Scanning systems for reverse engineering

Transcription

1 Scanning systems for reverse engineering Automatic unmanned scanning with easy-to-use software Scanned data manipulation and output for CAD/CAM systems Comprehensive CAM software for machining of production tooling Reverse engineering solutions for finished component or tool production

2 WHAT IS SCANNING? Scanning is the process of gathering data about an undefined 3-Dimensional surface. It is used in fields such as tool and die, mould making, press tools, aerospace, jewellery, medical and confectionery, in fact anywhere there is a need to reproduce a complex free-form shape. During the scanning process, an analogue scanning probe is commanded to contact and move back and forth across the unknown surface. During this process, the system records information about the surface in the form of numerical data. This data may then be used to create a CNC program to machine a replica or geometric variant of the shape. Alternatively, the data can be exported in various formats to a CAD/CAM system for further processing. What is the difference between digitising and scanning? The terms digitising and scanning are often used to describe the same process. Traditionally the term digitising referred to the process of taking discrete points from a surface using a touch-trigger probe. However, with the introduction of new technologies in data capture such as laser, camera, vision and analogue probe systems, the term digitising is now used as the generic description for the process of acquiring data from undefined surfaces. What type of sensor should be used? As the world s largest supplier of scanning systems, Renishaw has extensive experience in the application of scanning technology. New sensor developments are constantly evaluated and the optimum methods of gathering surface data recommended to customers. For most applications, the best results in terms of accuracy and quality of surface finish are obtained using contact sensors. However, where very soft and fragile materials are to be scanned, Renishaw offers noncontact, laser systems. Contact systems have several fundamental advantages over the majority of available non-contact systems: Treatment of surfaces to prevent reflections is not required. Vertical faces can be accurately scanned. Data density is not fixed and is automatically controlled by the shape of the component. Time-consuming manual editing of data to remove stray points is not required. The last two problems have been addressed by the Renishaw laser system, due to an advanced technical specification and powerful easy-to-use software. Scan The Renishaw scanning process Manipulate data Create variant of original Contact Non-contact Create output CNC program or export data to CAD system Finished component Mould, die, press tool, reproduction part, EDM electrode prototype

3 SYSTEMS AVAILABLE System introduction There are four complete systems available from Renishaw, three of which can be retrofitted to a CNC machine tool and one which is a stand-alone scanning machine. Certain CNC machines have inbuilt scanning capability which can make use of a Renishaw analogue scanning probe and Tracecut software. A comprehensive range of styli, designed specifically for scanning applications, is available. RETROSCAN Retrofit scanning system for CNC machine tools Provides an economical entry into scanning and is ideal for occasional scanning. Easy installation in less than 30 minutes causes minimum disruption to your shop/production schedule. Adds extra capability to your machine tool and is compatible with a wide range of CNC controllers. Being portable means that even after installation, it can be quickly exchanged between different machines and types of CNC control. Full range of datum functions make complex fixtures unnecessary and allow rapid job set-up. The process is fully automatic and requires no manual intervention which allows lights out operation. Retroscan system installation (A personal computer is required) SP2-1 probe RS232 Probe interface card System operation Retroscan works by taking the output from the scanning probe and calculating the surface coordinates and machine positioning commands. After each incremental move the probe stylus deflection is evaluated and a new target position calculated and sent to the CNC via the RS232 link from the PC. The data describing the model surface is then stored on the PC. Tracecut software The package includes:- SP2-1 analogue scanning probe Five styli Probe/PC interface card (CC1) Tracecut CAM software Connection cables Shank Anti-rotation clutch Installation and commissioning Carrying case 12 months system warranty

