December 9, 2010
Nikon Metrology offers a complete range of examination and measurement services for the inspection of medical devices and components. These include microscopy, manual metrology, automated non-contact video measuring, non-contact geometry inspection, X-ray radiography and computed tomography.
Accurate inspection of small medical components
With medical devices, failure is not an option. Reproducible examination and measurement of key components and specified tolerances play a key role in ensuring the reliable and repeatable performance needed for items such as simple, single-use catheters right through to the most advanced drug delivery systems. In order to avoid the rejection of rogue batches, examination and measurement methods also need to be able to verify the quality of purchased materials prior to release from inventory, and provide a complete audit trail for regulatory purposes.
Microscopy examination of medical devices
Microscopy is a key tool in the examination of medical devices and components as it provides the means to produce the high-contrast images needed to spot small imperfections on and below the surface of samples such as catheters and surgical blades. It can also prove beneficial in examining failures, to assess whether they are due to a manufacturing error or misuse.
Manual metrology for medical device quality control
Manual metrology provides an accurate means to assess prototypes, check the performance of new injection-molding tools and perform lower-volume quality control checks.
Automated non-contact video measuring of medical components
Automated non-contact video measuring allows multiple measurements to be reliably made on large numbers of small and complex components at a rate that can keep pace with demanding production schedules. With the correct illumination settings, and repeatable and reproducible edge detection, even the edges on dark and clear parts can be correctly refracted, detected and reproducibly measured. Non-contact video measurement can also be used to compare CAD versus actual data and perform real-time SPC.
Non-contact geometry inspection of medical components
For some components, like knee, hip or dental implants and hearing aids, the as-built shape of the component is crucial for fast patient recovery and maximum comfort. State-of-the art digital laser scanners create high-accuracy, high-density 3D digital copies of the part with a minimum of effort. These point clouds can be used for the inspection of the surface geometry.
Color diagrams instantly highlight deviations and facilitate the communication with the production department. Alternatively, these copies can be used to create CAD surface models from components that have been tuned manually or where no CAD file is available.
X-ray radiography and computed tomography for inspection of complex medical devices
Medical devices are highly complex components where critical parts can’t be reached by touch probes or seen by video and laser systems; think about the dimensions of an inhaler chamber or any other drug delivery system. Of course, you want to be sure that all components in a pacemaker are connected properly before it is implanted.
In this case X-ray radiography and computed tomography (CT) is the ideal solution. CT is a non-destructive technique that creates full 3D copies of the test specimen that not only allows dimensional inspection but also fault detection, failure analysis and the assembly inspection of complex mechanisms.
Nikon Metrology offers a wide range of CT solutions that all feature in-house-built X-ray sources that give very sharp, high-resolution images. Real-time radiography enables interactive visual inspection, but automation capabilities are available for the inspection of larger batches.
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CMM Laser Scanning, Microscopes, Nikon Metrology, Optical Scanning, X-ray and CT Inspection | Tagged: 3D digital copy, assembly inspection, automated non-contact video measurement, CAD, CAD models, CT, digital laser scanners, dimensional inspection, drug delivery system, edge detection, failure analysis, fault detection, iNexiv, injection-molding tools, inspect surgical blades, manual metrology, measurement, medical components, medical devices, medical inspection, microscopes, microscopy, NEXIV, Nikon Instruments, Nikon Metrology, non-contact geometry inspection, part deviation, point cloud, quality control, radiography, SPC, surface geometry, x-ray | 
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Posted by Metrology Solutions Provider
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.
Leave a Comment » | Case Studies, Experts in the field of Metrology, Nikon Metrology, Optical Scanning | Tagged: adaptive robot control, aerospace, Airbus, Airbus UK, ARC, automated drilling, automated riveting, Automatic drilling, automation and robotics, automotive robots, Delmia, dynamic tracking, end effector, fastening, industrial robots, jig certification, K-Series Optical CMM, Kuka, KUKA Robots, KUKA UK, M3, machining, Mark Summers, Metris, Nikon Metrology, optical CMM, partners, QA, Real time motion control, Realistic Robot Simulation, Robot Metrology, robotic platform, Roger Holden, sealant application, Virtual Robotic Manipulator, wing assembly, wing part holes | Permalink
Posted by Metrology Solutions Provider
September 9, 2010
Nikon Metrology introduces its range of handheld 3D laser scanning solutions integrated into Rapidform XOR/Redesign and XOV/Verifier software. This solution enables design and manufacturing professionals to take full advantage of using premium Nikon Metrology scanners in combination with leading 3D point cloud analysis software to tackle reverse engineering or inspection tasks. Thanks to the new application programming interface (API), it becomes very straightforward for 3rd-party software vendors such as Rapidform to integrate Nikon Metrology 3D laser scanning.
Seamless integration for unmatched user experience
Collecting geometry data with Nikon Metrology’s leading-edge laser scanners is now easier than ever for Rapidform customers. Completely transparent to designers and manufacturers using Rapidform XOR/Redesign, the most comprehensive scan-to-CAD reverse engineering software and XOV/Verifier, the CAD-friendly inspection software, the Focus Handheld Scanning API manages point cloud acquisition by controlling all interaction between the ModelMaker laser scanners and handheld localizer of choice. As it handles all interfacing with the scanner, such as scanner parameter modifications or running a qualification routine, the API ensures the highest accuracy and reliability of the acquired data. The resulting point cloud data is fed directly into the Rapidform application in real time, ready for further processing.
