Increasing Productivity/Quality through Better Utilization of Dimensional Data

Transcription

1 Increasing Productivity/Quality through Better Utilization of Dimensional Data By John Reed

2 Dimensional measurement is accepted as standard operating procedure Geometric Dimensioning and Tolerancing Geometric Dimensioning and Tolerancing What do you do with your data after the operator collects it. Most information is discarded immediately or saved only to be ignored in the future.

3 Format of the Presentation Name of the measuring device Primary Applications Operating Principle. System Performance Typical uses Example of additional uses

4 During this presentation we will show examples of output from devices such as White Light Scanners, Photogrammetry, and data from the Gap/Mismatch systems. These systems can produce your needed dimensional measurement information. We will also use them as examples of how to utilize this data again to increase productivity and quality Breuckmann Stereo Scan GapGun System TubeInspect

5 Gap & Flush measuring device Primary Applications Gap/Mismatch Aerospace Gap/Flush Automotive Radii & Chamfers

6 Gap & Flush measuring device Operating Principle. A laser line is projected normal to the surface Move into operating range Can use standoffs to center or non-contact mode. The system will automatically take 16 images of the laser line using an embedded digital camera. This line is digitized, the desired calculations made, nonconforming measurement discarded, Gap, flush or form displayed and stored

7 Gap & Flush measuring device System Performance Operator is shown The measurement is Results displayed Result recorded the correct point to done. Measure Accuracy.001 to.004 Speed Up to 8 features per minute

8 Gap & Flush measuring device Typical uses. operator performs the measurement, the results are shown (green or Red) of PDA and recorded on an Excel spreadsheet to be viewed. The trend comparison from the last several pieces can be seen and the data archived. GapGun sample output

9 Gap & Flush measuring device Example of additional uses Nissan Motors System is on-line taking between 16 to 32 features. They are using multiple Gap/Flush measurement devices connected to the same computer and program. The operator gets immediate feedback and results are put into an SPC pack for long-term evaluation. The results for each vehicle will be displayed to the area assembling components giving them a running real-time indication (within a few minutes) for the consistency of the work.

10 Gap & Flush measuring device Example of additional uses Lockheed Martin. Every F35 contains a number of gap/mismatch measurements. Lockheed developed a system to store all data from every plane. After a number of planes are manufactured it is possible to look at all the dimensional data on each plane to include gap/mismatch in an attempt to correlate changes in performance to the dimensional variance. F35 JFS F35 JFS Checkplan

11 White Light Scanner Primary Application. Creation of point cloud (2 to 200 million surface points). Free-form shaped parts or parts with many small surface features. To be used for inspection, comparison to cad or reverse engineering for small to mid size parts Scans (unfinished) part Scans finished

12 White Light Scanner Operating principle. Structured light is projected (a series of lines) onto the surface. There is a known angle and distance between the projector and the camera(s). This allows triangulation to be used to calculate the surface points allowing several million surface points created in a few seconds. Topometrical Setup with Miniature Projection-Technique echnique ( MPT ) Topometric Data Acquisition and Evaluation MPT-projector MPT-projector digital camera triangulation angle digital camera Image recording with combined GrayCode- / Phaseshift-technique ( about 1 s ) evaluation of the image sequence calculation of 3D-coordinates optotop-he Matching ( STL-data ) GrayCode Phase image Fringe contrast How a White Light Scanner Works Example of results

13 White Light Scanner System Performance. The size of each scan can vary from ½ inch square to 60 square. The scan time (2 seconds) and the number of points remain the same. The accuracy.0002 to.020 and the resolution will change as the field of view increases (.1/2 to 60 ). Multiple scans can be merged together to create a point cloud.

14 White Light Scanner Typical applications: Applications vary widely. It is used in industrial applications such as turbine blades, dashboards, molds and dies. It is also used in measuring skin roughness, artifact preservation, art, and in a number of other industries reverse engineering projects Blaser Jagdwaffen - Hunting Weapons Measuring of prototype rifle stock models Reverse engineering Milling out of precious root wood engineering projects and feasability studies Snecma/IBS/Clever Engineering Aircraft and Space Engines Development of an Adaptive Grinding Process Until now the airfoil area is measured on a multi tactile measuring machine. Cultural Heritage Smithsonian Institution / Accurex Largest Museum Complex Worldwide Deer Stones Project in Mongolia Thursday, 16 October Thursday, 16 October Thursday, 16 October Reverse Engineering Inspection of complex parts Cultural preservation

15 Mold Measurement Using a White Light Scanner Example of additional uses Scanning a die. Both halves of the die are scanned and the results can be compared. This information can also be given to an operator to hand repair the die For better utilization, use the model and data and analysis in package such as Polyworks for more options to best fit the data. For example, the error can be shifted around to permit a decrease of the hand sanding or the wielding. Another option is to optimize the work to allow for longer life of the die before it needs be Next slide for examples

