and computer tomography (CT) inspection. Engineers investigate electrodes and other parts of high-intensity discharge (HID) lamp prototypes, to push the boundaries of lamp performance, lifespan and ecological material usage. They inspect lamps from every angle, and repeat the inspections on the same units after extended lighting periods. Deeper insight into the progression of glass corrosion, component wear and deposit formation allows Philips Lighting to reduce extensive life testing, thus saving tremendously on energy cost.

A tradition of X-ray inspection carried forward

The Philips Lighting business division produces billions of bulbs a year. Philips Lighting kicked off X-ray inspection in 2003 to support the design-through-manufacturing process of high-intensity discharge (HID) lamps. The multinational’s division in Turnhout, Belgium, manufactures long-lasting HID lamps from 20 to 4000 Watt offering high light output and premium light quality. These innovative illumination solutions raise comfort standards in offices, public buildings and factory halls; enhance traffic safety through street lights and passenger car headlights; and add entertainment value with splashing light shows toning up rock stars’ performances.

X-ray machine

Philips lighting decided to make X-ray and CT an integral part of its internal processes.

  

HID lamp

X-ray helps Philips Lighting to successfully respond to the tight electrode requirements imposed on HID lamp engineering.

“There is no doubt that X-ray inspection presents the best strategy to study the feasibility of new technologies, assemblies and materials and maintain high production quality,” says Chris Dries from Philips Innovative Applications in Turnhout. “For this reason we decided to further increase and sharpen our non-destructive testing (NDT) capability. To select a new system, we performed a thorough evaluation involving systems from most major X-ray and CT system vendors. Ultimately, the benchmark resulted in the purchase of a Nikon Metrology XT V 160 machine. We use the new system for critical measurement tasks and automated inspection jobs whereas the older system is still suitable for visual checks.”

Getting a grip on performance-critical aspects

The ability to literally look inside HID lamps is a great asset for Philips Lighting. X-rays penetrate the lamp and subsequently hit a 13×13-inch Varian flat panel, which generates radiography images with different shades of gray depending on material and geometry. On these translucent images, all the lamp’s constituent components are displayed in their entirety. The proprietary X-ray source incorporated into the system is equipped with a 1 micron transmission target. The XT V 160 is a high-precision imaging system that recognizes hidden features as tiny as 500nm, ideal for engineers to deduce structural, dimensional and connectivity related facts.

HID lamp electrodes are performance-critical components that undergo detailed X-ray research. Chris Dries explains that electrode characteristics influence the light the lamp produces by passing an electric arc through a compact tube filled with a high-pressure mixture of gases. “We measure the size and shape of electrodes contained in lamp prototypes as well as the distance between both electrodes. Inspect-X software allows us to automatically measure the distance between the electrodes’ tip planes. X-ray helps us a great deal in studying the way electrodes’ shape and structural characteristics evolve after every so many lighting hours. This is why Philips Lighting is able to successfully respond to the tight electrode requirements imposed on HID lamp engineering.”

Philips Lighting
NDT insight allows Philips toreduce the number of prototyping rounds and downscale life test activity.

  

Philips Lighting

X-ray proves technical facts that are indispensible in stretching the performance limits of lamps.

Chris Dries mentions that submicron image resolution provides great insight into other internal lamp phenomena, such as wall corrosion, glass frit, crazes and salt and mercury fillings. The XT V 160 system also supports the reconstruction of a CT volume, generated on the basis of hundreds of X-ray images. “By navigating CT volumes, we are able to locate and investigate crazes that may develop in ceramic discharge tubes. Similarly, we change position, angle and zoom as desired to take a close look at the otherwise invisible welds connecting electrodes with their supports. High image quality and magnification make it even possible to detect minuscule cavities in salt particles, something we were unable to do in the past.”

Automation and off-line inspection

To allow engineers to focus on their research and production work, most measuring tasks are delegated to system operators. They slide a tray with an array of lamps in the X-ray and CT system and start automatic data capture. The tray is indexed from one lamp to the next in order to subject all items to the same X-ray imaging routine. “Zoom level consistency and flux normalization maximize the repeatability of X-ray imaging, generating output that is truly operator independent,” says Dries. “This offers us the possibility to reliably set up macros for X-ray jobs that can run unattended at any time.”

All acquired imaging data can be sent to an offline station that runs Inspect-X software for inspection and macro preparation purposes. Engineers analyze X-ray graphics or navigate a CT volume to drill down on a particular detail, while having all relevant numerical information available at their fingertips. They value the fact that they can easily include X-ray shots and CT sections in their engineering reports.

Philips Lighting

Nearly all Olympic Game sports stadiums use Philips high-intensity discharge (HID) lamps.

  

CDM lamp

Philips Turnhout produces HID lamps from 20 to 4000 Watt offering high light output and premium light quality.

Philips Lighting benefits from decades of experience in X-ray and CT system design, development and production that is present at Nikon Metrology. In addition to high-quality imaging, the system’s proprietary open-tube X-ray source is almost maintenance free compared with conventional closed-tube microfocus sources. Nikon Metrology is renowned for controlling all aspects of the technology, and in the unlikely case of failure, service engineers come on site and solve the problem.

A resolute choice for extended NDT

“The Nikon Metrology system is part of a strategic decision of Philips Lighting to make X-ray and CT an integral part of internal processes,” says Dries. “Angled views in highest resolution prove technical facts that are indispensible in stretching the performance limits of HID lamps. Important in this regard is studying the use of environmentally friendly materials and their impact on light, yield and reliability. With the insight gained, the number of prototyping rounds can be reduced and life test activity can be downscaled to some extent, saving both time and money. The resulting decrease in power consumption also contributes to greener economics. By extending NDT capabilities, Philips Lighting underlines its position of leading innovator and supplier of high-quality illumination solutions.”

Visit www.nikonmetrology.com for details.

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Leveraging Little Holes To Lure Additional Work

January 28, 2011

Article From: Modern Machine Shop, Derek Korn, Senior Editor
Not many contract shops can drill a 0.001-inch hole. This one can, and it uses its micro-hole-making capabilities to attract more ‘traditional’ machining work from its customers.

Intense competition has some contract machine shops searching for the elusive, profitable manufacturing niche. National Jet (LaVale, Maryland) is on a different quest.

This shop identified its niche 73 years ago. Its claim to fame is micro-drilling holes as small as 0.001 inch–one-third the diameter of a human hair. The ability to deliver metal parts needled with thousands of micro-holes has won the shop a great deal of work in the textile and medical industries because others simply couldn’t do it.

However, much of the work delivered to National Jet was pre-machined by other vendors. National Jet became the specialty shop that just added the micro-holes.

That clashed with the company’s do-it-yourself manufacturing approach. This shop manually grinds its own carbide micro-drills. It uses its own micro-drilling machines, which it previously manufactured and sold. It machines its own EDM electrode dies to match a variety of unique hole shapes. So it was fitting that the company make a concerted effort to go after the whole machining job, not just the hole-machining job.

National Jet brought in additional CNC machining equipment, including a Swiss-type lathe with air spindles and a vertical machining center with through-spindle coolant, to bolster both its general machining and micro-drilling capabilities.

The micro-drilling specialty still draws the attention, but now the company often wins the entire part-production job by selling the benefits of single-source machining—quicker delivery, reduced part handling steps and lower costs.

Chuck Condor, National Jet’s sales manager, and James Odom, general manager, shared information about the company’s approach to making micro-holes and how it parlays that talent into additional work from its customers.

How Small Is Small?

National Jet was started in 1937 by John Cupler, who was an innovator in micro-drilling technology. Some years ago, a foreign drillmaker sent him its smallest drill and asked if he could make one that small. Mr. Cupler answered by drilling a hole in that company’s drill and returning it to them.

To National Jet, 0.001- to 0.005-inch holes are small, but they are drilled on a daily basis. The company primarily uses its own spade micro-drills, which have diameter tolerance of +0.0000 to -0.0001 inch. For demonstration purposes and to give customers a sense of scale, the company will perform the “small feat” of drilling a hole in a strand of human hair.

