NIKON METROLOGY NEWS Case Studies and Product News VOLUME 11
LASER RADAR
SHOP FLOOR CMM FOR CAR BODY INSPECTION
Continental doubles inspection throughput Highly efficient rock sample categorisation CT reveals insight into ancient specimens
High accuracy non-contact sensor gear inspection system HN-C3030
• 3D scans provide better insight into complex shapes • Laser scanning offers higher measurement speed • Non-contact eliminates the need for probe tip compensation • Reveal surface defects not detectable by tactile measurement • Measure small features impossible for tactile probes
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NIKON METROLOGY I VISION BEYOND PRECISION
Content 4 | Next-generation shop floor CMM for car
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body inspection
7 | Faster inspection and reporting with 3D laser scanning
10 | Improved performance and larger CMM sizes 12 | Equipped to double inspection productivity 14 | Ground-breaking knowledge discovered
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from ancient specimens using X-ray CT
16 | Cranking up gear inspection 18 | Nikon microscope allows highly efficient rock sample categorisation
20 | Mindful distraction:
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Therapeutic art created with mineral photomicrographs
22 | Nisan Engineering reduces inspection time by a factor 5
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Next-generation shop floor CMM for car body inspection There is an increasing importance for automotive assembly plants to continuously monitor process quality throughout the production process. This need is driven by OEMs pushing the limits of design by using complex shapes, new materials, and cutting edge processes. Locations of holes, slots, studs, and welding lines along with flush & gap of doors, hoods, deck lids, and other hangers need to be measured and monitored throughout the assembly process. These inspections ensure that vehicles are built within the ever more stringent tolerances set by automotive manufacturers. Nikon Metrology – in close cooperation with key automotive OEM and integration partners- addresses these challenges by introducing an innovative approach to body-in-white (BIW) inspection based upon its non-contact Laser Radar system. Unlike a horizontal-arm CMM, the Laser Radar high-speed measurements fit within short production cycle times. The new MV331/351 Laser Radar doubles surface scanning speed and drastically increases feature measurement performance. New usability features such as an integrated robot mount, removable air filters and positive air pressurization make the system even better suited for robotized inspection on the shop floor.
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Traditional body-in-white inspection is under pressure In the recent past, body-in-white measurements have been performed in two phases - on the production line with low accuracy sensors to monitor process and in a CMM room where a sample of parts are sent to be inspected offline by large horizontal arm CMMs for more accurate measurements and to correlate the data from the inline sensors. Although CMMs can provide highly accurate absolute measurements, they tend to be slow and require an expensive, dedicated metrology room. Vehicles need to be removed from the production line and then taken to the metrology room, manually
fixtured and aligned to the CMM. The CMM then starts its time-consuming measurement process. Taking into account the setup and measurement time, at best two vehicles can be inspected per shift on a CMM, but often only one vehicle is measured. This is a very small sample considering that over 1,000 vehicles of various styles can be built each day on a single production line. This is certainly not a large enough sample to monitor the production process. Inline systems typically measure every vehicle but can require over 100 individual fixed sensors to inspect the required features. Although these sensors are very quick to measure they are demanding to install and
New usability features such as an integrated robot mount, removable air filters and faster measurement directly target robotized inspection on the shop floor
Features like holes, slots, pins, studs etc are inspected in an automated way at a scanning rate of 2,000 pts/sec
maintain and do not provide measurements directly in the car’s coordinate system. In addition, most assembly lines now are ‘flexible’, meaning that they can produce more than one type of vehicle. Fixed sensors cannot be used across different vehicles styles; every vehicle requires its own custom set of sensors making them even more expensive and onerous to maintain.
accuracy. These systems typically have four or more robots with a sensor located on the end effector of each robot that is re-positioned to measure each of the features that need to be inspected. Hundreds of locations need to be programmed, making them time-consuming to set up and difficult to maintain and they still do not provide the required accuracy and correlation to a CMM.