Calvin J. Hur, CEO for INUS Technology Inc., remarked: “We’re very pleased to enhance our relationship with Nikon Metrology. By joining forces with Nikon Metrology, Rapidform offers designers and manufacturers the possibility to drive all handheld Nikon Metrology 3D scanners from XOR/Redesign and XOV/Verifier. Their favorite software environment allows them to acquire 3D scan data, and immediately run geometric inspection or directly create native, editable CAD models for reverse engineering purposes. Through our partnership with Nikon Metrology, a market leader in 3D scanning hardware, we are offering best-in-class reverse engineering, inspection and other engineering solutions to high-end customers worldwide. This further extends Rapidform software to support the sophisticated needs of high-end customers in automotive and aerospace industries.”
Rapidform XOR/Redesign is the only 3G (third-generation) reverse engineering software in the world. It is unique in the sense that you can collect data with any Nikon Metrology 3D scanner of choice and quickly create editable, parametric solid models of virtually any physical object. These models can be transferred from XOR into popular CAD applications with complete feature trees intact. This means that – unlike second generation reverse engineering software – the models from XOR are editable just like any other part designed in CAD. XOR, paired with a Nikon Metrology 3D scanner, is simply the fastest, most accurate way to create a design model of a real-world object that is ready for manufacturing.
API supporting MMDx scanner and MCA II arm
The Focus Handheld API supports Nikon Metrology’s latest-generation handheld scanning solution: the MMDx digital laser scanner on an MCA II articulated measuring arm. It also supports this scanner in combination with the K-Series Optical CMM as well as 3rd‑party measuring arms such as Romer/Cimcore and Faro. Nikon Metrology’s digital laser scanners offer superior optical and digital technology, translating into higher accuracy, automatic laser intensity adaptation and faster data acquisition.
With the new API, it becomes very straightforward for 3rd-party point cloud software vendors to integrate Nikon Metrology 3D laser scanning. This offers design and manufacturing engineers fast-lane access to world-class laser scanning, while enjoying the convenience of the point cloud engineering environment they know inside out.
Leave a Comment » | Nikon Metrology, Optical Scanning, Portable Metrology, Press Release, Software | Tagged: 3D point cloud analysis, 3d scanning, CAD models, Calvin J. Hur, Focus Handheld Scanning, geometric inspection, handheld scanning, inspection, INUS Technology, K-Series Optical CMM, MCA II articulated measuring arm, MMDx digital laser scanner, ModelMaker scanner, Nikon Metrology, parametric solid models, point cloud data, portable laser scanner, Rapidform, reverse engineering, scan-to-CAD, XOR/Redesign, XOV/Verifier | Permalink
Posted by Metrology Solutions Provider
September 7, 2010
When measuring large objects such as tractors, it’s a challenge to use traditional coordinate measuring machines (CMMs). Not only is a large and expensive CMM required, but any position change of the measurement object during the inspection measurement will result in losing the alignment. This challenge can be met by the Nikon Metrology K-Series optical CMM, a portable optical CMM that auto-aligns the measurement object by tracking reference points attached to the object.This auto-alignment functionality obsoletes the requirement for manual and time consuming re-alignments. The K-series system comprises a camera system with 3 camera units, a hand-held SpaceProbe for touch probe measurements and a portable controller with measurement and analysis software.
The key factor in deciding to select the K-series portable system was the combination of extended measurement volume, flexibility, and both the static and dynamic capabilities of the system,” explains Product Engineering Manager Gerald Werner of John Deere tractor manufacturing. ”Another important benefit is the ability to measure the prototypes directly in the workshop without having to transport them to the metrology hall. This saves a lot of time and enables us to fulfill the time-to-market requirements much faster than we could before.
In the past, measuring complete tractors was almost impossible for us. Only single parts or subcomponents of the complete vehicle were measured. The “auto-alignment” feature is an additional advantage of an articulated arm CMM and another reason for us to select a K-Series system”. By using three reference markers on the object, it is possible to measure all small movements dynamically and absolutely. The main advantages we get from the auto-alignment is that, when the tractor position changes, the initial alignment measured with the SpaceProbe is automatically updated. The auto-alignment also enables repositioning the camera system in order to measure hidden areas or to further extend the measurement volume.
The 17m3 measurement volume easily covers the cabin and a tracing or side in a single position. The ergonomic hand-held SpaceProbe allows the user to freely measure around the whole vehicle. The SpaceProbe can be equipped with long, automatically recognized touch probes for interior measurements. By relocating the camera system, the user can reach any point on the tractor while using the initial coordinate system. The portability of the K- series enables frequent position changes.
An additional advantage is that besides its application in coordinate measurement technology, the K-system is also specialized in dynamic measurements for suspension analysis or structure movement analysis, for example.
Applications
John Deere uses the K-System for R&D purposes in Product Engineering. With the SpaceProbe, the user can easily compare complex parts with virtual part data (CAD). The K-System provides fast and accurate dimensional information enabling a comparison toward the nominal data in the inspection software.
When it comes to the testing applications, the camera system can detect the smallest movements of the structure by measuring the small infrared LEDs. The dynamics software outputs functional correlations, enabling the identification of dimensional deviations as well as variations in the structure of the components.