Micro-holes are often found in parts through which liquid or gas must precisely flow. A large portion of National Jet’s business is machining spinnerettes, or extrusion dies, for the textile industry. Made from hardened 17-4 stainless steel, these circular or rectangular dies may have a single micro-hole or thousands of them.

While holes this small can only be seen under a microscope, many micro-drilling decision factors are similar to standard-sized drilling operations. When examining a new job, National Jet first must determine the most efficient means of making the hole. This largely depends on the type of part, hole shape and depth, number of holes, and lot size.

Microscope-equipped manual machines are often used for R&D projects, one-offs, small production runs or parts that require only a few micro-holes. Some of the company’s dedicated micro-drilling machines are fully manual and date back to the 1930s. Others have been retrofitted with CNC tables but retain manual drill feed. Manually feeding such small-diameter drills requires a skilled touch, and National Jet has a number of experienced micro-drillers on staff. “Our operators are actually able to ‘feel’ when a micro-drill is becoming dull,” says Mr. Condor.

Pecking routines are performed for nearly every micro-drilling operation to ensure quality surface finish and maximize drill life. Coolant or lightweight oil is used to remove material from the drill tip. According to Mr. Condor, most spade micro-drills National Jet makes have an L/D ratio of 7 to 1, while 10 to 1 is generally considered to be the maximum ratio that will still deliver tight tolerances.

Drilling a micro-hole on a curved surface requires a blind pilot hole to prevent the drill from flexing or “walking” on the part. Pilot hole micro-drills tend to be very short, having a maximum L/D ratio of 2 to 1. The company has a proprietary process for making small pilot holes on very sharp edges.

For high production runs or parts with many micro-holes, National Jet will use its CNC machining centers or lathes. The manual machines are often used to test drill new jobs before delivery to the CNC machines. The main reason for this is to determine how frequently the micro-drills should be changed during part production.

The company’s new 2215 VMC from Fadal Machining Center (Chatsworth, California) can drill holes as small as 2.5 mm using through-spindle coolant. This eliminates the need for peck drilling, because chips are flushed away from the cutting zone. Smaller-diameter drills without coolant passages can also be used on the machine. Parts are positioned using traditional edge finders or specially ground pointers.

The L32 Swiss-style lathe from Marubeni Citizen-Cincom (Allendale, New Jersey) was purchased to allow complete machining of round parts, including the drilling of the micro-holes, in one setup. The lathe has two 30,000-rpm air spindles that power the micro-drills. The air spindles are used more for small-diameter drilling accuracy rather than very high speed capability. The lathe is also equipped with a bar feeder to allow long, unattended part runs.

Mr. Condor admits many are surprised that micro-holes can be drilled at relatively low speeds. “We’ve had great success running from 500 to 3,000 rpm for a 0.005-inch hole,” says Mr. Condor. “By using a conservative feed, you don’t have to spin tens of thousands of rpms to drill micro-holes.”

How, or even if, the part can be deburred is also a big factor in how the hole will be made. Every drilling operation requires deburring to clean up the exit side of the hole. National Jet commonly hand-deburrs by lapping the part surface and then using a micro-broach to poke out the burr.

National Jet uses its small-diameter wire or ram EDM equipment for parts that would be difficult to deburr, such as small-diameter tubing, as well as non-circular holes. “We often won’t use EDM for deep holes, though, because a taper may develop towards the bottom of the hole as the electrode burns away,” says Mr. Odom.

National Jet’s EDM machines can produce holes down to 0.001-inch-diameter. Besides hole making, the micro-EDM machines are also used to remove broken drills from parts. Breakage is understandable given the very small drill diameters.

Some of the company’s EDM machines have been fitted with linear motors for fast XY table movement and also feature pallet fixturing systems to allow off-line setup and quick job change-over. The EDM machines often run unattended overnight and on weekends. The newest EDM machine has a PC-based control, which allows CAM programs originally written for the CNC machining centers to be quickly modified for use on the EDM machine.

Hole Verification

While National Jet does not measure every hole on every part, it does visually inspect every hole on a Nikon vision system. The vision system allows accurate micro-hole measurement, as well as a detailed view of a hole’s finish, which can be e-mailed to the customer for verification.
Some spinnerettes have micro-holes with critical diameter transitions that can’t be visually inspected. To check these internal profiles, National Jet injects a two-part rubber compound into the holes. After the rubber sets up, it is pulled from the holes to reveal the exact hole profile. These rubber molds can then be examined on the measuring microscope.

Single-Source Machining

National Jet’s micro-drilling capability helped carry the company through the recent manufacturing downturn. However, the company realizes that it must branch out to other industries in order to grow the business. “Our micro-drilling capability got our foot in the door of targeted industries such as telecommunications and aerospace, and it helped us secure a number of R&D projects,” says Mr. Condor. “We’re also focusing on the growing micro-machining market.”

The recent economic ebb also reaffirmed the company’s decision to go after the entire machining job. “We often were the part’s last stop; the company that just put the tiny holes in a nearly completed part,” says Mr. Odom. National Jet now makes every effort to sell customers on the advantages of single-source machining. The new CNC machining centers were purchased in support of that strategy.

It is often helpful for a niche manufacturer to be flexible enough to offer more than just its special machining process. Here are a few single-source machining benefits National Jet offers its customers.

  • Quicker delivery—Having one vendor complete the part means less shipping and handling, which translates to quicker delivery. One of the first jobs National Jet was able to bring completely in-house was a small, cylindrical carburetor part that required general turning and threading operations, as well as a critical 0.005-inch through-hole. The company had previously just added the micro-hole to the pre-machined part. National Jet proved to its customer that it could cut delivery time in half by completely machining the part on its Swiss-type lathe, and the company ended up winning the work.
  • Design change accommodation—Fast turnaround of new product designs is also vital. To that end, National Jet now stocks spinnerette blanks for its major textile customers. Because carpet manufacturers can’t wait months for new spinnerettes, the company pre-machines blanks so it can quickly add the micro-holes and any other special features in order to deliver new designs in a matter of days.
  • Better accuracy­—Dealing with a single machine shop eliminates the vendor blame game when parts are not machined to specification.
  • In addition, a vendor shop that is charged to make the overall shape might not take into consideration issues that are important in special secondary operations like micro-drilling, such as depth of cut.
  • Specialty experience—National Jet calls on its micro-drilling know-how to suggest design changes to make the manufacturing process easier and/or less expensive. “If a customer wants an especially deep micro-hole that might be difficult to drill, we might suggest drilling a larger diameter that would taper to the final hole size and minimize the micro-hole drilling depth,” says Mr. Condor.

Having a niche is nice, but specialty shops may find it helpful to maintain the versatility to handle a variety of customer needs. The ability to offer a customer more than it thought it needed, or thought it could get from a machine shop, might be the ultimate specialty.

Visit www.nikonmetrology.com to learn more about Nikon vision systems.

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Case Study: A Better Way to Inspect Engine Components

January 20, 2011

The Volkswagen (Wolfsburg, Germany) foundry in Hanover, Germany, produces more than 1.5 million cylinder heads and 1.3 million intake manifolds each year for Volkswagen, Audi and Bentley engine manufacturing. In Hanover, these aluminum engine parts are manufactured using the ‘hot box’ sand core production method.

Nonstop use of the same casting molds in the manufacture of thousands of sand core units inevitably leads to slight wear of the molds. To monitor the quality of sand core production equipment, Volkswagen quality assurance engineers regularly verify the geometry of sand core parts. They subject a predefined number of sand core samples to full 3-D geometric inspection. A coordinate measuring machine (CMM)-mounted Nikon Metrology (Brighton, MI) LC50 laser scanner scans the entire surface of the parts, capturing tens of thousands of point measurements per second.

High-Speed, Large-Part Scanning

In one second, the LC50 laser scanner captures 20,000 point locations. Source: Nikon Metrology

The Nikon Metrology LC50 laser stripe scanner was developed specifically for scanning large parts at high speed, and the complete inspection-to-reporting procedure takes about 30 minutes for most free-form parts. The interface between the laser scanner and the CMM is a five-axis Renishaw (Hoffman Estates, IL) PH10. This unit allows the laser scanner head to be positioned at different angles, providing access to difficult-to-reach surface sections.