Recently inline inspection systems have been moving towards robotic based solutions which are flexible, but rely on the robot’s positional precision which limits the overall
A new approach: Flexible inspection, absolute measurement Innovative inspection stations are being installed today, both lineside and in-line, by major automotive OEMs using Nikon Metrology’s Laser Radar. The Laser Radar has been used for many years in the aerospace and renewable energy sectors and is now providing a unique alternative to
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the shortcomings of traditional automotive metrology systems like CMMs and inline sensor systems. The new MV331/351 Laser Radar is further optimized for car body shop floor inspection. The Laser Radar’s high speed vision scans at rates of 2.000 points per second – enable fast measurement of surfaces, sections and complex features. The Laser Radar performs automated, highly accurate, contactless measurements in the car coordinate system by using a focused laser that is controlled by a precision azimuth and elevation system. The Laser Radar requires a fraction of the reflected signal to make accurate measurements, enabling it to inspect almost any material, color or surface texture, such as bare sheet metal, coated BIW or painted cars.
What customers gain
With the need for shorter and more flexible production cycles, automotive manufacturers are continuously looking to cut time and costs whilst maintaining quality. For automotive inline inspection, the automated Laser Radar on a robot offers the right capabilities to meet the need for flexible and absolute measurements directly on the shop floor. For car manufacturers this results in: • Shorter startup of new production line or vehicle model changes: during the startup phase initial produced vehicles can be completely measured and compared to CAD. This provides better insight into product conformance and enable faster finetuning of the production process. • Reduced scrap: By closely monitoring the production quality, the process can be instantly adjusted when variances occur over time. • Future proof data: Measurements in absolute coordinates fit in the digital manufacturing process where data is used as a reference to compare data over time and to speed up future product development etc.
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The measurement accuracy and repeatability of the Laser Radar is comparable to measurements taken with a traditional horizontal arm touch probe, while it is many times faster. Two Laser Radars working in parallel can measure 700 features on a BIW vehicle in less than one hour; this can take a full shift for traditional CMM. The configuration of a Laser Radar inspection station can vary based on the specific needs of the OEM but typically consists of one or more Laser Radars that are manipulated by 6-axis industrial robots. The industrial robots are used to automatically reposition the Laser Radar to enable it to inspect areas that are not visible from a single location.
After repositioning the robot, the Laser Radar automatically realigns to the part by measuring alignment points on the vehicle or tooling. Unlike other inline robotic measurement systems, this guarantees that all measurements are collected in the vehicle coordinate system and ensures feature accuracy is independent of the robots ability to accurately locate the Laser Radar. Laser Radar has a spherical field-of-view, meaning it has visibility to large sections of the vehicle at any time and dozens of features on the vehicle can be measured from a single location. Just like a CMM, measurements are pre-programmed directly from the vehicle’s CAD model using the inspection software. After the initial programming, data collection and
reporting is fully automated. Specific inspection scripts can also be written for each vehicle style and model being built on the production line making the Laser Radar inspection station completely flexible for changes to inspection plans and even new vehicle styles. Changing the features to inspect or adding in new vehicle styles is completely software based and does not require any physical changes to the setup or new hardware. The application software takes care of the interaction of the Laser Radar, robot, and data processing; inspections are completely automated and do not require manual intervention during runtime. This improves both speed and quality of the measurements compared to traditional methods.
Revolutionizing large volume inspection in aerospace applications Originally the Laser Radar was applied in aerospace applications for targetless inspection of objects ranging in size from a passenger door to an entire aircraft. The automated, non-contact operation without a need for retro-reflectors were unique benefits to reduce labor, to improve inspection productivity and increase measurement repeatability.
Engines
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Wings / Flaps / Tailfins
The Laser Radar is used for nacelle, thrust reverser, and panel inspections. Tens of thousands of surface points can be collected on these parts automatically without the need for ladders or a dedicated operator, as such improving quality while reducing labor.
More aerostructures are being built with composite materials, which drives the need for higher tolerance part fitting. The Laser Radar is used to measure the as-built condition of wing ribs, skins and other control surfaces so proper shims can be installed to optimizing each build.