Highly Precise
Our demand for 0.1 mm of accuracy over the measurement range is easily fulfilled by the K-system,” says Michael Biedermann of Product Engineering. The K-system is pre-calibrated and can be fine-tuned by the user at any time. Even the smallest influences (e.g. of temperature) can be compensated.
Anton Nirenberg, also from Product Engineering, places particular importance on high functionality and reliability: “Our workshop is often flooded with sun, but the K600 environment light filtering function operates perfectly.” This filtering function optimizes the applicability and robustness for measuring in all kind of industrial environments.
Leave a Comment » | Case Studies, Large-scale, Optical Scanning | Tagged: agricultural machines, Anton Nirenberg, auto-alignment, coordinate measurement, dynamic measurements, Gerald Werner, inspection, John Deere, K-Series, Michael Biedermann, Nikon Metrology, optical CMM, portable metrology, product engineering, SpaceProbe, suspension analysis, tractors | Permalink
Posted by Metrology Solutions Provider
September 1, 2010
Covering 3000 km between Darwin and Adelaide
Umicar Infinity’s dynamic wind resistance is six times better than serial-produced sports cars.
The challenge is simple. Cross the Australian desert as fast as you can without one drop of fuel. Fourteen selected engineering students of Groep T Engineering School in Leuven, Belgium, took up the challenge to hunt for a medal in the World Solar Challenge, the world championship for solar-driven vehicles.
From their predecessor team they inherited a solid, proven vehicle design along with ample know‑how and experience. In partnership with high-tech companies such as Nikon Metrology, these youngsters succeeded in developing the second generation of the solar race car, named Umicar Infinity.
“The focus of our engineering teams in creating the Umicar Infinity was somewhat different than what is usual in regular automotive vehicle development programs,” stated Koen Van Beneden, Head of Solar Team Marketing.
“To get the most out of limited solar cell power, our race car was engineered specifically for low weight, little aerodynamic
The space frame underneath the body shell consists of welded extruded aluminum tubes.
resistance and high energy efficiency of vehicle driveline mechanisms. The Umicar Infinity is a one-seater that only weighs 175 kg, and features dynamic wind resistance that is roughly six times better than premium serial-production sports cars. With just the electrical power of a vacuum cleaner available, the Umicar Infinity is capable of reaching speeds higher than 140 km/h!”
Pertinent need for metrology-level alignment
To create the race car’s rigid, light-weight space frame, engineers used extruded aluminum tubes that were welded together. To compensate for slight frame deformation due to the welding heat, engineers relied on technology from Nikon Metrology. After welding, the positions of key locations on the frame were measured using the hand-held SpaceProbe of the Nikon Metrology K-610 Optical CMM system.
This optical metrology solution operates using a fixed carbon-fiber structure that houses three linear CCD cameras. Through triangulation, the system is able to accurately track the positions of infrared LEDs integrated into the SpaceProbe that is held onto the frame point being measured. Based on the acquired frame coordinates, the team was able to verify specific shape characteristics of the frame. Engineers additionally measured datum points to define
To compensate for slight frame deformation, due to welding heat, engineers use Nikon Metrology.
reference planes to be used for alignment purposes later on in the subsystem assembly process.
According to Pieter Vangeel, Team Manager of Solar Team, alignment was critical, in particular when connecting the completed frame to the suspension subsystems. “The suspension units play an essential role in aligning the three wheels with respect to the body of the race car. The powered rear wheel has a swing-arm suspension unit, while a double-wishbone suspension unit keeps the front wheels in position. Special attention went to the locations on the frame where suspension parts need to be fitted, because they require perfect orientation to one another. Therefore, we relied on the Nikon Metrology K-610 system to accurately identify the positions of all suspension attachment points on the frame structure. With this information in hand, we were able to weld all connections between the space frame and the suspension units with high positioning precision.”
Further pushing race car’s operation efficiency limits
The next highly sensitive alignment job was the positioning of the aerodynamic body shell around the rest of the vehicle. Pieter Vangeel noted that the Nikon Metrology equipment, once again, proved very useful in adding metrology accuracy to the attachment procedure of major vehicle subassemblies. “Precise measurements and finishing are an absolute must in order to ensure that the wheels
Nikon Metrology K-610 uses triangulation to track LEDs integrated into the SpaceProbe in order to accurately measure the point held onto the frame.
are in their optimum position and orientation. Even the slightest wheel misalignment causes excess tire wear and mechanical friction. This means that we would potentially lose valuable time with additional tire exchange stops, each requiring about ten minutes standstill time. And additional mechanical friction would decrease the dynamic performance of the Umicar Infinity, reducing vehicle speed through lower operation efficiency.”
“Nikon Metrology truly helped Solar Team to develop a better race car,” Pieter Vangeel stated when asked about the role of Nikon Metrology in this ambitious Umicar Infinity project. “Metrology-level assistance in assembling main vehicle subsystems was essential in obtaining higher precision and better vehicle dynamics. We took the mechanical accessory gauge, which was used in Nikon Metrology alignment test campaigns, with us to Australia to perform wheel alignment tests in between racing days. The gauge allowed us to re-establish the original alignment, compensating for any wheel misalignments that resulted from mechanical and tire wear. Although measurements only take minutes, the impact of precision alignment has a significant impact on the competitive edge of our race car. We are convinced that this will propel the Umicar Infinity to success in the Solar Challenge world championship race.”