Volkswagen metrology engineers use Nikon Metrology Focus software to define the CMM-operated path the scanner follows during the scanning procedure. Engineers either program the scan path online at the CMM or offline on the basis of the computer-aided design (CAD) representation of the part. Compared with tactile probe programming, scan path definition for a CMM-mounted laser scanner is fairly straightforward. This is because the CMM only needs to move the scanner from one point to another to perform a partial scan, following a linear or polygonal motion path. The result of a sand core scan is a cloud of millions of measured points, which represents a digital 3-D copy of the scanned surface.

After performing point cloud processing actions—such as point reduction, meshing, shading and feature detection—Volkswagen engineers align the measured sand core surface to the original CAD model. When the measured and nominal sand core shapes are aligned for best fit, an automatic comparison is run between both.

As color-coded areas indicate sections that are out of geometric tolerance, surface irregularities immediately attract attention. This enables engineers to analyze the wear of the casting molds that produce the sand cores. The information is saved as part of graphic inspection reports, which can be shared among internal and external parties.

Easing Quality Assurance

“Nikon Metrology laser scanning is very effective in evaluating the geometric quality of the entire sand core parts,” says Frank Jeltsch, metrology technician at Volkswagen in Hanover, Germany. “The sand grain surface makes it difficult to perform reliable touch probe measurements. Therefore, noncontact Nikon Metrology technology is ideally suited to support efficient and accurate quality control on sand core structures.”

The Nikon Metrology laser scanner offers measurement accuracy of approximately 20 microns, far beyond the 200-micron diameter of a sand grain.

“This digital graphic approach enables us to really capture the texture of the sand core surface and detect the slightest degree of wear to the tool that forms the sand cores,” says Jeltsch. “Now we literally see the entire shape of the part, and with part-to-CAD comparison we are able to drill down to consistently trace local geometric surface imperfections. This kind of quality assurance is an important asset in maintaining high-quality manufacturing of sand core and aluminum parts.”

Besides offering a more comprehensive level of geometric quality assurance, the laser scanner has made quality assurance more efficient. The tactile inspection process previously used delivered satisfactory results only after much work. Tactile measurements only provided geometric information for selected inspection locations, as the touch probe was unable to access all areas. Based on this partial information, serious effort was required to numerically detect surface imperfections.

Improving Production Methodology

Enlarge this picture
Color-coded areas indicate significant geometric deviations. Source: Nikon Metrology

Laser scanning also helped to establish improved sand core production methodology. After deploying Nikon Metrology laser scanning, Volkswagen quality assurance engineers identified slight bending in sand core structures that produce engine water jackets. Further investigation revealed that water jacket sand cores had the tendency to bend slightly during sand core production.

“Laser scanning results were indispensible in tracing the bending,” says Jeltsch. “And during the evaluation of potential solutions to overcome the bending, laser scanning helped us pick the solution that yielded the best results.”

The process change resulted in accurate and straight engine water jacket sand core units. “In this way, sand core prototype geometry can be optimized on the sand core level rather than on aluminum parts produced on the basis of sand cores,” says Jeltsch. “During a longer period, this avoids iteration cycles during the aluminum casting stage, translating into reduced machining scrap as well as considerable savings in terms of cost, time and effort.”

Benefits

  • The Nikon Metrology LC50 laser stripe scanner affords Volkswagen complete inspection to reporting in about 30 minutes for most free-form parts.
  • Graphic geometric deviations help Volkswagen evaluate the quality of the entire sand core surface, providing consistent monitoring of sand core production equipment.
  • In addition, the laser scanner helped Volkswagen to establish improved sand core production methodology.

    • Visit www.nikonmetrology.com for more details.

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    Integrating Ultrasonic Data Collection and Analysis with iGPS Scanning System

    January 6, 2011

    SURVICE Metrology was recently awarded a U.S. government research grant to improve upon the current methods used to measure and repair damage to composite materials associated with next-generation aircraft. The problem is that current ways of measuring and repairing damage (as a result of combat incidents, weather, or mishaps) is inadequate for composite structures and components, with measurements having to be collected manually.

    This time-consuming process is prone to human error and it also limits the detail and accuracy of the data being collected. This complicates and slows down the engineering analysis, disposition, and repair process. Identifying the exact location and extent of damage is crucial for determining the type of repair that is suitable. An accurate, portable, and automated method of collecting damage information (to include location and ultrasonic sensor data), electronically storing, and transferring the data, and subsequent damage evaluation/processing is essential to ensure that repair methods and technologies match the advancements made in material science. The goal of the proposed approach is to assemble current state-of-the-art metrology hardware with ultrasonic sensing equipment and customized software to provide an integrated data collection and processing system to meet the Navy requirements.

    The patent-pending approach to solving this problem includes integration of ultrasonic sensors and data collection with Nikon Metrology’s  iGPS laser-based metrology system. The iGPS system consists of two or more laser transmitters that can be set up on tripods, or affixed to walls in shop or work areas.  The transmitters flood the vicinity with encoded laser light, which is received by sensors on a vector bar. Through collaboration with the University of Delaware Center for Composite Materials, SURVICE is coupling the Nikon Metrology iGPS system with portable ultrasonic inspection equipment to identify the extent of nonvisible delamination within composite structure in the vicinity of otherwise-visible combat damage to automate and expedite maintenance and repair activities.

    Introduction

    SURVICE, in coordination with our team members at Nikon Metrology and the Center for Composite Materials (CCM) at the University of Delaware, proposed the development of a customized damage collection and evaluation system to meet Department of Defense (DoD) needs for streamlining aircraft maintenance activities. The system heavily leverages commercial state-of-the-art metrology (i.e., laser scanning) equipment as well as some existing and customizable SURVICE-developed 3-D visualization and manipulation software.

    SURVICE selected the use, enhancement, and extension of the Nikon Metrology iGPS large-volume metrology equipment (as seen in figure 1) as part of the solution. The iGPS system is a lightweight and portable laser-based metrology device that is ideally suited for the requirements of the research effort. By having Nikon Metrology as part of the team, SURVICE has been able to develop customized hardware adaptations to the existing commercial metrology equipment offerings.

    Figure 1:  Metris iGPS system

    The iGPS system consists of two or more laser transmitters that are set up on tripods or affixed to walls in a shop or work area. The transmitters can run on standard electric power or internal/rechargeable batteries. The transmitters flood the vicinity with encoded laser light, which is received by sensors on a “vector bar,” as seen in figures 1 and 2.  The sensor data are fed to a battery-powered belt pack and sent wirelessly to a laptop (or desktop PC), where the raw sensor data from multiple laser transmitters are triangulated and converted into spatial coordinates. The precise location of the measurement tip is updated continuously as the vector bar is moved around the subject.

    Figure 2: iGPS setup

    The iGPS system allows multiple operators to roam around a given area and collect 3-D data. The system has a range of approximately 50 meters and can collect spatial data within 100–400 μm. The iGPS system provides a constant stream of xyz coordinate data, and the user clicks a button on the vector bar (as seen in figure 1) to store the current/selected location. SURVICE proposed the integration of ultrasonic sensor technology to the standard vector bar and allowed a second data stream to be fed, collected, and stored with the corresponding spatial information. This new configuration allows the operator to seamlessly collect composite delamination and location information quickly and easily.

    Under separate but related research grants as well as internal research and development activities, SURVICE has developed custom 3-D software solutions that integrate with the iGPS system, which streamline data acquisition and subsequent analysis, including superimposing the damage onto existing CAD models, as seen in figure 3.