Barrel sections
Wing to body join
Large barrel sections are inspected with the Laser Radar both at the factory and in the join station. The Laser Radar provides data that is used to optimize the fit of the barrel sections allowing aircraft manufacturers to build straighter, more efficient planes.
The Laser Radar scans the relative positions of the wing root and side of body in join position. This data is used to virtually fit the wing and side of body together allowing shim packs to be installed prior to the join. It also feeds back the relative location of the wing to the join automation to ensure an accurate fit and optimize aircraft symmetry.
Case study
Faster inspection and reporting with 3D laser scanning
Automotive and aerospace pressings specialist invests in bridge-type and portable arm CMMs for freeform surface data acquisition A significant increase in orders for the supply of prototype pressings and bracketry, notably to Jaguar Land Rover (JLR), has prompted Birmingham Prototypes (www.birminghamprototypes.co.uk) to install two multi-sensor co-ordinate measuring machines (CMMs) from Nikon Metrology. The goal was not only to measure the sheet metal parts faster but more importantly to speed subsequent report generation. The investment has also resulted in the establishment of a new subcontract service offering laser scanning and inspection work.
Based in Redditch, UK, Birmingham Prototypes started working directly for JLR two years ago. To receive its supplier’s code, the subcontractor needed to be able to fulfil the OEM’s stringent quality control requirements in respect of first article inspection reporting and PPAP (production part approval process) documentation. They required an increase in the number of reports that had to be produced as well as more detail on component accuracy and repeatability than is requested by other customers in the automotive, aerospace and other sectors. Using the former manual CMM at Redditch, report generation was a
laborious process requiring entry of data and drawings by hand into Microsoft Office applications. A single report took anything from an hour to half a day, depending on its complexity, according to Birmingham Prototypes’ managing director, Mick Adams. So in 2013 he decided to install a Nikon Metrology LK V 15.10.8 ceramic bridge coordinate measuring machine to automate and speed up the reporting process. It also allows inspection cycles to be completed faster and without operator attendance after components have been fixtured, saving further time especially when measuring a batch of identical components.
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Rather than choose another static CMM, we decided to install a portable co-ordinate measuring arm, an MCAx from Nikon. It is twice as fast at producing inspection results for a one-off part. Mick Adams, Managing director
A Nikon Metrology LC15Dx laser scanner is the default method of inspecting pressings at Birmingham prototypes. It allows high accuracy resolution of freeform surfaces and geometry. For measuring tight dimensional tolerances and sometimes for initial job setup, a touch probe is picked up automatically from the stylus changer on the LK V 15.10.8 by a Renishaw PH10M motorised indexing head. Most drawing tolerances on pressed parts at Redditch are fairly open, ± 0.25 mm being typical on surfaces and ± 1 mm for trim edges. Only hole positions are measured to within tens of microns. The LK CMM is capable of measuring to an accuracy that is at least an order of magnitude better than is required for these applications.
Software is key to data handling and reporting Nikon Metrology’s multi-sensor CAMIO V8 software in use at Redditch produces industry-standard DMIS programs that support both laser scanning and touch probing. The software applies the optimum measurement strategy based on the feature and sensor selected. For measuring complex surfaces, it automatically generates scan paths that result in fast and smooth laser scanning that closely follows the part
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Close-ups of the Jaguar prototype pressing being inspected using the Nikon Metrology LC15Dx laser scanner head.
surface, with full machine simulation and collision detection. CAMIO also has instant, highly productive reporting functionality based on standard templates. Tabulated tables, graphics and form plots derived from scanned point clouds and touch probing are combined in a single, concise report. It is Nikon Metrology Focus 10 software that manages the point clouds acquired during laser scanning and allows inspection data to be compared against the customer’s original CAD model. A typical pressing at the Redditch factory, such as a prototype aluminium engine bay mounting plate for a Jaguar car, comprises seven to eight million points. Focus software produces annotated, colour deviation maps showing how the 3D scanned model correlates with and deviates from the original CAD file. For such global comparisons, a 0.1 mm grid is generally selected by Birmingham Prototypes’ quality manager, Bob Rose.