With just the electrical power of a vacuum cleaner available, the Umicar Infinity is capable of reaching speeds higher than 140 km/h!
Leave a Comment » | Case Studies, Nikon Metrology, Optical Scanning | Tagged: Australian desert, Groep T Engineering Shool, K-610 system, Koen Van Beneden, Leuven Belgium, Metris, Nikon, Nikon Metrology, optical CMM, Pieter Vangeel, solar cell power, solar race car, solar vehicles, Umicar Infinity, World Solar Challenge | Permalink
Posted by Metrology Solutions Provider
August 24, 2010
After upgrading optical metrology equipment with a handheld Nikon Metrology ModelMaker D (MMD) scanner for non-contact 3D measurement, PSA radically increased scanning productivity. Featuring a 100 mm laser stripe width and all-digital operation, the MMD enables PSA metrology engineers to complete detailed geometric scans of small to large vehicle body parts in record time. They can take the portable systems to any location or site, set it up and measure parts on the spot. The perfect interaction between localizer, scanner and software speeds up scanning throughput and decreases post-processing and analysis work. Laser scanning also enables PSA to systematically digitize body frames, doors, windshields and other parts, and use the acquired data to validate numerical calculations, ultimately contributing to fewer mechanical prototypes.
A single system that is suitable for many metrology tasks
Europe’s second-largest carmaker has a history with digitizing that dates back to 2001. Since then, PSA has gained significant experience in applying laser scanning to digitize the geometry of vehicle body parts of prototype or early production vehicles. “Dimensional accuracy is of prime importance in vehicle body assembly,” states PSA Poissy’s metrology department. “During the assembly process of a trunk lid, for example, the geometry of the lid slightly changes due to the mechanical interaction between frame, glass, trim, lock, etc. When we prototype vehicle body parts, we closely monitor geometry using the Nikon Metrology MMD to ensure assembled body elements will fit perfectly. The use of a wide variety of materials – including composites and plastics – sets specific manufacturing and measurement challenges, and increases the need for reliable and efficient metrology solutions.”
ESP enables the operator to scan a shiny logo as well as the dark base surface all at once.
Physically the largest part that PSA metrology engineers scan using the handheld Nikon Metrology MMD is a body-in-white structure. Positioning the articulated measurement arm at one or two locations is sufficient to digitize a hood or the entire backside of a vehicle body, for example. Metrology engineers at PSA also use the Nikon Metrology MMD to scan interior trim parts, light units and various other parts. To deliver top-quality data for different surface types even under difficult lighting conditions, the Nikon Metrology MMD scanner features ESP (Enhanced Sensor Performance). ESP is an algorithm that automatically adapts camera and laser settings to accommodate varying surface shape, color and reflectivity. This helps PSA engineers accurately deal with sheet metal, composites and plastics – without having to apply spray or other preparation measures. With a laser line that counts as many as 1028 measurement points, the scanner reliably digitizes freeform surfaces as well as the edges of individual features. Another reason why PSA opted for a non-contact scanning solution is the ability to reliably digitize softer trim material, eliminating the risk of scratching fragile components or pressing flexible parts. On finished cars, the system serves as an optical gauge for flush & gap inspection between body panels.
Reducing scanning throughput time and post-processing effort
When scanning a vehicle body part, a PSA engineer operates the laser scanner while the scanned surface takes shape in
The process of acquiring scan data to delivering optimized polygon mesh is managed by KUBE software.
real time on the laptop screen. The displayed information provides instant feedback regarding scanning speed, coverage and progress. Scanning takes place at a relentless pace, thanks to the scanner’s extra large laser stripe and fast digital signal processing. “The result of the scan is a cloud of hundreds of thousands or even millions of measured surface points,” explains a PSA scanner user. “After filtering the point cloud to eliminate excess points, we generate a polygon surface mesh and optimize it. The entire process is smoothly managed by Nikon Metrology KUBE software. The tight integration between scanner software and hardware not only streamlines the scanning process, but also cuts the remaining post-processing effort in half compared to the previous scanning solution.”
According to PSA Poissy’s metrology department, the metrology team represents a centralized unit that runs measurements at PSA sites across France to support vehicle development from prototype to release. “Regardless of whether measurements are scheduled to take place in the PSA Poissy facilities, or at PSA sites in Rennes or Sochaux, for example, metrology engineers take the portable system with them and start scanning right away. This pragmatic approach offers maximum measurement flexibility and saves on logistics by reducing transportation of vehicle body (parts) to our metrology laboratory.”
Scanning jobs performed four times faster than before
PSA applies laser scanning to verify the shape of lighting units and their positioning onto the body.
Besides monitoring the geometric quality of vehicle body parts – Nikon Metrology laser scanning forms an essential step in verifying numerical calculations PSA performs as part of virtual simulation. Metrology engineers at PSA systematically use the Nikon Metrology MMD scanner to acquire digital 3D copies of structural components such as body frames, doors, windshields and other parts. This touch with reality increases simulation accuracy and helps reduce the number of lengthy and costly physical prototype cycles. “Overall, when using the all-digital Nikon Metrology laser scanner with its wide laser stripe, we are able to complete scanning jobs four times faster than before,” says the PSA scanner user. “Productivity improvements of this degree enable us to take on additional metrology assignments and yet increase the level of data quality, all within the current capability of our metrology team.”