4 SYSTEMS AVAILABLE RENSCAN 200 Retrofit closed loop scanning system for machine tools - an enhanced scanning system for CNC machine tools which has all the features of Retroscan plus the following advantages:- Faster scanning speed reduces the amount of non metal cutting machine time. Superior control allows higher volumes of data to be collected resulting in better surface quality. Learn mode adapts feedrate to suit part geometry thus giving optimum scanning speed at all times. System operation Renscan 200 works by taking output from the scanning probe and machine tool axes positions. The software calculates the surface coordinate data point and the new target position to which the machine should move. This process is carried out dynamically and results in a smooth continuous motion of the machine as the probe scans the surface. The data describing the model is then stored on the PC. Renscan 200 system installation (A personal computer is required) Available as an upgrade to an existing Retroscan system. Cable junction unit Scale/encoder board SP2-1 probe RS232 Renscan output cable (PL96) Axis position interface card Probe interface card Tracecut software The package includes:- SP2-1 analogue scanning probe Five styli Probe/PC interface card(cc1) Axis position/pc interface card(cc4) Tracecut CAM software Connection cables Shank Anti-rotation clutch Installation and commissioning Carrying case 12 months system warranty

5 SYSTEMS AVAILABLE RENSCAN 350 Integrated scanning system for machine tools - harness the full power of your CNC by making use of in-built scanning cycles provided by the CNC manufacturer:- Fully integrated system means that very fast scanning speeds are achievable with the SP2-1 probe. No requirement for RS232 communications means that your computer does not have to be next to the machine tool. System operation Renscan 350 works by taking the output from the SP2-1 scanning probe directly into the CNC unit. The whole system is integrated and calculation of the machine movement is carried out by the CNC and acted upon immediately. As there is no requirement for RS232 communications during scanning, the performance of this type of system exceeds the performance of non-integrated ones. Renscan 350 system installation (A personal computer is required to run Tracecut software) CNC manufacturer s probe interface card SP2-1 probe RS232 RS232 PC (optional) Tracecut software The package includes:- SP2-1 analogue scanning probe Five styli CNC manufacturers probe interface Tracecut CAM software (optional) Connection cables Shank Anti-rotation clutch Installation and commissioning Carrying case 12 months system warranty

6 SYSTEMS AVAILABLE CYCLONE - a stand alone scanning system designed for users who require the ultimate in high speed and fine detail scanning. Dedicated off-line scanning leaves machine tool free to cut metal. High speed scanning reduces lead times from pattern to finished item/tool. Very low probing forces allows scanning of delicate materials. Ability to use extremely small styli (0.3mm) allows the scanning of very fine detail. Magnetic breakaway of stylus provides crash protection for workpiece/stylus. Availability of a non-contact, laser probe. Quiet and clean in operation - allows installation in an office-like environment. System operation Cyclone combines output from its scanning probe and axes positions using the purpose built scan control card. The Tracecut software calculates the surface coordinate data point and a new target position to which the machine should move. As there is no requirement for RS232 communications, and the machine is of lightweight construction, much faster scanning speeds can be achieved than on machine tooi based systems. As with the other three systems the scanning process is fully automatic. Scanning cylinder head Contact probe scanning (A personal computer is required to run Tracecut software) Optional laser scanning probe (Part by permission of The Royal Mint, UK) The package includes:- Analogue scanning probe Stylus Scan control card Servo power amplifier Tracecut CAM software Connection cables Clamp kit Installation and commissioning 12 months system warranty

7 SYSTEMS AVAILABLE CYCLONE OPTIONS Cyclone long-bed option which enables parts larger than the standard machine range to be scanned Scanning of a shoe last utilising the Cyclone indexer (optional) An application using a disc stylus for use in scanning a turbine blade, utilising table riser option (allows scanning of tall components)