Scanning with articulated arm is twice as fast Early in 2015, Birmingham Prototypes installed a Trumpf 5-axis laser profiling machine so that it could bring in-house the laser cutting work it was subcontracting at a cost of £350,000 per year.
Mr Adams commented, “Practically every job that comes off the machine is a unique prototype that needs to be inspected, a job that was previously done by the laser cutting subcontractors before parts were delivered to us. “As our CNC CMM needs to be programmed for each new part, making it more suited to our low volume, pre-production runs, it made sense for us to invest in a manual measuring system to check the output from the Trumpf laser. “Rather than choose another static CMM, we decided to install a portable co-ordinate measuring arm, an MCAx from Nikon. It is twice as fast at producing inspection results for a one-off part.” The facility is used in-house on a dedicated steel table in the quality control room. It often inspects or reverse engineers components and fixtures for other manufacturers that have requested subcontract measuring to be carried out, a service that was introduced two years ago when the CNC CMM arrived. The measuring arm has extended the scope of the service by allowing off-site inspection at customers’ premises of fabrications that are too bulky to be transported easily.
The CMM control screens, showing on the left hand screen a CAD model with hole comparisons and on the right hand screen a global comparison of the measured data against the CAD model. Different colours denote where each measurement is within the tolerance band.
The MCAx 7-axis, counterbalanced arm with continuous rotation is used mainly with a digital laser scanner at Redditch, together with Focus 10 handheld scanning and inspection software. Occasionally a touch-trigger probe is employed if additional accuracy is needed. The arm is equipped with absolute angle encoders for high precision and the model at Redditch has a four-meter diameter measuring envelope. Features of the equipment are the ability to reliably scan steep sided and reflective components, temperature stability and zero warm-up time.
Other departments served The Nikon CMMs have greatly enhanced quality control of sheet metal parts at Birmingham Prototypes and allowed the firm to increase turnover by launching subcontract inspection and reverse engineering. They are backed by ISO 9001:2008 quality management accreditation, which has been held for over 10 years. The move to laser scanning has improved not only the firm’s sheet metalworking activities, but also its additive manufacturing service using a Dimension 1200es 3D printer. The laser scanner generates a CAD model of components for which there is no drawing or electronic data. It is altered as necessary, STL files are exported for printing the plastic
The MCAx measuring arm with a hand-held laser scanner inspecting part of an aircraft seat.
part layer by layer and the customer is given both the component and the CAD file in any format. The factory also houses four Hurco CNC machining centres including 5-axis models to manufacture prototype tooling and low volume production components around the clock. The output from these machines is also checked on the Nikon Metrology CMMs.
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ALTERA multi-sensor CMM
Improved performance and larger CMM sizes Nikon Metrology has extended its ceramic bridge CMM range with high accuracy ALTERA+ and larger size ALTERA models. Thanks to the use of advanced materials and optimized designs, ALTERA provides high performance and superior accuracy across a host of metrology applications, including harsh shop floor environments. Probing support is extended with REVO 5-axis scanning technology to dramatically improve CMM productivity for complex tactile inspection applications. Uniquely in this market, ALTERA is delivered with a manufacturer’s 10 year accuracy guarantee for extra customer satisfaction.
Advanced design and superior materials for maximum performance in any application Built and designed to exacting standards, ALTERA CMMs use advanced ceramic components for structural integrity and enduring performance. With near perfect stiffness-to-weight ratio, ceramic guideways facilitate impressive accuracy: 1.4+L/375 (E150 according to ISO10360-2:2009). The ceramic bridge, with greater resistance to temperature shifts, makes the ALTERA suitable for metrology applications in a host of manufacturing and shop floor environments. The stress-free horizontal ceramic beam and advanced multi-point bearings counter any negative effect on accuracy when using long probes.