Click here to learn more about ModelMaker handheld laser scanners
Leave a Comment » | Case Studies, Large-scale, Nikon Metrology, Optical Scanning | Tagged: 3d scanning, articulated measurement arm, automobile assembly, body-in-white, digitizing, dimensional accuracy, enhanced sensor performance, flush & gap inspection, increase productivity, Kube software, laser scanning, Metrology, MMDx, ModelMaker, Nikon Metrology, non-contact measurement, portable CMM, prototype, PSA, PSA Peugeot Citroen | Permalink
Posted by Metrology Solutions Provider
August 20, 2010
This South Dakota production plant found a faster way to verify large production fixtures and manufactured parts of construction and agricultural equipment by positioning a
portable optical CMM on the production floor and measuring points of choice right away using a wireless tactile probe.
K-Series’ inspection volume fits a complete skid steer vehicle with loader moved in upward position.
The wireless SpaceProbe and graphic operator assistance speed up inspection.
K-Series supports fast inspection of geometric features and surface points in and around skid steer loaders.
Visual feedback highlights measurement validity and displays where the next point is located.
Engineers at the Gehl South Dakota production plant in Madison found a faster way to verify large production fixtures and manufactured parts of construction and agricultural equipment. They simply position a portable K-Series Optical CMM from Nikon Metrology on the production floor, and measure points of choice right away using a wireless tactile SpaceProbe. This ergonomic metrology system enables Gehl to halve geometric verification time-spending on chassis and driver compartment, and yields deeper insight when troubleshooting equipment prototypes.
Farmers and construction workers value compact Gehl skid loaders, telescopic handlers, track loaders, excavators, all-wheel-steer loaders, articulated loaders and asphalt pavers for their ingenuity, innovation and reliability. At this production site in Madison, engineers manufacture skid and track steer loaders and telescopic handlers that have been designed at the company headquarters in Wisconsin. To monitor the production quality of this compact outdoor equipment, Gehl staff run geometric measurement right at the production line.
“Quality control involves the inspection of selected geometric features and surface points on steel parts after being stamped, drilled, and painted,” explains Joseph Palmiotto, the quality assurance manager for Gehl in Madison. “We not only monitor finished parts, but also verify mechanical fixtures used for part production and assembly of chassis and driver compartment, for example. To more efficiently execute metrology tasks on components of various sizes, we moved from an articulated measuring arm with a limited reach to a Nikon Metrology K-Series system that covers a considerably larger measuring volume early last year.”
Read the rest of this article in Fabricating & Metalworking magazine
Leave a Comment » | Case Studies, Nikon Metrology, Optical Scanning | Tagged: Dale Yeager, Gehl, geometric features, inspection volume, K-Series, Madison, Metris, Nikon, Nikon Metrology, NMI, optical CMM, quality control, wireless tactile probe | Permalink
Posted by Metrology Solutions Provider
August 12, 2010
The innovative Nikon Metrology Cross Scanner is used at Volvo Cars Gent to further accelerate the design-through-
manufacturing process for its brand new Volvo XC60 crossover vehicle. By digitizing physical sheet metal and plastic body parts and virtually assembling vehicle bodies in software, Volvo engineers completed pre-production geometry verification nearly twice as fast! 3D laser scanning technology, point cloud processing and virtual assembly shortened physical evaluation of prototypes and eliminates the need for costly specialized verification tooling.
BODY ASSEMBLY ON THE CRITICAL VEHICLE DEVELOPMENT PATH
Volvo Cars built up a solid reputation in terms of vehicle safety, environment and design. Recently, the Swedish car maker released the brand new Volvo XC60, which is stirring up the crossover vehicle segment. The design and manufacture of this innovative vehicle body required the coordination of many different groups. Sheet metal stamping and welding, in combination with the use of new materials and joining technologies, set ever-tougher geometric challenges. Process and product tolerances, as well as material and equipment behavior, can influence body geometry, when shifting from the vehicle body CAD model to the physical nominal model, and finally to the mass-produced car. The position of edges, holes and other geometric features plays an essential role in correctly assembling the different body parts of a passenger vehicle. Belgium-based Volvo Cars Gent and Nikon Metrology participated in a project that aimed to streamline the pre-production phases by simplifying the geometric body verification process. Both companies joined forces to develop a new geometric verification method for vehicle bodies, which builds on a digital inspection process using 3D scanning and virtual assembly. This method provides better insight and effectiveness compared to traditional body tuning, which involves extensive tactile inspection, physical part conflict analysis and complex verification tooling.
GROUND-BREAKING 3D LASER CROSS-SCANNER TECHNOLOGY
In close collaboration with Volvo Cars, Nikon Metrology optimized its existing cross scanner to match the performance level required to drive the new geometric verification method. We jointly integrated the laser scanner for use on horizontal-arm CMMs, and increased the scanner’s field-of-view depth. The increased scanning standoff distance range offers higher measuring flexibility and better access to clamped body components. The cross scanner incorporates 3 laser beam / digital camera sets, each shifted 120 degrees in position. This allows the laser scanner to capture slots, sleeves, holes and other features in a single scan. Although inherently designed for scanning geometric features, the cross scanner is also suitable for digitizing 3D surfaces and edges. The positions of features and edges are imperative to correctly mate parts and assemble car bodies. The development work also impacted laser optics technology and digital data processing. The cross scanner design has been enhanced to flexibly deal with all material types and colors without the use of spray. Now, reflective sheet metal as well as painted surfaces can be captured quickly and reliably. Laser scanning generates point cloud data at high scan rates, which by far outperform tactile point-by-point acquisition technology. Furthermore, it is much easier to define the linear and polygon scanner travel paths than to specify individual touch sensor points for a tactile inspection job.