    Figure 3: Superposition of damage onto CAD model

    One of the SURVICE-developed tools is graphics package called Archer, which is specifically designed to visualize and manipulate large 3-D data sets (as seen in figure 4).  Archer is built upon the U.S. Army BRL-CAD suite (reference http://www.brlcad.com) and SURVICE’s proprietary IVAVIEW graphics database. The Archer “core” is freely distributable as part of the BRL-CAD package (with more than 300,000 downloads to date). The code is designed to be extensible, allowing new features to be developed and integrated to support specialized/vertical markets. This software served as the basis for modification under the subject research grant.

    Figure 4: SURVICE-developed graphics package

    Phase I research and results

    The first effort under the research grant was to integrate a selected ultrasonic sensor into the iGPS hardware configuration. Figure 5 shows design drawings developed to house the ultrasonic sensor. Unlike laboratory systems that use dual sensors in a pulse-receive mode (with one sensor transmitting on one side of the test article and another sensor receiving the signal on the opposite side of the test article), the proposed system uses a single sensor in “pulse-echo” mode, requiring the same sensor to perform both duties of signal generator as well as signal receiver, and do so from the same side of the test article.

    Figure 5: Vector bar modifications

    This design was then fabricated and integrated into prototype hardware, as seen in figure 6.

    Figure 6: Hardware prototype

    Next, the core of the existing Archer graphics package was modified and enhanced to process multiple data streams; one from the iGPS hardware and one from the ultrasonic sensor (and its associated hardware). This new software application, dubbed Sherlock (for its inspection capabilities), is seen in figure 7. In addition to storing ultrasonic measurement information as metadata to 3-D data points, the software uses heuristics about the data being collected to automatically assign damage into associated groups (based upon aspects such as point proximity, time, etc.), allowing data to be collected with minimal user interaction with the computer.

    Figure 7: Sherlock software prototype

    With functioning hardware and software prototypes in place, the research effort then focused on the feasibility of the system to accurately collect and identify composite delamination in a portable system.

    The University of Delaware (UD) Center for Composite Materials (CCM) fabricated a composite laminate for testing of the ultrasonic sensor and pulse-echo hardware.  Induced voids were added to the panel by using azodicarbonamide (a blowing agent) and Teflon inserts placed within the layers of the composite to simulate debonding. Finally, the panel was impacted with a steel ball at multiple locations. The majority of these defects were not visually observable. Figure 8 shows the test panel used for the tests with the fabricated defects at various locations.

    Figure 8: Test panel scan

    The panel was evaluated using the prototype system. The probe allows introduction of the ultrasonic pulse into the sample using a coupling agent. In addition, a polymer-based coupler was used to extend/delay the signal in a range (> 9 µs) where the transducer ringing is negligible. Figure 9 shows two specific locations that were evaluated, including one area containing a Teflon insert where a debonding reflection would be expected, and in another area (no voids, Teflon, or damage) where an average signal is expected. This result is similar to the dual-sensor laboratory-based baseline signals at the same locations.  At the defect location, there is virtually a complete reflection at the surface with almost no reflection afterward, and the average panel signal shows the back surface return signal after approximately 1.5 µs and subsequent reflections (as expected).

    Figure 9: Ultrasonic scan comparisons

    This test verified the feasibility of the prototype system, clearly being able to distinguish between normal and delaminated (or defective) composite material in a portable, pulse-echo ultrasonic sensor configuration integrated into the iGPS hardware.

    Conclusions

    The goal of the subject research grant was to develop a modern, integrated data collection and sensor system capable of assessing damage and then evaluating and processing repairs to advanced composite materials on fixed- and rotary-wing aircraft. SURVICE’s approach was to assemble current, state-of-the-art data collection hardware and sensing equipment with customized software to provide an integrated data collection and processing system, ensuring that repair methods and technologies match the advancements made in material science.

    All of the key objectives were met under the Phase I effort, demonstrating key technologies required to proceed to the Phase II effort. SURVICE is currently awaiting formal notification to proceed to Phase II, where the prototype system developed under the Phase I effort will be fully developed and realized.

    Acknowledgements

    The author would like to acknowledge the contributions of several key personnel involved with successful completion of this Phase I research effort:

    Dr. Dirk Heider of the University of Delaware’s Center for Composite Materials was instrumental in the selection, integration, and verification of the prototype system.

    From Nikon Metrology, Mr. Anderson Sheng was instrumental is supporting the hardware/software interface to the iGPS system.

    From SURVICE, Mr. Doug Howard worked on the software modifications, Mr. Kyle Herr and Mr. Jason Duvall developed and fabricated the necessary prototype hardware, and Mr. Michael Hardin and Mr. Dave Turner supported the validation testing and documentation of the results.

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    Measure Before Machining & Avoid Errors

    December 23, 2010

    Die Tech avoids errors by inspecting electrodes prior to EDM

    by Peter Zelinski, Senior Editor of Modern Machine Shop

    A laser scanning head measures an EDM electrode.

    Here, the EDM machine produces a simple hole. The combination of palletization and automatic EDM programming makes this approach more efficient than using a drill press.

    Despite Die Tech & Engineering’s investment in machining centers, the shop still does plenty of sinker EDM work. Using EDM electrodes in a tight-lead-time process is “scary,” says president William Berry, because of the risk of error. An error in milling a complex graphite electrode, or in programming it at the machine, might not be detected until the EDM cycle has made a faulty part.

    From Mr. Berry’s perspective, a coordinate measuring machine never made sense. Inspecting a part after machining adds no value, he says. Instead, when the shop finally did buy a CMM, it was for inspection before machining. Specifically, all EDM electrodes in the shop—hundreds of electrodes per week—now pass across a non-contact laser scanning head from Nikon Metrology, mounted on a Brown & Sharpe CMM.

    Here, the EDM machine produces a simple hole. The combination of palletization and automatic EDM programming makes this approach more efficient than using a drill press.

    Verifying electrode geometry in this way costs little lead time. Electrode CMM inspection programs are generated automatically. In fact, DTE has engineered its system to create EDM machine programs automatically as well, so every electrode is used correctly, without human error.

    This electrode process, combined with palletization, has produced some counter-intuitive economies for the shop. I saw an example while visiting. In the photo seen here, a sinker EDM is used to produce a simple hole that, by any intuitive guess, ought to be drilled. However, Mr. Berry points out that the only savings drilling can offer would be cycle time. A human would still have to run the job on a drill press or machining center. By contrast, DTE’s EDM process is so seamless that there is no harm in letting an EDM machine produce the hole if an EDM machine happens to be available. Doing this frees employees to devote their attention to higher-value tasks.

     

     Click here to read this article in Modern Machine Shop.

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    Precision Engineering Company Invests Shrewdly, Competes Globally

    December 8, 2010

    Top-line equipment lures high-end customers

    Reprinted from Quality Digest

    Manufacturing is getting easier in many ways, at least as far as the technology is concerned. For example, machine tools are simpler to program and operate, rapid prototyping means that product development is faster and cheaper than ever, and user-friendly CAD software may even negate the need for physical prototypes entirely. All of this assumes that what you are actually making, or trying to make, is relatively uncomplicated. It’s a different matter, however, if you are building complex multimillion-dollar aerospace systems, such as those engineered by Mecanizados Escribano.

    The Madrid-based precision engineering business, which specializes in complex parts for aerospace and defence applications, has invested in a Renishaw REVO five-axis measuring head and probe system. The investment has reduced inspection time by as much as a factor of five, ensuring that quality control and inspection keep up with the company’s high-productivity CNC machine tools.

    “When we buy a machine tool we specify all the options,” says company project manager Juan A. Humanes. “But having the best machines is only part of the equation. Our customers demand very rigorous part inspection, which means there’s always the chance that the metrology department can become a bottleneck, especially when the parts are complex and machined to very tight tolerances.”

    Exceptional scanning speed and accuracy

    The key attribute of the REVO five-axis head is its ability to overcome the limitations of three-axis scanning methods, where any attempt to rapidly move the large mass of a coordinate measuring machine (CMM) results in inertial errors caused by accelerations and decelerations. Therefore, the only possible way to maintain acceptable accuracy in three-axis scanning has been at the expense of measuring speed. However, REVO uses synchronized head and machine motion when scanning, rapidly following changes in part geometry without introducing its own dynamic errors. The CMM is able to move at a constant velocity while measurements are being taken, without affecting accuracy.