16 Mold Measurement Using a White Light Scanner PolyWorks/Inspector PolyWorks/Inspector Process Overview: Left Die vs Draw CAD 1 Feature-Based Alignment vs Best-Fit Alignment Data Alignment 3 CAD 2 Initial Stage: Data & CAD in two different coordinate systems Comparison Report the results 1 st : 4-Way Locator 3 rd : Reference Points (3) in 2 nd : 2-Way Locator the y axis Hemmer Die Right versus Inner Panel CAD and Upper Frame CAD Door after left Die 2-34 versus Inner Panel CAD Aligned reworked Optimization thru best fit Color deviation diagrams

17 Mold Measurement Using a White Light Scanner Example of additional uses Another possibility is to output the data to a laser projection system where it will projects different colors on the sections of the die needing work, thereby showing the hand grinding operator exactly where and how much material needs to be removed. This will increase the productivity of the machinist working on the repair. Color deviation diagram projected on part

18 Bent Tube Inspection by a Photogrammetry System Primary application. Dimensional Inspection of bent tubes, hose and attachments made with a CNC bender. Theoretical tolerance zones of a typical bent tube.

19 Bent Tube Inspection by a Photogrammetry System The operating principles. Enclosure that houses 8 to 16 CCD cameras Light table with embedded photogrammetry target. The bent tube is placed on the table in a free (unrestrained) state. Each camera then takes an image in approximately 30 milliseconds. The system digitizes the profile of the tube Using the photogrammetry targets, the system merges all the images together to create a 3D model. The model is put into a simulated restrained condition to take out the effects of gravity. Creates an inspection report.

20 Bent Tube Inspection by a Photogrammetry System Basic Principle Images from 16 digital cameras Basic Principle Creating 3D model and bending points Work Flow Optical Gauge Printout of deviation report The Parts are place in the TubeInspect Images are merged Inspection Results

21 Bent Tube Inspection by a Photogrammetry System System Performance. Bent tubes or hoses from 1/8 to 8 Diameter length is unlimited Accuracy is.001 to.004. The system can measure an 8 foot tube with 20 bends in 15 seconds. Sampling rate of thousands of points, increasing the reproducibility.

22 Bent Tube Inspection by a Photogrammetry System Typical application. Application in aerospace or automotive tube or tube assemblies (with hoses) coming from a CNC tube bender are typical applications. Theoretical tolerance zones of a typical bent tube.

23 Bent Tube Inspection by a Photogrammetry System Example of additional uses Take the measurement data, Correction can be sent to the CNC bender. Work Flow Bending Program Set Up Work Flow Bending Program Set-up Generate correction data Send set-up data to machine (RS232, TCP/IP) tube info SERVER SERVER Bender 1 deviation values control panel for datatransfer Bender 2 Bender 3 Bender 4 PBR correction are automatically calculated Corrections are sent to the CNC bender

24 Bent Tube Inspection by a Photogrammetry System Example of additional uses Typically after the tube is bent, it is measured and the excess length is hand marked on the tube. It is then hand trimmed on a saw with the operator positioning each end as close a possible to the hand marked location. TubeInspect can use the existing measurement data and automatically calculate the amount of tube to be removed. Automatically positions a motorized stop behind the saw in order to put the tube in the correct location. The operator then takes the tube out of the TubeInspect, puts the first end of the tube against the backstop, cuts off the end, and rotates the tube before repeating on the opposite end.

25 Basic Single Camera Photogrammetry Primary application. Create small point clouds to be used for large or difficult to reach part measurements measure deformation on parts due to temperature, weight or position changes.

26 Basic Single Camera Photogrammetry Operating principle. Reflective photogrammetry targets are placed on the desired measurement object at each location where a recorded point is needed. A reference bar is placed in the measurement field with two targets of known distance. A special digital camera is used to collect the images, which are digitized and downloaded to a computer. A point cloud of these points is created, which can be used for feature measurement or compared with an earlier survey to establish deformation Z 5 4 Y X Photogrammetry The theory of Photogrammetry equipment camera positions Example output

27 Basic Single Camera Photogrammetry System Performance: 1 to several hundred feet. Accuracy is from.0002 to.010.

28 Basic Single Camera Photogrammetry Typical application. Measure primarily free-form surfaces or forms on large parts. Measure deformation due to Gravity or Temperture Antenna prepared for survey Color deviation diagram of antenna

29 Basic Single Camera Photogrammetry Additional photogrammetry examples Large Fabricated Part Large round free standing case

30 Basic Single Camera Photogrammetry Example of additional uses By adding cubic target to your target list you can measure geometric features much easier. These points can be automatically downloaded to a software design for easy comparison between the measure data (features) and the nominal through the use of CAD, which also generates an inspection report. Standard flat or paper reflective targets New style cubic feature target

31 Closing Summary These descriptions of additional usage for dimension measurement are examples of benefits that can be achieved with the extra step of utilizing the dimensional measurement data already collected. The goal of this paper is to give pertinent examples of how to better utilize your data. Since applications and requirements vary widely you may not be able to use these exact examples. However, it can serve to enable various problem-solving approaches for uncovering how this data can improve your production/quality with various applications and data collection systems.