FASTER AND BETTER VOLVO XC60 BODY GEOMETRY VERIFICATION
In the pre-production stage at Volvo Cars, metrology engineers scan sheet metal and castings (steel and aluminum) as well as composite and plastic body parts. After acquiring data at approximately 20 micron accuracy, they filter the resulting point cloud, and analyze geometry against nominal CAD data. Volvo Cars relies on digital graphic reports to evaluate the parts, and streamline supplier interaction with regard to adjusting molding and stamping equipment. Digital component verification only requires standard holding fixtures, whereas traditional inspection methods demand costly dedicated positioning and fixation tooling. After digitizing individual parts, engineers align and virtually assemble sheet metal, interior, exterior and chassis components in software in order to build a complete virtual vehicle body. Even before body parts are physically assembled, the new geometric verification approach already gives information about potential part fitting issues. To run specialized investigations, virtual body assembly models are loaded into dedicated software for reverse engineering, variation analysis, and spring-back prediction, for example. Analysis between scanned and numerical vehicle body models enables engineers to efficiently tune component geometry to fall within the assembly processing window.
VERIFYING SURFACES AND FEATURES USING HANDHELD LASER SCANNERS
The collaboration project with Volvo Cars also contributed to the development of K-Scan, a handheld laser scanner with a single laser stripe for in-situ inspection. An optical CMM continuously tracks the scanner so that the operator can freely walk around and take scans in an area that spans the entire vehicle. Volvo engineers use K-Scan to verify flush & gap, body deformation and static/dynamic geometry on prototype or early production vehicles. Color-coded visual inspection reports illustrate how flush & gap evolves along complete spines in between hood and front fender, for example. Optical handheld verfication is used in special applications where manual methods fall short, or in case an urgent issue comes up that needs fast troubleshooting. In summary, the new process reduces times for matching loops, and realizes an important cost reduction for test materials and screwed body, nominal blue bucks and dedicated fixtures. Virtual verification on the basis of 3D scanning is a major step forward. This project received the Henry Ford Technology Award in Detroit. 3D scanning covers reverse engineering of clay models, virtual geometry verification of vehicle body structures, and geometric feedback data collection on finished cars.
REDUCTION IN NUMBER OF GEOMETRY ITERATION LOOPS
When preparing production rollout for the Volvo C30, the virtual body geometry method was applied and evaluated for the first time. In parallel, traditional tactile verification methods were performed to set benchmarks in terms of inspection precision and throughput. When ramping up Volvo XC60 production, the company actually managed to reduce geometry iteration loops and the lead-time of individual loops. Fewer physical evaluation prototypes also reduce material scrap and decrease expenditure of complex verification tooling, such as body-in-white cubing. 3D scanning technologies are already well accepted at Volvo Cars where they are used in different stages of the car manufacturing process. Non-contact metrology is systematically applied in the early design stages when engineering styling by digitizing clay models. In pre-production, engineering digitizes body parts and body-in-white structures to optimize part manufacturing and assembly. After kicking off serial production, specific aspects of car components or full cars are scanned to serve as SPC samples for quality monitoring and product audit purposes. For the future, laser scanning is seen as a key enabler of in-line quality control. The successful project was partially funded by IWT, a Belgian institution supported by the Flemish Government that encourages technological innovation projects, and managed by Flanders’ DRIVE, an innovation and collaboration platform for the Flemish vehicle industry.
Leave a Comment » | Case Studies, CMM Laser Scanning, Coordinate Measuring Machines, Nikon Metrology, Optical Scanning | Tagged: 3d laser scanning, automotive plastic body parts, automotive prototype, automotive sheet metal, automotive vehicle assesmbly, CAD model, CMM, cross scanner, design-through-manufacturing, digital inspection, flush & gap, geometric body verification, Henry Ford Technology Award, IWT, K-Scan, Nikon Metrology, non-contact measurement, optical CMM, point cloud processing, quality control, reverse engineering, sheet metal stamping, sheet metal welding, virtual assembly, Volvo, Volvo Gent, Volvo XC60 | Permalink
Posted by peppercom
August 10, 2010
CARAT-Duchatelet integrates the highest level of security and luxury into prestige vehicles.
As the world leader in armored prestige vehicles, CARAT-Duchatelet counts sheiks, kings, presidents, CEOs and other wealthy VIPs among its customers. Before stretching and armoring luxury vehicles, CARAT-Duchatelet engineers remove seats and trim, and scan the entire vehicle body using Nikon Metrology K-Scan MMD. The geometric 3D scan acquired by this portable metrology solution forms the basis for drastic vehicle modifications and detailed craftsmanship. The portable Nikon Metrology K-Scan MMD enables them to ergonomically capture vehicle interior and exterior in one pass.
