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INTRODUCING MODERN METROLOGY SYSTEM IN STEELWORK INDUSTRY AUTHORS:

Zoran DELEV, Zoran SIMJANOVSKI, Aleksandar POSTOLOVSKI

PRESENTER: Zoran DELEV, FAKOM AD Skopje


FAKOM AD, Skopje  leading company for designing,  production and erection of steel  structures and processing equipment for  the industry in South East Europe

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50 years of tradition, success and  development   Continuous investments in latest  modern technologies and training of  the staff 

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Long term strategy for closing the  supply processes - from design through  production and erection to  finished building / industrial equipment DESIGN BIM

MEASUREMENT/CONTROL modern METROLOGY

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PROUCTION / ERECTION FIM / CNC 4


Informatics supported processes Design  BIM (Building Information Modeling)   Software - Autodesk REVIT platform, 

TEKLA, Naviswork, VICO…

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Informatics supported processes Production / Erection  FIM (Fabrication Information Modeling)   Modern CNC machines with high 

precision (cutters, machines for cutting  and drilling, robotics, machine  processing) 14th INTERNATIONAL SYMPOSIUM OF MASE Zoran DELEV

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Informatics supported processes  Measurement / Control  Modern metrology :

Leica Laser Absolute Tracker AT401, Leica Laser Total Station TDRA6000, Innovmetrics 

PolyWorks Inspector Probing V11 14th INTERNATIONAL SYMPOSIUM OF MASE Zoran DELEV

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Modern metrology 

Easy, interactive, real time and precise  measurement of 3D (x, y, z) spatial data  for the facility (construction, assembly,  item, points), existing, under  construction, or during production and  erection

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Modern metrology Modeling,  Inspection of the projected 3D model,  Simulation of a Virtual assembly,  Reverse engineering / design      (reconstructions, repairs …)  Dimension control  CAD import/export …. 

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Modern Metrology System – Combination of Hardware and Software 

Hardware part – Leica Absolute Tracker  AT401 – Leica Laser Total Station  TDRA 6000

Software Part – Innovmetric Polyworks  Inspector/Probing 14th INTERNATIONAL SYMPOSIUM OF MASE Aleksandar POSTOLOVSKI

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Schedule of measuring technology

MACRO MICRO NANO

Accuracy < 10 Meters

100 μm

14th INTERNATIONAL SYMPOSIUM OF MASE Aleksandar POSTOLOVSKI

0.3 μm

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Leica Absolute Tracker AT401 Field of view:                  H:+/-360˚         V:+/-145˚ Max. Distance                   : 160m Max. Volume                     : 320m Angular Resolution           :  0.07" Distance accuracy (MPE*) :  +/- 10 μm 3D(xyz) accuraacy        :+/- 15 μm + 6μm/m

* MPE –Maximum Permissible Error 14th INTERNATIONAL SYMPOSIUM OF MASE Aleksandar POSTOLOVSKI

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Feature Benefit IP54 sealed  Extremely light and compact: 8.1 kg  incl. controller, just over 290 mm tall 

Independently certified IEC 60529 usage in even the most demanding conditions. Measuring where no other laser tracker can go. The controller stays out of the user’s way, e.g. attached to the tripod.

Cable-less design 

By combining built in WiFi connectivity and on board battery power, the sensor can operate without any wires connected at all.

Hot swappable battery operation 

No need to worry about AC (mains) power – the sensor can run continuously with a new set of batteries able to be swapped in without interruption

Automatic target recognition (ATR)  PowerLock beam recovery technology 

The ATR allows constant tracking and fine positioning with different reflector types to a typical radial volume of 320 m. No need to worry about “breaking the beam”: the tracker automatically locks onto the user providing up to 20% time savings over traditional laser tracker technologies

Proven Absolute Distance Meter  technology 

The most accurate Leica Geosystems distance meter ever: The ADM has a resolution of 0.1 micron and a maximum uncertainty of 10 microns over a full 160 m radial volume.

Quick Release tribrach and precision  level to gravity sensor 

A built in “survey grade” level to gravity sensor is combined with a simple three screw leveling quick release platform for quick and easy machine setup and relocation.

Overview Camera 

Integrated Overview Camera to allow on-line steering of the laser tracker for remote or fixed installations

Integrated environmental monitor 

Automatic reading and updating of the environmental param­eters avoids inaccurate calculations or wrongly input values.

Leica Geosystems proprietary  quadruple reading absolute angle  detection system 

The absolute angle encoders provide traceable ISO 17123-3 0.5” accuracy with a 0.07” resolution guaranteeing system accuracy over extremely long ranges.

Power Over Ethernet 

14th INTERNATIONAL SYMPOSIUM OF MASE Aleksandar POSTOLOVSKI

Due to its low power requirements the sensor can use POE+ technology that combines power and data into a single off the shelf Cat5 LAN cable.