Multi-sensor technology for the broadest range of metrology applications ALTERA CMMs support an extensive range of tactile and non-contact probing and software options. Multisensor technology extends the ALTERA capability to measuring parts which are large or small, 2D or 3D, hard or soft and prismatic or free-form. With almost 30 different models and 7 bridge sizes, the ALTERA offers solutions for an array of applications and requirements. The extended sizes range from the smallest measuring volume - 7.7.5 to the largest – 60.20.15, of the standard sizes available. Software options consist not only of CAMIO and CMMManager, but also MODUS – to operate the Renishaw REVO-2 probe head.
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Ready for shop floor use
Enduring accuracy
Fast and smooth operation
The shop-floor-ready ALTERA CMM makes use of several innovative new features. Folding guideway covers protect the air bearing guideways from airborne contaminates such as dust and oil. Superior pneumatic, self-levelling vibration isolators provide optimum performance in areas subject to high levels of low frequency vibration. Automation capability for manual or fully automated FMS production cells, can integrate machine tools, transfer systems and material handling.
Ultra-stable ceramic bridge and spindle guideway with closed-loop stainless steel belt friction drive and high resolution 0.05µm optical scales result in volumetric accuracies as low as 1.5μm + L/375.
Precision dove-tail table guideway and unique single orifice grooved pre-loaded wrap-around air bearings for smooth and controlled high motion.
Stability above all
Shop floor ready
Active vibration mounts (AVM) guarantee stable operation and the highest accuracy in environments that are subject to vibrations or where measurement rooms need to meet the most stringent isolation requirements.
ALTERA+ and larger ALTERA CMMs feature an optimized CERAMIC Y-beam resulting in unprecedented stiffness and thermal stability. To protect the machine from dust or oil, the moving components are shielded behind machine covers.
Unique accuracy guarantee – Nikon Metrology are the only manufacturer to guarantee the accuracy of their CMMs for 10 years. Accuracy of the ALTERA is fully ISO 10360 compliant, and comes with the Nikon Metrology 10 year original accuracy guarantee – demonstrating the utmost confidence in the quality and reliability of the ALTERA. With over 50 years of experience and close collaboration with its large customer base, the ALTERA builds on foundations of high quality, exceptional stability and enduring performance.
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Case study
Equipped to double inspection productivity
Continental Chassis & Safety installs twin ALTERA multi-sensors CMMs
The Quality department of Continental’s Chassis & Safety department recently invested in dual multi-sensor CMMs to revamp the inspection capabilities of their measurement laboratory. Continental wanted to gain a quicker, more comprehensive insight into their products, therefore began to look into multisensor metrology solutions. They required a high capacity system capable of high speed inspection cycles and combined fast surface scanning with highly accurate feature measurements. After outlining their criteria, several companies were consulted, prior to selecting two Nikon ALTERA CMMs, featuring the state-of-the-art LC15Dx laser scanners.
Multi-sensor metrology paves the road for faster inspection In Continental’s measurement laboratory, their single tactile CMM was handling the vast majority of their inspection tasks. The Measuring Technician – Peter Somogyi explained that the main limitation of their existing CMM was its low capacity and that it was time to find a quicker solution. Tamas Brunner – Quality Engineer added that the software wasn’t up to their standard either requiring automation with latest GD&T measuring standards. They both continued to explain that with so many measuring tasks to process, their single, low capacity CMM just wasn’t able to keep up with their demand, let alone provide the level of insight necessary.
Vesz-Mont 2000 provide the Nikon solution After consulting CMM vendors, Vesz-Mont 2000, a Nikon Metrology reseller located in Veszprem offered the multisensor ALTERA CMM, as the most comprehensive answer to their requirements. The final decision was made to install two ALTERA 8.7.6 CMMs, each providing multisensor technology with Nikon’s most accurate digital Laser scanner – the LC15Dx complemented with CAMIO
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Dimensional inspection of the O-ring fitting of a small speed sensor
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The dense point clouds are compared to the nominal CAD of the sample and all deviations are visible in an easy-to-interpret colour map.