    “Depending on what the customer requests, we inspect between 10 and 100 percent of machined parts,” explains Humanes. “The Renishaw REVO system, recently fitted to a Metris [now Nikon Metrology] CMM, measures nonprismatic surfaces very quickly, many of which would be difficult or impossible to measure with touch-trigger systems. In some cases, such as a complex avionics chassis for the Typhoon, the REVO has increased our inspection throughput by a factor of five and typically up to 80-percent reduction in time per part.”

    REVO also benefits CMM users with infinite head positioning and innovative tip-sensing probe technology, which further improves measurement accuracy by sensing close to the measured surface. This combination of speed, flexibility, and accuracy has proven to give exceptional performance in a wide range of scanning measurement applications, including circle, helix, sweep and gasket scanning, and, if required, rapid single-touch routines.

    Expanding to meet increased demand

    Any visitor lucky enough to tour the Escribano factory can see the size and significance of the investment required for such production. Humanes reveals it to be between €1 million and €1.5 million ($1.3 – $2 million) a year, and most of the company’s CNC machines are top-end, Japanese or Swiss-built, multipallet, and multi-axis units from Makino, Matsuura, and Mazak; Sodick wire EDMs; and CNC precision grinders from Jung. All of them are the latest models, meticulously maintained and configured to minimize setup and nonmachining time, mostly using Renishaw OMP40 spindle-mounted touch probes and NC4 noncontact laser tool setting systems.

    Escribano has outgrown its current building and has designed and built a new facility, where it will relocate in the next few weeks. Until then, the two small rooms adjacent to the main workshop that house the company’s inspection equipment will remain crowded. In the larger of the two rooms, three DEA Global Advance CMMs with Renishaw probes check samples of parts for everything from thermal imaging cameras to components destined for the Joint Strike Fighter. Alongside the main metrology lab is a smaller room housing the company’s largest CMM: a Nikon Metrology LKV equipped with the Renishaw REVO five-axis measuring head and probe system, part of a recent investment in inspection equipment that totalled about €300,000 ($402,000).

    For most precision-engineering businesses, the Nikon Metrology and Renishaw REVO combination would be enough to cater to their metrology needs. But Escribano isn’t your typical workshop, and its customers are somewhat more demanding. The company has invested in other advanced metrology systems such as a white-light interferometer microscope for measuring roughness, and a contact profile meter capable of assessing the size and texture of a part’s surface.

    Sophisticated expertise and technology

    Companies such as Escribano, a privately-owned engineering workshop with the expertise and technology to deliver components and systems for such sophisticated applications, are few and far between. No one at Escribano can or will talk about its customers or their products, but Humanes is happy to discuss what the company is equipped to do and how it does it.

    “We specialize in machining complex, five-axis parts in aircraft-grade aluminium, stainless steel, nickel alloys, copper and titanium,” he says. “The only way to be good at this kind of work is to make the necessary investments in technology and people. Our customers can choose between some of the best-equipped suppliers in the world, so we have to make sure we can deliver exactly what they want, when they want it.”

    A large proportion of Escribano’s production is for the U.S. defence sector, which probably can choose among more small, privately-owned precision engineering companies than any other country. So why would a U.S. defence contractor choose to outsource some of its most complicated, quality-critical parts to a company in Spain instead of one closer to home?

    “Some people might assume that we win business because Spanish labor costs are lower than they would be at a similar, U.S. company,” says Humanes. “But they would be wrong. If that were the case, the work would simply migrate to Asia. The truth is we are competitive because we invest in the best technology, and we train people to high levels. We don’t just benchmark ourselves with competitors in Spain or Europe; we aspire to be the best in the world.”

    General precision engineering may, thanks to the technology, be getting easier, but Escribano’s willingness to meet almost any standard of engineering precision means that even during the worst recession in living memory—and the Spanish economy is suffering the effects as acutely as any country’s—this family-owned company is still busy 20 hours a day.

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    Robot Control Brings Aerospace Tolerances to Automotive Robots

    November 19, 2010

    A major Airbus research project to develop greater levels of accuracy in automated drilling and riveting has led to the formation of a consortium to build a robotic platform incoporating a Nikon Metrology K-series Optical CMM.

    Since industrial robots do not meet Airbus process specifications; Airbus, Nikon Metrology, KUKA and Delmia have formed a consortium to build a new aerospace grade robotic platform. This patent-applied-for solution establishes a dynamic on-line link between a KUKA robot and a Nikon Metrology K-series Optical CMM. This system will result in a robotic platform that features adaptive real-time motion control. Airbus expects that the robotic solution – operating on aerospace accuracy tolerance – will reduce cost, cut production time and improve build quality once deployed.

    “Company-wide, we drill around 50 million holes per year and half of these are manually processed,” says Mark Summers, Engineering Group leader, Automation and Robotics, Airbus UK. “Our research is part of a drive to significantly reduce manual processing across current and future aircraft programs as our build rate increases to meet market demand. Standard industrial robots are not accurate enough for our process specifications, as absolute positional accuracy of ±0.2 mm is required in many application areas. Our team has brought together two developmental partners, KUKA UK and Nikon Metrology to address this problem. We believe we have come up with a winning solution, which could bring a flexible, low-cost robotic platform into the aerospace sector.”

    A flexible, low cost robotic platform for the aerospace sector

    Initially the system will be applied to two KUKA production robots that jointly pick up an unfinished large wing assembly, and present this part to a drilling/riveting station at a fixed location. Both the drilling/riveting machine and the part being manufactured (through its fixture) are tracked dynamically by means of infrared LEDs and the Nikon Metrology K-series Optical CMM station. As part of the control feedback loop, the position of the part with respect to the machine is systematically returned to the robot controller. This Nikon Metrology/KUKA robotic solution is responsible for positioning wing part holes and rivets at CAD-specified wing locations with accuracy levels 10 times higher than before.

    “This project has been a real partnership between all involved parties,” explains Roger Holden, Managing Director of Nikon Metrology. “Everybody agreed that considering part programs being so large and accuracy requirements so high, an off-line robot programming solution was needed. DELMIA’s V5 and KUKA’s VRC software provide an excellent solution that – linked with Nikon Metrology interface and integration – is capable of consistently driving the robot to run programs accurately, by referencing back to the CAD master dynamically on-site. Nikon Metrology now has the order for the first production system to be put into action at Airbus, and we are now going live with the product at Filton, UK.”

    Intelligent, real-time adaptive robot control driven by Nikon Metrology

    The unique and fully integrated metrology system measures the virtual world first, and adapts the real world to fit. This intuitive system is called Adaptive Robot Control, as it makes the robot intelligent enough to make its own adaptations. This means that the robot can accurately compensate for robot deformation (under dynamic load), temperature fluctuations and mechanical play. The metrology system makes the robot aware of deflections by measuring the relative positions of the target and the robot as it moves toward it. The robot is able to coordinate that data on-line and make the necessary compensations instantaneously.
    Since the robot(s) carry out tasks at great positional accuracy and faster than a person, they could be used for a range of tasks, such as sealant application, component handling, fastening and machining. Such robotic platforms could become truly multi-functional. The multi-functionality is generally agreed to become key for the aerospace industry, as single process automation tools are often under-utilized, owing to the long cycle times for each wing set, for example. Another benefit is that the robotic system, in effect, becomes an in-line CMM, which is capable of certifying jigs and products in real time. There is potential to re-certify jigs without taking them out of production at regular intervals.  Instead, geometry changes in the jig could be identified in the real-time production environment. Similarly, it could become unnecessary to divert products to a laboratory for QA, as the robot could measure them as they are being made via a multi-functional 3D scanning end effector.

    Higher level of simulation prove-out and robot integration

    Although beneficial to any robot configuration, the Adaptive Robot Control solution responds well to highly accurate robot operation requirements in the aerospace sector. One reason for this is the extensive use of lightweight materials like aluminum, which requires far more accurate drilling and riveting. Since the loads robots are asked to bear are too great for a single robot, load sharing among multiple cooperating robots has become common practice. The accurate robot solutions are designed to smoothly interact with one another, and are now made available through Nikon Metrology integration services.