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Laser Total Station TDRA6000 Field of view                         H:+/-360˚                                               V:+/-145˚ Max. Distance                        :300m Max. Volume                          :600m Distance accuracy (MPE*) with prism                                                :+/- 0.3 mm Distance accuracy (MPE*) reflectorless                                                 :+/- 0.5 mm 3D(xyz) Accuracy           :+/- 0.3 mm + 13  μm/m * MPE –Maximum Permissible Error

14th INTERNATIONAL SYMPOSIUM OF MASE Aleksandar POSTOLOVSKI

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Laser Total Station TDRA6000 With a typical 3D point uncertainty of 0.25 mm in a 30 meter volume, the new Laser Station Leica TDRA6000 is the most accurate Total Station ever designed for industrial use. The PinPoint Reflectorless Distance Meter allows noncontact measurements within the full 600 m volume, and has a very small visible beam that allows precision measurements on difficult surfaces.

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Laser Total Station TDRA6000 Based on piezo technology, these new direct drives enable high speed motorization and acceleration, at up to 4x our previous generation, but still allow sub micron level fine positioning. A new high speed absolute angle encoder paired with our 4th generation Automatic Target Recognition (ATR) technology. This new quadruple angle detection system is accurate to 0.5 Arc Seconds and is capable of 5000 measurements per second. 14th INTERNATIONAL SYMPOSIUM OF MASE Aleksandar POSTOLOVSKI

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PolyWorks, Inspector Probing V11 Flexibility – Robustness – Powerful capabilities        

14th INTERNATIONAL SYMPOSIUM OF MASE Zoran SIMJANOVSKI

Dimension control CAD import/export Reverse engineering Virtual assembly Visual reports / export Automatic temperature  compensation Multiple device positions Supports many  instruments

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EXPECTED IMPROVEMENTS AND  ADVANTAGES OF ITS APPLIANCE Instruments with greater precision  Shorter inspection time  Online and offline operation  Complete portable battery operated  solution for both facility and field operation  Better products – our ultimate goal 

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APPLIANCE AND ADVANTAGES 

Dimension control

14th INTERNATIONAL SYMPOSIUM OF MASE Zoran SIMJANOVSKI

Table Type

Feature

Name

Control

point 1

X

0,000 1,000 -1,000

point 1

Y

1,460 1,000 -1,000

point 2

X

0,000 1,000 -1,000

point 2

Y

0,000 1,000 -1,000

point 3

X

-15,748 1,000 -1,000

point 3

Y

-11,119 1,000 -1,000

point 4

X

-13,852 1,000 -1,000

point 4

Y

-11,767 1,000 -1,000

angle 1

Y/Z Angle

90,227 2,000 -2,000

angle 2

Y/Z Angle

90,139 2,000 -2,000

Nominal Measured Tol+

Tol-

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APPLIANCE AND ADVANTAGES 

Produced model inspection to 3D CAD model Table Type

Feature

Name

Control

datum plane A Flatness

Nominal

Measured Tol+ 3,108

Tol-

TZ Size Deviation Test

3,000

Fail

datum plane A X Angle

90,000

90,000 2,000 -2,000

0,000 Pass

datum plane A Y Angle

180,000

180,000 2,000 -2,000

0,000 Pass

datum plane A Z Angle

90,000

90,000 2,000 -2,000

0,000 Pass

vector 1

X Angle

180,000

180,000 2,000 -2,000

0,000 Pass

vector 1

Y Angle

90,000

90,000 2,000 -2,000

0,000 Pass

vector 1

Z Angle

90,000

90,000 2,000 -2,000

0,000 Pass

plane 2

Parallelism A  

plane 2

Flatness

circle 2

Radius

distance 1

Z Distance

vector 3

X Angle

90,000

vector 3

Y Angle

180,000

0,163 2,000 -2,000

vector 3

Z Angle

90,000

89,996 2,000 -2,000

distance 2

Y Distance

14th INTERNATIONAL SYMPOSIUM OF MASE Zoran SIMJANOVSKI

724,833

6,709

3,000

5,840

3,000

Fail Fail

724,849 1,000 -1,000

0,016 Pass

8590,000 8590,080 1,000 -1,000

0,080 Pass

89,837 2,000 -2,000

3850,000 3843,611 1,000 -1,000

-0,163 Pass -179,837 Fail -0,004 Pass -6,389 Fail

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APPLIANCE AND ADVANTAGES 

Simulation of virtual assembly Table Type

Reference Points

CSYS

World

Name

Direction

RP 1

Along Z

RP 2

Along Y

RP 3

Along XYZ

14th INTERNATIONAL SYMPOSIUM OF MASE Zoran SIMJANOVSKI

Nom (x)

Nom (y)

10,921 3843,611

Nom (z) Meas (x) Meas (y) Meas (z) Tol 0,303

10,921 3843,611

Dev

Test

0,303 1,000 0,000 Pass

0,000

0,000

0,018

0,000

0,000

0,018 1,000 0,000 Pass

1828,467

0,000

0,000 1828,467

0,000

0,000 1,000 0,000 Pass

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APPLIANCE AND ADVANTAGES 

Reverse engineering/design used for:  reconstruction, repairs, etc.

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MASE2011-CK-17 Metrologija v3 en  

AUTHORS: Zoran DELEV, Zoran SIMJANOVSKI, Aleksandar POSTOLOVSKI PRESENTER: Zoran DELEV, FAKOM AD Skopje 14th INTERNATIONAL SYMPOSIUM OF MASE...