The high accuracy of the LC15Dx was the main deciding factor in choosing the Nikon solution. Tamas Brunner, Quality Engineer
software. Both Tamas and Peter strongly emphasised that the high accuracy of the LC15Dx (1.9 µm) was the main deciding factor in choosing the Nikon solution. With such a wide range of shapes, sizes and surfaces to deal with, the LC15Dx is perfectly suited to Continental’s needs. The Enhanced Sensor Performance (ESP3) eliminates the need for preparation, such as powder spraying of dark or multi-coloured plastic parts. The specifically developed Nikon Lens provides the sharpest detail to measure the shapes, edges and features. The new set-up also includes a TP200 tactile measurement probe for outlining parts or inspecting new features. The Renishaw ACR3 change rack ensures a smooth, automated exchange between tactile and non-contact probes, all controlled by Nikon’s CAMIO acquisition and processing software.
Short term benefits point towards long term prosperity
Continental’s long term goals. Peter Somogyi explained that the multi-sensor CMM allows for almost all type of measurements to be done with one machine, whilst previously needing to use a range of inspection equipment such as tactile probe, microscope, projector and conturograph. The Quality department have complete trust in the multi-sensor system and its insight, stating that it is also a very good tool for handling claims. As all measurement data is stored and available for reprocessing or further analysis, the new inspection system serves as a critical tool in handling potential customer claims. The quality of the new inspection process has introduced an increased insight into the parts critical dimensions, cavities and functional features. This enables faster corrective action, demonstrating the high level of productivity the Nikon solution brings.
The Nikon Metrology solution has immediately proven to be a resounding success. The direct benefits such as faster inspection cycles and increased productivity point to the inevitable achievement of
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Case study
Ground-breaking knowledge discovered from ancient specimens using X-ray CT
X-ray Computed Tomography (CT) at the Smithsonian Institution’s National Museum of Natural History is delivering new knowledge from ancient specimens The vision statement of the Smithsonian Institution, the world’s largest museum and research complex is as follows: “Shaping the future by preserving our heritage, discovering new knowledge, and sharing our resources with the world.” Within this statement is a commitment to finding and using the most effective tools to accomplish these ideals. The following describes how the Smithsonian’s Natural History Museum together with an engineering consulting firm are using X-ray computed tomography (micro CT) to not only scan marine mammal fossils, but also make 3D scans and all the data available for knowledge-seekers around the world.
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The consulting lab - Chesapeake Testing was founded in 2006 by Jim Foulk, originally envisioned as a ballistic testing laboratory. “We saw a big uptick in the research and development of armors, with trying to get lighter weights, better performance,” Foulk says. “Essentially, our quest to understand armor led us to acquire some unique complimentary capabilities,” adds Chris Peitsch, lead NDT engineer. “It’s these capabilities, such as CT scanning, that allowed us to diversify our business very easily.” To expand its suite of testing equipment, Chesapeake Testing started researching X-ray system suppliers and began working with Nikon Metrology, quickly discovering the largest offering, a combined 225/450kV micro-focus X-ray and computed tomography system. The system’s powerful source, walk-in bay, and panel shift capability allow Chesapeake Testing the versatility to inspect larger components that other cabinet CT systems are unable to accommodate.
Chesapeake walk-in CT facilities
Non-destructive testing with X-ray micro CT continues to make inroads into quantifying and improving components in many vital and essential industries such as aerospace, medical and more. This is mainly due to micro CT’s ability to inspect and measure internal and external component surfaces and even produce component slices that yield significant information without destroying the part. These are the same attributes driving it into new frontiers, one of the most exciting being the scanning of marine mammal fossils at the Smithsonian Institution’s National Museum of Natural History.