8 TRACECUT SOFTWARE The heart of all Renishaw scanning systems is the Tracecut software. More than just a data capture system Tracecut enables you to manipulate data and then create an NC program or CAD output. An optional surfacing module, TraceSurf, creates true CAD surfaces in IGES or STL formats, suitable for export to any CAD system. Recently introduced standard features include 2 1 2D profiling, full modelling capability, a module for turbine blade tip refurbishment and simple dimensioning. The Tracecut software is compatible with:- Windows 95/98/NT/NT2000/ME. Capture The ability to define planes and align axes plus a full range of datum functions make complex fixtures unnecessary and allow for rapid job set up. The many options for data capture allow almost any free form shape, no matter how detailed, to be scanned. Several modes of 2D profiling are possible:- Single 2D profile Multiple 2D profiles various Z heights Multiple 2D profiles single Z height Capture of profiles with variable Z A variety of 3D scan patterns is available, and may be used individually or combined to provide the optimum scan path for a particular set of features X Y Any angle When scanning in x,y or angular a polygonal boundary may be defined Radial Pencil mode (on Cyclone) Manipulation of data If required the captured data can be manipulated to create a variant of the original Original Combine models to create multi-impression tools including mirroring in X and Y axis Scale XYZ Triple zone scaling Male/female Rotate Merge two or more models Generate split face

9 TRACECUT SOFTWARE Machining Tracecut offers a complete CAM package with a variety of powerful machining strategies, and will create gouge proof machining programs for any CNC machine tool. It is even possible to scan on one system and cut the part on a totally different machine. Tracecut can also create an output to import into your CAD system if you wish. Features include:- Automatic area clearance machining from solid. Tool diameter, shape and machining path can be totally independent of the stylus diameter and scan path used. Negative and positive surface offsets can be applied to allow for spark gaps or material thickness. Tool shapes can be defined by the user. Graphical representation of machined surfaces. Original Semi-finishing Roughing Finishing Ball Nose Flat Bull Nose Tapered Bull Nose Tapered Flat Nose Tapered Ball Nose D Bit The following toolpaths can be employed when machining:- Terrace X Y Any angle Spiral Concentric Radial 2D Profiles can limit the machining area Helical machining (turbine blade module only) CAD outputs CAD outputs available:- IGES points/stl binary ASCII data DXF polyline VDA points System specific outputs also available for leading CAD CAM suppliers IGES/STL surfaces (optional) Surface area/ volume Volume and surface area calculations provide many users of Renishaw scanning systems with beneficial capabilities, particularly in the automotive industries. The volume of a scanned model may be calculated. For each option the boundary for the calculations may be minimum/maximum Z, a specific Z value or a pre-defined split-face, thus providing full flexibility for the user. Rendered image of cylinder head

10 SCANNING APPLICATIONS We are even scanning in detail from old dies and clipping tools created by hand, meaning no data exists. The Renishaw Cyclone machine gives us such a vast scope. We are thinking of new ways of using the technology every day. Oromet (User of Cyclone scanning machine) Anchor button The Cyclone has been used to recreate 3D models, copy patterns, define split lines and to design electrodes for modifying existing tools. Jaymark Mould & Tool (user of Cyclone) Brake backplate for car Cyclone is a very cost-effective scanning system. It now allows us to produce scanned data, from which we can produce CNC code for machining of electrodes, tooling components or models. Toolmaking Industry Research and Advisory Centre (user of Cyclone) Cameo brooch With today s modern press tool it is essential that an exact 2D profile is produced to act as a clipping die. Traditional methods would produce hand made dies which were rarely satisfactory - using Cyclone this problem ceased to exist. Sterling (EDM) Ltd (user of Cyclone) Glass paperweight The Cyclone will replicate the detail on dies sometimes taking up to 400,000 reference points in a 1.5in diameter. It will also allow us to scan existing stock, adding features if we want to, thereby adding to a particular product range. MMI Group Ltd (user of Cyclone) Badge Polish medal It has reduced our lead-time from model to pattern considerably. Phoenix Pattern & Tool (user of machine tool scanning probe) We can now scan far more accurately and faster than we could with earlier generation (copy milling) machines. Lismold (user of machine tool scanning system) Plastic face for model display Chocolate mould Embossing tool Wheel hub