Adding security and luxury to prestige vehicles
Far away from mass and series production, CARAT-Duchatelet integrates the highest level of security and luxury into prestige sedans, limousines and off-road vehicles. Currently, over 40 Heads-of-State from Africa, Europe, the Middle East, Far East and former Soviet Republics are chauffered in CARAT-Duchatelet vehicles. To armor the VIP vehicles, CARAT-Duchatelet engineers and craftsmen stretch vehicles both in length and height, and create personalized luxury interiors. Today, the Belgian company is recognized as the world leader in armor integration and the manufacture of specialty vehicles in the automotive industry.
At CARAT-Duchatelet, the armor development and integration process starts with crafting armor component shapes in wood. Since wood is easy to manipulate, engineers quickly gain a rough idea of how new armoring will fit into a particular vehicle brand or type. This is where reverse engineering comes into play. “Using Nikon Metrology K-Scan MMD, we scan the entire vehicle body; one time with the wooden parts attached and one time without,” says Eric Appelmans, R&D engineer at CARAT-Duchatelet in Liège, Belgium. “This approach allows us to accurately digitize the vehicle body and generate digital CAD information. Detailed CAD data provides the insight we need to create an invisible bullet-tight cage by optimizing the design of steel plate and glass armor parts.”
Optical CMM provides unmatched scanning comfort
The setup of the Nikon Metrology K-Scan MMD system is fairly straightforward. The engineer positions the camera of the Optical CMM module next to the vehicle body. The three high-resolution CCD cameras of the Optical CMM dynamically track the precise location and orientation of the handheld 3D Nikon Metrology MMD laser scanner. “The absence of mechanical constraints creates a superior comfort level when scanning the surfaces of the body,” explains Eric Appelmans. “The scanner is equipped with a laser stripe of 100 mm, which enables us to acquire measurement points at a rate of tens of thousands per second. With Nikon Metrology K-Scan MMD, we easily and consistently reach the required measurement accuracy of 100 micron. But most important for us is the ergonomic handgrip of the scanner and the unmatched ease-of-use delivered by the system’s optical CMM technology.”
When scanning is ongoing, it is important for the user to see the point cloud develop on the computer screen in real-time. Nikon Metrology KUBE software manages the captured point cloud of the vehicle body, which typically consists of hundreds of thousands or even millions of accurate measurement points. To conveniently access all locations inside the car body, CARAT-Duchatelet engineers carefully select optical CMM positions that provide optimum coverage of the scan area. To compensate for any vehicle movement during measurement, the operator applies the Optical CMM’s unique dynamic reference feature. 3 to 6 small LEDs stuck to the car body and dynamically tracked by the Optical CMM ensure that all movement is compensated accurately. Using this information, the K-Scan MMD system is able to dynamically relocate the laser scanner position, avoiding leap-frogging or part realignment. K-Scan MMD also supports multiple standpoints for the Optical CMM. Data acquired from different Optical CMM locations refer to the same reference axes system and contribute to a single unified point cloud.
Point cloud data drives the CAD generation process
To reduce the amount of measurement data, CARAT-Duchatelet engineers apply curvature-based filtering algorithms to eliminate obsolete measurement data in flat plane surface areas. “After point filtering, we export the point cloud in IGES or ASCII format, and import the file in CATIA V5 software. On the basis of the point cloud data, we create a surface mesh and generate CAD surfaces. For us, the process of fitting freeform CAD surfaces through measurement points represents a mostly automatic procedure. For particular edges and roundings that are deemed critical, we manually fit surfaces and select the optimum level of smoothing. This flexibility enables us to take control of the CAD generation process and obtain high CAD definition quality.”
According to Eric Appelmans, scanning with K-Scan MMD provides better insight in a shorter time frame compared to taking manual touch probe measurements using an articulated measurement arm. “K-Scan MMD offers a comfort level and data acquisition rate that are simply beyond comparison. Our approach of digitizing a complete car in one pass at the start of the project avoids many costly and time-consuming iterations later on the process. This enables us to design and develop all different vehicle modifications in the most effective way.”
Reverse engineered steel armoring parts make up a bullet-tight cage around the interior of a vehicle body.
Scanning streamlines all vehicle modification actions
Starting from the CAD data they generated, the R&D team of CARAT-Duchatelet specifies detailed requirements for steel and glass armoring and interior design. For radical vehicle modifications – such as vehicle extension and raised roof – a pre-scan may be executed to design adaptations to body, doors, hinges and windows, and driveline transmission. “The K-Scan MMD helps us a great deal in streamlining all our vehicle modification actions, providing top quality in the shortest time frame possible. With accurate and complete CAD data, we minimize the risk for development surprises that may introduce expensive rework and process delay.”
To read more on our website, click here.
Leave a Comment » | Case Studies, Nikon Metrology, Optical Scanning | Tagged: 3d scanning, armored vehicles, CARAT-Duchatelet, CCD cameras, digitizing, dynamic tracking, Eric Appelmans, K-Scan, Kube software, laser scanning, luxury car interiors, MMD, ModelMaker scanner, Nikon Metrology, optical CMM, point cloud, prestige vehicles, reverse engineering, vehicle extension, vehicle raised roof | Permalink
Posted by peppercom
July 7, 2010
This blog article was written by John Parry. We have re-posted this blog entry because Voxdale used Nikon Metrology’s optical scanning solution to achieve their results.