    Nikon Metrolgy/KUKA robot solutions can now be commissioned off-line, eliminating time consuming robot teach-in procedures. All of the robot programs being created off-line use the DELMIA V5 Robotics simulation solution. KUKA connects real-time information on the movements of its own Virtual Robotic Manipulator (VRC) into the second-generation Realistic Robot Simulation (RRS2) software it developed in conjunction with DELMIA. This results in a significantly higher level of simulation prove-out and integration into real robots. The Airbus project takes advantage of this solution, with the final full syntax programs being run on the KUKA VRC, enabling accurate cycle-times and clash detection.

    Learn more about Adaptive Robot Control.

    Click here to watch a video about Adaptive Robot Control.

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    Philips Lighting pushes innovation using Nikon Metrology X-ray and CT

    November 18, 2010

    Radiography imaging and metrology drives research, quality, productivity and a reduced ecological footprint

    Philips Lighting in Turnhout, Belgium, recently took delivery of a Nikon Metrology XT V system for X-ray and computed tomography (CT) inspection. Engineers investigate electrodes and other parts of high-intensity discharge (HID) lamp prototypes, to push the boundaries of lamp performance, lifespan and ecological material usage. They inspect lamps from every angle, and repeat the inspections on the same units after extended lighting periods. Deeper insight into the progression of glass corrosion, component wear and deposit formation allows Philips Lighting to reduce extensive life testing, thus saving tremendously on energy costs.

    A tradition of X-ray inspection carried forward

    The Philips Lighting business division produces billions of bulbs a year. Philips Lighting kicked off X-ray inspection in 2003 to support the design-through-manufacturing process of high-intensity discharge (HID) lamps. The multinational’s division in Turnhout, Belgium, manufactures long-lasting HID lamps from 20 to 4000 Watts, offering high light output and premium light quality. These innovative illumination solutions raise comfort levels in offices, public buildings and factory halls; enhance traffic safety through street lights and passenger car headlights; and add entertainment value with flashy light shows to amp up rock stars’ performances.

    Philips lighting decided to make X-ray and CT an integral part of its internal processes.

    X-ray helps Philips Lighting to successfully respond to the tight electrode requirements imposed on HID lamp engineering.

    “There is no doubt that X-ray inspection presents the best strategy to study the feasibility of new technologies, assemblies and materials and maintain high production quality,” says Chris Dries from Philips Innovative Applications in Turnhout. “For this reason we decided to further increase and sharpen our non-destructive testing (NDT) capability. To select a new system, we performed a thorough evaluation involving systems from most major X-ray and CT system vendors. Ultimately, the benchmark resulted in the purchase of a Nikon Metrology XT V 160 machine. We use the new system for critical measurement tasks and automated inspection jobs, whereas the older system is still suitable for visual checks.”

    Getting a grip on performance-critical aspects

    The ability to literally look inside HID lamps is a great asset for Philips Lighting. X-rays penetrate the lamp and subsequently hit a 13×13-inch Varian flat panel, which generates radiography images with different shades of gray depending on material and geometry. On these translucent images, all the lamp’s constituent components are displayed in their entirety. The proprietary X-ray source incorporated into the system is equipped with a 1 micron transmission target. The XT V 160 is a high-precision imaging system that recognizes hidden features as tiny as 500nm, ideal for engineers to deduce structural, dimensional and connectivity related facts.

    HID lamp electrodes are performance-critical components that undergo detailed X-ray research. Chris Dries explains that electrode characteristics influence the light the lamp produces by passing an electric arc through a compact tube filled with a high-pressure mixture of gases. “We measure the size and shape of electrodes contained in lamp prototypes as well as the distance between both electrodes. Inspect-X software allows us to automatically measure the distance between the electrodes’ tip planes. X-ray helps us a great deal in studying the way electrodes’ shape and structural characteristics evolve after every so many lighting hours. This is why Philips Lighting is able to successfully respond to the tight electrode requirements imposed on HID lamp engineering.”

    NDT insight allows Philips to reduce the number of prototyping rounds and downscale life test activity.

    X-ray proves technical facts that are indispensible in stretching the performance limits of lamps.

    Chris Dries mentions that submicron image resolution provides great insight into other internal lamp phenomena, such as wall corrosion, glass frit, crazes and salt and mercury fillings. The XT V 160 system also supports the reconstruction of a CT volume, generated on the basis of hundreds of X-ray images. “By navigating CT volumes, we are able to locate and investigate crazes that may develop in ceramic discharge tubes. Similarly, we change position, angle and zoom as desired to take a close look at the otherwise invisible welds connecting electrodes with their supports. High image quality and magnification even make it possible to detect minuscule cavities in salt particles, something we were unable to do in the past.”

    Automation and off-line inspection

    To allow engineers to focus on their research and production work, most measuring tasks are delegated to system operators. They slide a tray with an array of lamps in the X-ray and CT system and start automatic data capture. The tray is indexed from one lamp to the next in order to subject all items to the same X-ray imaging routine. “Zoom level consistency and flux normalization maximize the repeatability of X-ray imaging, generating output that is truly operator-independent,” says Dries. “This offers us the abililty to reliably set up macros for X-ray jobs that can run unattended at any time.”

    All acquired imaging data can be sent to an offline station that runs Inspect-X software for inspection and macro preparation purposes. Engineers analyze X-ray graphics or navigate a CT volume to drill down on a particular detail, while having all relevant numerical information available at their fingertips. They value the fact that they can easily include X-ray shots and CT sections in their engineering reports.

    Nearly all Olympic Game sports stadiums use Philips high-intensity discharge (HID) lamps.

    A resolute choice for extended NDT

    “The Nikon Metrology system is part of a strategic decision by Philips Lighting to make X-ray and CT an integral part of internal processes,” says Dries. “Angled views in highest resolution prove technical facts that are indispensible in stretching the performance limits of HID lamps. Important in this regard is studying the use of environmentally friendly materials and their impact on light, yield and reliability. With the insight gained, the number of prototyping rounds can be reduced and life test activity can be downscaled to some extent, saving both time and money. The resulting decrease in power consumption also contributes to greener economics. By extending NDT capabilities, Philips Lighting underlines its position of leading innovator and supplier of high-quality illumination solutions.”

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    Qualis Makes Smart Moves with 3D Laser Scanning

    November 11, 2010

    Qualis, a specialized contract metrology firm in Germany – uses a CMM-operated laser scanner from Nikon Metrology. Where tactile measurement falls short on fragile, flexible or complex parts made of metal, plastic or composite, the non-contact laser scanner accurately and efficiently digitizes the complete geometry of parts. The acquired 3D scans help Qualis metrologists assist customers in optimizing product design and verifying serial production quality.

    Straightforward CMM programming and automated inspection and reporting in Nikon Metrology Focus software enable them to turn around inspection jobs quickly. Also for tactile inspection jobs, Qualis customers increasingly request laser scanning and associated interactive reporting to gain deeper and more complete insight.

    Stretching the limitations of existing CMM infrastructure

    Qualis quickly turns around 3D laser scanning assignments using the Nikon Metrology Focus software suite.

    Qualis is a growing contract metrology firm located in the Frankfurt area. Founded by metrology specialist Martin Reinhardt, Qualis gradually built a name for itself in the German automotive supplier industry. On customer demand, Qualis metrology engineers perform contract inspection work on tooth wheels, covers, valves, plastic buttons and switches, electronics, turbine blades, and a diversity of other parts. 90% of Qualis metrology activity focuses on non-metal components, such as plastics, composites and other compound material types. In addition to executing contract metrology work, Qualis Service maintains and supports metrology equipment of different makes.