11 SCANNING APPLICATIONS Shoe last (top) Crown brooch Medal Some of our customers do not have CAD data available, or the product design has not been completely finalised. The digitised data is quickly converted into CAD/CAM data to produce tooling. Once we have the data, we can incorporate customer modifications as the tooling design progresses. Inmans Ltd (user of Renscan 200 system) Scanning of a shoe last Shoe last (bottom) Automatic split line generation from existing 2D profile The switch to Cyclone and Tracecut has not only streamlined the overall moulding process by reducing the need for pattern making, it has also cut machining time by roughly 40%. Creative Blow Mould Tooling Inc (user of Cyclone) Crankshaft application (Cyclone) The introduction of the Cyclone has already resulted in time savings of over 50% being achieved for new mould developments. Beaubury Moulds (user of Cyclone) Scanning a crankshaft to regenerate a new master We can make most changes ourselves without the customer having to re-invent the design, whether in CAD or in model form. Duplicraft Inc (user of Cyclone) Screen display of captured data Rendered image of captured data Saint Christopher Tutankhamun bottle Sample part cut in soft wax Authorisation should always be obtained from the copyright owner before copying any article.

12 º Global solutions from Renishaw Renishaw is an established world leader in metrology, providing high performance, cost-effective solutions for measurement and increased productivity. A worldwide network of subsidiary companies and distributors provides exceptional service and support for its customers. Renishaw designs, develops and manufactures products which conform to ISO 9001 standards. Renishaw provides innovative solutions with the following products: Probe systems for inspection on CMMs (co-ordinate measuring machines). Systems for job set-up, tool setting and inspection on machine tools. Scanning and digitising systems. Laser and automated ballbar systems for performance measurement and calibration of machines. Encoder systems for high accuracy position feedback. Spectroscopy systems for non-destructive material analysis in laboratory and process environments. Authorised distributor Renishaw plc, New Mills, Wotton-under-Edge, Gloucestershire, GL12 8JR, United Kingdom Tel +44 (0) Fax +44 (0) uk@renishaw.com Renishaw Inc Trillium Blvd., Hoffman Estates, IL 60192, USA Tel Fax usa@renishaw.com Renishaw K. K. Across City Nakano-Sakaue, 38-1, Chuo 1-chome, Nakano-ku, Tokyo , Japan Tel Fax japan@renishaw.com Renishaw GmbH Karl-Benz Straße 12, D Pliezhausen, Germany Tel Fax germany@renishaw.com Renishaw S.A. 15 rue Albert Einstein, Champs sur Marne, Marne la Vallee, Cedex 2, France Tel Fax france@renishaw.com Renishaw S.p.A. Via dei Prati 5, Pianezza, Torino, Italy Tel Fax italy@renishaw.com Renishaw Iberica S.A. Edificio Océano, Calle Garrotxa 10-12, Parque Más Blau, Prat de LLobregat, Barcelona, Spain Tel Fax spain@renishaw.com Renishaw A.G. Poststrasse 5, CH 8808 Pfäffikon, Switzerland Tel Fax switzerland@renishaw.com Renishaw (Hong Kong) Ltd. Unit 4A, 3/F, New Bright Building, 11 Sheung Yuet Road, Kowloon Bay, Hong Kong Tel Fax hongkong@renishaw.com Renishaw Latino Americana Ltda. Calçada dos Crisântemos 22, Centro Comercial de Alphaville, C.e.p , Barueri-SP, Brazil Tel Fax brazil@renishaw.com Renishaw Metrology Systems Private Limited #1101, 1102 Prestige Meridian 2 30 Mahatma Gandhi Rd, Bangalore Tel Fax india@renishaw.com Renishaw s Representative Offices The Peoples Republic of China, Beijing Tel Fax china@renishaw.com The Peoples Republic of China, Shanghai Tel /5697 Fax china@renishaw.com Singapore Tel Fax singapore@renishaw.com Indonesia, Jakarta Tel Fax indonesia@renishaw.com Australia, Melbourne Tel Fax australia@renishaw.com Taiwan, Taichung City Tel Fax taiwan@renishaw.com Renishaw s Liaison Office South Korea, Seoul Tel Fax southkorea@renishaw.com uk@renishaw.com Corporate telephone number for Renishaw plc, New Mills: +44 (0) or RENISHAW 1999 Renishaw plc Printed in England m Part No. H A