 |
|
Measuring/Inspection
Next generation metrology systemsSince the earliest days of the Industrial Revolution, dimensional inspection has been used as a quality control and/or quality assurance tool to discover non-conforming parts before they are shipped. Over the past several years, manufacturing engineers have discovered that dimensional inspection data is even more powerful when it is applied directly to process control. The logic is clear. It is more cost effective and more efficient to produce parts that meet tolerance specifications the first time rather than reworking them. To be truly effective as a process control tool, however, metrology systems must leave the inspection laboratory and move to the shopfloor. They must be placed as close as practical to the process itself, if not within it, while maintaining the capability to accurately gather large amounts of dimensional data. Therein lies the challenge for metrology equipment manufacturers. Building rapid, accurate, production measurement systems with the ability to quickly analyze massive quantities of dimensional data, while being hardened against the harsh conditions of the shop environment, is the primary new technology driver in the metrology industry as it enters the 21st century. Research and development efforts in the industry are focused in two important areas--data gathering sensors and measurement and inspection software. Advanced sensors must be immune to the effects of shopfloor temperature gradients and airborne contaminants while gathering large amounts of data more quickly and accurately than is possible with today's touch trigger probes. Measurement software must be powerful enough to process data accurately, plus easy for operators of all skill levels to use. In addition, with continuing interest in process automation and the introduction of CAD/CAM systems in both large and small manufacturing operations, it is critical that measurement software seamlessly interface, and in many cases drive, these systems. At Brown & Sharpe, we're working to develop practical sensor and software technology solutions to meet the increasing market demand for simple, in-process metrology applications. For example, the operator interface of our new generation software will be designed to be sensitive to the type of measuring device that it is running. It will know if the operator is using a manual measuring instrument, such as an electronic caliper or a full-featured coordinate measuring machine. The software will present only those interactions required for whatever application is being used. Our next generation software will underscore the importance of dimensional measurement by using metrology as the bi-directional information conduit that joins design and manufacturing. It will work effortlessly with CAD/CAM and off-line inspection systems to facilitate the inspection process and provide an advanced level of process control. It will seamlessly interface with all CAD systems so that CAD models do not have to be translated when they are downloaded to the measuring system. The next generation software will also include a complete GD&T tolerancing engine for advanced statistical process control capability. New sensors will combine elements of optics, video and laser technologies into devices that can rapidly scan complex shapes and surfaces and accurately gather dimensional data. Combined with these sensors are powerful mathematical engines that will quickly analyze the large amount of dimensional data these systems can generate. Initial systems will be designed for turbine engine blade and electronic device inspection applications. This new sensor technology will be scaleable for use in the measurement of complex contours in the aerospace and automotive industries as well and will be powerful enough to look at whole car bodies and aerospace fuselage sections and provide large amounts of accurate dimensional data. Shopfloor data gathering not only provides immediate feedback concerning the quality of individual parts, but can also be the basis for the analysis of the condition of the machining operation. Going one step further, by integrating the measurement and design functions, overall productivity can be improved and operations fine tuned to account for a number of production variables. Measuring/Inspection Originally published in the August 1998 issue |
|