    Driven by a desire to successfully tackle any inspection challenge, Qualis retrofitted one of its CMMs with a Nikon Metrology LC15 laser scanner. This 3D laser line scanner, specifically designed for highly accurate scanning, inspects a specimen by beaming a 15mm wide laser stripe on the surface of the part being inspected. The built-in camera dynamically captures the projected laser stripe, and scanner electronics generate a continuous stream of 3D measurement point coordinates. Following this approach, the entire surfaces of parts – including features and freeform areas – are digitized in an accurate and efficient fashion. These kinds of metrology solutions are very helpful in the inspection of plastics and polymer (coated) parts, which often face different mold and post shrinkage and moisture growth characteristics.

    Qualis engineers confidently run automatic 3D inspection of thin components of open roof systems.

    Compared to touch probes that can potentially scratch fragile components or press flexible parts, laser scanning is entirely non-contact. Also for structures with low rigidity, such as thin bended bars, the use of laser scanning avoids challenging fixturing and unreliable touch probing. Qualis engineers opted for laser scanning when asked to investigate a thin component for an open roof system for a major German vehicle. It concerned a spring-loaded thin bended bar made of metal that forms the core of the air-lifting flap that minimizes noise disturbance when the roof is open. At Qualis, engineers simply put the part on a pedestal on the CMM granite, and scan the part to digitize its shape.

    Less effort to collect more data in a shorter time

    Qualis takes advantage of the versatility of laser scanning, as it runs optical inspection on diverse objects.

    “Defining straightforward scanner movements in Nikon Metrology Focus Scan only takes us a fraction of the time that we would otherwise need to program hundreds of touch points,” says Martin Reinhardt, CEO of Qualis. “During inspection, we watch the 3D surface that is being scanned build up on the screen in real time. A complete scan consists of a dense cloud of hundreds of thousands or even millions of accurate surface points that eliminate anomalies that potentially remain unnoticed through touch probing. Tests we performed confirm that the Nikon Metrology scanner is able to investigate smaller parts with accuracy levels lower than 10 micron.

    Focus Inspection offers us the choice to interactively or automatically analyze the data, perform CAD comparison, and generate metrology reports. After reducing point cloud data using filtering technology, point cloud data is converted into a mesh that is aligned with the CAD model. Qualis often applies the 3-2-1 alignment procedure, which consecutively executes space, planar and last zero point alignment.  “To maximize serial inspection productivity, Focus Automation allows us to replay the same inspection procedure as many times as needed.”

    For turbine blades, Qualis opts for laser scanning to get the complete picture in record time.

    At Qualis, laser scanning is applied to evaluate the quality of prototype samples and pre-production batches. The Nikon Metrology LC15 is also used to scan serial-produced parts to indirectly monitor degrading production mold geometry. In cases where customers conclude that prototype parts crafted from original CAD files do not live up to expectations, the decision is sometimes made to immediately implement countermeasures in hardware. Subsequently, Qualis metrologists scan the 3D surfaces of many modified part variants, and use the acquired data to assist the customer in defining optimum geometric settings. The sample part that is selected as the master part is then scanned to accurately reverse engineer the CAD file that will go into pre-production. This procedure, for example, was applied to a key part of new medical equipment of which millions will be produced.

    Interactive reporting supports well-informed decisions

    To allow measurement results to be evaluated efficiently, Focus Inspection reports shows the comparison of the 3D scan with the CAD model by using color-coded areas that mark local deviations. “We regularly send Focus inspection reports to customers, who access the file using a free downloadable Focus Inspection viewer,” explains Martin Reinhardt. “The interactive report enables customers to evaluate the inspected part from any preferred viewpoint and click locations of interest to consult the underlying metrology data. Customers also request 3D laser scanning and associated reporting as a means to put their touch sensor measurements into perspective. The huge number of measurement points provides a higher degree of measurement confidence that forms a solid basis for well-informed quality decision making.”

    Click here to request more information from Nikon Metrology.

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    Supersize CMM at Biesse Wood Division

    November 10, 2010

    With a measurement volume of 24 meters cubed, one of the largest ever bridge-type CMMs is in use at Biesse Wood Division in Pesaro, a department of Biesse Group in Italy.  Biesse Wood Division develops and produces machinery for the furniture and carpentry industry, and uses this supersize CMM to perform geometrical inspection of prototype and production parts and assemblies of woodworking machinery. The company’s manufacturing machinery for working furniture includes CNC machining centers as well as equipment for edgebanding, sanding, calibration, sawing and handling.

    The granite load table of this 10-ton bridge CMM provides an 8 x 2 x 1.5 meter measurement volume that conveniently fits a series of mechanical assemblies or a very large piece of furniture-machining equipment. Accurate geometric inspection of woodworking machining parts is essential in obtaining high-quality furniture products. In the past, Biesse Wood Division used a horizontal measuring machine that became insufficiently accurate to reliably inspect the geometric quality of such mechanical parts.

    The increasing demand for high quality products and cost-effective manufacturing was the key driver in upgrading their metrology facilities with this new supersize  bridge CMM. To combine metrology-level inspection capability and high measurement productivity, the CMM features high acceleration, low cycle times, high accuracy and excellent repeatability. The CMM is equipped with 0.5 micron resolution scales, aluminum Y and Z guideways, and air bearings on all axes. The system is supplied with Nikon Metrology CMM software and controllers, and equipped with touch trigger probes.

    “We carefully looked into different suppliers and the C3 bridge CMM provided the best match in terms of size, performance, customization and budget,” said Luciano Pardini, Manager of the Quality department at Biesse Group. “We are confident that this large-scale CMM will keep contributing to increasing manufacturing quality and productivity of our machinery for making furniture.”

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    Industrial Rubber quality-checks rubber road stud reflectors with iNexiv video measuring system

    November 3, 2010

    Industrial Rubber has been manufacturing rubber moldings since 1975. One of its best known products, the “Light Dome” road stud reflector, is approved by the Department of Transport for use on all of the UK’s roads and highways. Industrial Rubber invested in a Nikon Metrology iNexiv VMA-2520 inspection system to assure its customers of consistent high quality products, no matter where in the world they are manufactured.

    Simon Elgar, quality manager at Industrial Rubber explains: “In addition to plants and machinery in the UK, Industrial Rubber also has sister companies in China, enabling dual manufacturing at home and abroad. This is a great advantage in meeting large batch orders and in ensuring continuity of supply even when customers have exceptional demand.”

    Quality-checking rubber components can be challenging as rubber is a dynamic material that can compress under its own weight, can be flexible and can deform on contact. Non-contact vision metrology systems are, therefore, the only realistic inspection option. All quality checks are carried out centrally at Industrial Rubber’s UK site.  When Industrial Rubber decided recently to upgrade its QC facilities, it chose to invest in an iNexiv VMA-2520 vision metrology system.

    “The iNexiv VMA-2520 has given us a whole new level of accuracy and precision. We can now measure to four decimal places of accuracy and can check the pieces visually with minute detail. This is an excellent quality control tool for some of our precision pieces destined for life-critical medical devices. It allows us to monitor the quality and repeatability of manufacture with great precision.”

    Once the initial set-up has been completed, measuring becomes much faster, and many more measurement tasks can be completed in any given time. To ensure that the system was up and running in the shortest time possible, Nikon provided training sessions for all the users both individually and in a group. Nikon Metrology also provides ongoing support and in case of questions, the answer is just a telephone call away.

    A new quality control room was built around the iNexiv VMA-2520, providing the ideal environment in which to demonstrate Industrial Rubber’s quality processes to customers. “Our customers have been impressed with our new facilities, and have gained further confidence in our manufacturing capabilities. The manufacture of rubber components is a highly competitive market in the UK that has been shrunk by the lure of off-shore manufacturing. Having this level of quality control in one central location means that we can take advantage of these markets without compromising quality,” Simon concluded.

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    ANT Industries cuts inspection times up to 83%

    November 1, 2010

    ANT Industries, a supplier to Rolls-Royce, has cut inspection times on complex parts by up to 83%, using a five-axis measurement system fitted to a CMM.