This work by Voxdale was done a couple of years back, not that long after Voxdale was founded, which makes it all the more impressive, and was done for Champ Car, now merged with Indy Car. The project was to optimize the existing Panoz chassis for Conquest Racing’s Champ Car – now unified with Indy Car.
The first hurdle Voxdale encountered was having no CAD files to work from. Their solution was to scan the entire car using a Nikon Metrology optical laser scanning system to produce a STL point cloud with better than 0.3mm accuracy – reverse engineering at its best!
The point cloud was then read into Pro/ENGINEER Wildfire – after which the rest of the design work and all the analysis was done within Pro/ENGINEER. Interactive Surface Design (ISDX) and Advanced Assembly (AAX) features were used to build the CAD model, and Pro/ENGINEER Mechanica was used for the thermal and structural analysis with FloEFD.Pro Concurrent CFD software was used for the aerodynamics.
The beauty of Concurrent CFD is that it works directly within the CAD system so everything is done within the one environment. The CAD geometry does not need to be exported and cleaned up for the analysis, it can be used as is, or simplified using Pro/E’s Publish Geometry feature whilst retaining all the model’s parametric features so design changes are carried out in the CAD tool on the native CAD geometry. Here’s an exploded image of a model Voxdale created.
Additional information is needed for the FloEFD.Pro analysis such as surface roughness information, plus the wheels need to be made to rotate and the ground move. Actually this makes the simulation better than most wind tunnel setups where it’s often impossible to achieve this on a full size car!
Once the model is built in the CAD tool, the opportunities to improve the design through analysis is really only limited by the designer’s imagination – specifically their ability to identify aspects of the design to improve and ask themselves the question “What if…?”, and changing the design accordingly to see how key performance parameters like aerodynamic drag change as a result.
Here are some of the flow trajectories and cut plots showing the flow over the whole car, and showing the air flow into the side pods
This post is a re-post of John Parry’s Blog entry.
Images courtesy of Voxdale
Leave a Comment » | Nikon Metrology, Optical Scanning | Tagged: CAD model, Indy Car, John Parry, K-Scan, Metris, Nikon, Optical scanning, reverse engineering, Voxdale | Permalink
Posted by Metrology Solutions Provider
May 18, 2010
This application example shows a drilling fixture built from BoxJoint components. The fixture was designed by DELFOi and physically built by Nikon Metrology. It was demonstrated in Nikon Metrology’s booth at the CONTROL 2010 fair in Stuttgart. Nikon Metrology needed a fixture to locate a small wing component during drilling. You robot users out there understand that robots are not accurate machines. Even if some robots today are accurate down to +/-0.3 mm, once a robot comes in contact with an object, such as drilling, the robot will deflect and maybe even skid along the surface of the part in contact. One way to maintain high accuracy in a robot is to measure its TCP (Tool Center Point) each time the accuracy is required, such as just before engaging the drilling. The idea is to integrate the robot controller with the metrology controller.
Nikon Metrology provides just such a solution by integrating their K600 optical CMM camera to the robot controller. The CCD cameras see LEDs, flashing in infrared frequency, and measure their spatial locations using photogrammetry . One set of LEDs were glued to the drilling machine, and one set of LEDs were glued to the BoxJoint fixture framework. By measuring the tooling pins relative to the framework LEDs the system detects the position of the part. When the robot moves along its programmed drilling positions the robot will go into a measurement loop and ask the metrology system about the location of the drilling machine. 2-3 iterations are performed where the robot updates its position to meet the accuracy requirements. The accuracy setting for this cell was better than +/- 0.1 mm.
Check out other case studies using Nikon Metrology’s K-Robot
Read the full article
Watch a video on a robotic drilling solution
Leave a Comment » | Case Studies, Nikon Metrology, Optical Scanning | Tagged: Boxjoint, cameras, Control show, DELFOi, Drilling, improve drilling accuracy, K600, Kuka, Kuka Robotics, Metris, metrology assisted production, Nikon, Nikon Metrology, optical CMM, photogrammetry, robot, robotic drilling, Robotic measurement, Stuttgart | Permalink
Posted by Metrology Solutions Provider
October 14, 2009
When you think of laser scanning, 3D measurement and CAD models, your thoughts tend to gravitate toward images of airplanes and automobiles. Not once have I ever thought that school mascots would become the object of the metrology world.
Lori Shontz, senior editor of the Penn Stater Alumni Magazine, wrote an excellent article in her blog about Penn State’s school mascot, the Nittany Lion. The university wanted to be able to preserve the 69 year-old sculpture, a gift from the senior class of 1940. This way, if any damage was ever inflicted on the mascot, Penn State could recreate the Lion from the 3D CAD model. They decided to bring in professionals from SURVICE Metrology. SURVICE Metrology is a close partner of Metris USA and they used none other than the Metris Optical CMM to scan this beast of a mascot. Now that this project is complete, there are plans to possibly animate the mascot.
Click here to read more on this fascinating article by Lori Shontz
Leave a Comment » | General Buzz, Optical Scanning | Tagged: 3D CAD model, 3d scanning, Lori Shontz, Metris, Nikon Metrology, Nittany Lion, optical CMM, Penn State, school mascot, Survice Metrology, university | Permalink
Posted by Metrology Solutions Provider