    When aerospace sub-contractor ANT Industries carried out a study on its production processes with the aim to make improvements, it was clear that inspection was a major bottleneck. “There were thousands of non-productive hours a year where parts were either in inspection or waiting to be inspected. These are expensive parts without any value being added”, says Shaun Rowley, ANT’s manufacturing and sales director.

    However, following the purchase of a new coordinate measuring machine (CMM) equipped with a Renishaw REVO five-axis scanning system, the situation has changed markedly. “Now that we have the new machine we are playing a different game – there is no other option to REVO, nothing else comes close”, adds Shaun Rowley. “The closest alternative was a system costing five times as much, but it wouldn’t have achieved the same levels of throughput.”

    ANT produces over 1000 different machined parts, approximately 85% of which are supplied to the aerospace industry, requiring a high proportion of final part inspection. CMM inspection of finished parts is taken for granted in the aerospace industry, and ANT has to offer it to their customers as part of the manufacturing process. Some parts need 100% inspection, while others must have at least 1 in 10 inspected. “REVO gives us a clear competitive advantage; I have no doubt it will help us win work”, says Alan Naylor, ANT’s technical director. “Not only does it massively reduce inspection time, it also measures complex features like the leading edges of blades, which we just couldn’t do before.”

    Measurement approach
    With a sophisticated, highly efficient machining operation, ANT Industries also uses Renishaw’s spindle-mounted touch probes and tool monitoring systems for process control on their multi-axis machining centers and CNC lathes. However, post-process inspection had to be improved to keep pace.

    “Our inspection method now uses a completely different approach,” Shaun explains. “We have taken a big jump in a very short time from slowly taking multiple touch-trigger points with the old Tesa CMM, to rapid 5-axis scanning. But the operators have taken to it very well and we are currently, on average, programming one new job a day. Added to that, the old CMM really struggled to maintain the accuracy needed; there were small but frustrating inconsistencies all over the measuring volume which we had to correct to keep an acceptable standard. We had to do something.”

    Shaun Rowley is particularly impressed with how the REVO system measures one type of turbine blade with a very complex form. “Each of these blades used to take 2 hours to measure, now it can be done in 20 minutes. With this sort of throughput I’m happy to agree to customer requests for 100% inspection of most components. But that’s not the whole story; this is a complex shape with a critical leading edge that the touch-trigger CMM just couldn’t measure at all.”

    Prior to the new REVO-equipped CMM, ANT had to analyze the form using a projector technique to measure the shape – a long and laborious task. Now, the REVO system does the same job with a rapid profile scan, overlaying measured data onto the CAD design model and applying variable tolerances in different areas. “The ability it has given us is undoubtedly a key business advantage”, adds Shaun.
    Calibration of the probe, required periodically to ensure accuracy, is also an area which has seen significant benefits. Previously it took two hours to calibrate all the different probe angles needed for a measurement routine, whereas the REVO system calibrates in just 20 minutes.

    Rapid introduction
    ANT needed their new CMM to be supplied quickly to satisfy the measurement needs of a large blade contract. They decided to purchase a new ceramic CMM frame from Nikon Metrology, without a probe system or controller, with axis travel of 2 m in Y, 1.2 m in X and 1 m in Z to allow the measurement of large engine rings. Renishaw then fitted the frame with its REVO five-axis measuring head and probe system, together with its UCC2 universal CMM controller.

    The system uses Renishaw’s MODUS metrology software. Alan Naylor said, “Support from Renishaw has been excellent, not just in training operators in using the MODUS software, but also in introducing a new way of thinking to inspection methods. It could have been intimidating, but it turned out to be a very straightforward transition.”

    Another potential benefit of the new CMM has been identified by ANT, as Shaun Rowley explains. “The customer gives us some part designs as 3D CAD models, but most parts are defined with 2D drawings, which our CAD department turns into 3D models to enable the calculation of machining paths in a CAM system.” However, the plan is now to train one of ANT’s CAD/CAM team to also program the REVO inspection routines so that they have an overview of the whole production process. He will then be able to consider all the implications for machining and inspection when creating the CAD model,” adds Shaun Rowley.

    ANT’s machine shop includes 14 machining centers, most of which are fitted with Renishaw spindle-mounted touch probes or tool setting systems. The probes were introduced in 2004, and the cost of each system was repaid in 2 or 3 jobs, simply through the elimination of expensive fixturing, which prior to probing, was needed to accurately locate parts relative to the machine’s coordinate system. Simple load-bearing clamps are now used to provide approximate positioning, with the Renishaw probe systems and software automatically measuring the position of key features in a matter of seconds and adjusting the coordinate system to prepare for machining.
    Summing up, Shaun Rowley has no doubts about the difference the REVO system will make. “This is new technology for us and took a change in thinking but, with the system up and running, we’ve transformed our inspection capacity and capability. We’re ahead of the game and have a clear advantage.”

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    Handheld Laser Scanner Helps Evernham Motorsports Design Faster Cars

    October 18, 2010

    Evernham Motorsports is using an Nvision handheld scanning system featuring a Nikon Metrology ModelMaker to develop its racecars more quickly by allowing the team to document even the smallest changes to the body design. The major components of the Model-Maker system are a 3-D laser sensor, a mechanical digitizer on which the sensor is attached, a PC, and software that extracts, displays, and manipulates the data.

    In automobile racing, where as little as 1/100th of a second difference in lap time can mean the difference between first and second place, slight variations in body design have a huge impact on performance. Teams work hard to optimize the car’s shape for the best aerodynamics, but until recently, they had no way of precisely documenting that shape.

    According to the NASCAR rules, all vehicles have many of the same components, including the transmission, steering gear, suspension, electrical, and fuel system as well as brakes. The chassis are also basically the same, a front-steer-type built by one of three major chassis builders: Laughlin, Hopkins, or Hutcherson-Pagan. The car bodies are tightly regulated by NASCAR. The acceptable shape is outlined by templates, 2-D silhouettes defining certain longitudinal or lateral cross-sections of the body. The templates include acceptable tolerances, which can be as much as 13 mm (0.50 in) or as little as 1.8 mm (0.07 in). Although the tolerances have been tightened in recent years, some latitude is given that allows for alternative body shapes that still fit within the scope of the NASCAR rules. As teams have become more knowledgeable about vehicle aerodynamics, for example, they have begun using the tolerances within the body templates to their advantage, fine-tuning the car’s exterior to minimize wind resistance as much as possible. These slight variations in body design have had a huge impact on performance. Since these changes are very minor, documenting them with a great deal of precision is a necessity.

    After the team built a prototype of the new Dodge Intrepid, Evernham Motorsports engineer Tim Malinovsky recorded the shape by simply holding the laser sensor so that a line of laser light appeared on the body. The ModelMaker uses a single viewpoint laser stripe sensor. Laser stripe sensors, which are significantly faster than simple laser point sensors, work by projecting a line of laser light onto the object while a small CCD camera views the line as it appears on the surface.

    The mechanical digitizer moved freely about the body, allowing Malinovsky to position the sensor easily and capture data rapidly and with a high degree of resolution. As he moved the sensor over the surface of the body, a dedicated interface card translated the video image of the line into 3-D coordinates. These data are combined with the Cartesian and angular coordinates generated at each position of the mechanical arm. The result is a dense cloud of 3-D data describing the surface of the object. A laser scan of an entire car body usually generates 25 million 3-D coordinates and can be done in 12 to 14 h.

    Once the coordinate data was acquired, the team sent the scan data to Dodge, which also uses a Nikon Metrology system in its development efforts. Dodge imported the data into its CAD system, CATIA, scaled it down, and used it to produce a 3/8-scale clay and fiberglass model, which was then tested in a wind tunnel.

    Evernham Motorsports also used the scan data as a precise record for tracking aerodynamic improvements. An original scan served as a record of the baseline shape. Then, as the prototype body was modified to improve aerodynamics, the scanner was used again to quantify these relatively minor adjustments, enabling them to benefit from the lessons learned on the vehicle’s aerodynamic performance.

    Visit http://us.nikonmetrology.com/handheld_scanners/mmdx_mmc/ for more details.

    (Original author: NVision – www.nvision3d.com )

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