How does the fossil record show us what happened in the past and how the world has shaped that since? Nick Pyenson, Ph.D., curator of marine mammal fossils at the Smithsonian Institution’s National Museum of Natural History (NMNH) says “Climate change is a critical issue right now, and mass extinction events in the past point to similar events going on in our lifetime. The fossil record comes to bear more importantly than ever before.” Pyenson has published research using CT data for more than 10 years, all in an effort to understand the big picture of how fourlimbed marine mammals such as whales descended from land-based tetra-pods and how the return to the sea over time changed
X-ray of blue whale foetus
their anatomy (legs into fins, for example). “Across 250 million years, many land-based vertebrates returned to the sea, and the CT scans help us see some of the resulting solutions.” Another is colleague Dr. Maya Yamato’s work on CT scanning foetal whale specimens from the NMNH’s collection to model the development of how whales hear.
What the X-rays reveal Andrew Ramsey of Nikon Metrology (Tring, UK) says “Computed tomography is essentially the coupling of ever-increasing computing processing power with X-ray technology and digital photography. A fundamental setup includes the X-ray source, the object being measured, and a detector. A rotating platform for the object being imaged helps keep the subject in the field of view while penetrating the sample from all angles.” A single micro CT session with a single sample can produce thousands of digital images. Each two-dimensional pixel in each image can become a three-dimensional voxel as computer algorithms reconstruct 3D volumes. With 3000 images, for example, a billion or so voxels are produced, and each is processed 3000 times. The result is a 3-D volumetric map of the object, where each voxel is a 3-D cube with a discrete location (x,y,z) and a density (ρ). Not only is the external surface information known, such as with a 3-D point cloud from laser scanning, but internal surfaces and additional
information about what is in between the surfaces from the fourth dimension (density) is provided. “We have a mission to expand and commercialize applications for micro CT, we hope the work with the Smithsonian will open some eyes”, says Peitsch. It’s very interesting how the work we’re doing with the fossils correlate with industrial work we’re doing in composites, among other industrial areas. Pyenson and the Smithsonian are using a number of digital tools: 3D printing to make copies of valuable originals; 3D web platforms (3d.si.edu) for downloading CT and other digital scans, and the CT scans themselves. “Nothing replaces the original, but with micro CT you get surface and internal structures that will definitely further research,” Pyenson says. “It’s the middle schoolers that will get the most out of this from artistic and creative standpoints as well as scientific. We cannot foresee the impact of this technology.”
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HN-C3030
Cranking up gear inspection
High speed, high precision, non-contact gear inspection
Nikon Metrology introduces the non-contact HNC3030 3D measuring system for precise, highspeed measurement of complex components including gears, impellers, turbine blades and more. With the HN-C3030, featuring an advanced laser scanner, Nikon is making a leap forward in ultrafast shape evaluation compared to traditional tactile measurement methods. By scanning and comparing the complete shape to the original CAD file, customers obtain better insights in product conformity resulting in faster problem-solving and earlier go-to-market.
Advanced optical technology Due to the development of more complex components, the demand for high speed, precise measuring of these parts has also increased. As a long-established manufacturer of high-quality optical instruments, Nikon now introduces the HN-C3030, a next-generation non-contact inspection system. In order to achieve the highest precision, Nikon has developed special optics for the laser scanner that also enables scanning of glossy or dark surfaces without manual preparation, such as powder spraying.
High-precision five axis control for optimum scanning angles The precise positioning by the synchronised 5-axis
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–20˚
+135˚ Rotatable laser scanner arm
hardware control is an important element to deliver the accurate measuring results. The HN-C3030 controls a high-precision 3-axis drive system, as well as an unlimited angular rotary stage and a laser scanner swing arm with an arc angle of -20° to +135°. This enables laser scanning of wide areas covering top and side surfaces, and even bottom surfaces, of parts. In addition, the direction of the laser scanner can be changed (-180° to +180° rotatable), allowing scans of various shapes from optimum angles.
A calculated combination of speed and accuracy Nikon Metrology’s compact HN-C3030 solution is capable of inspecting all toothed surfaces on a single automotive bevel gear in only 5 minutes. The laser scanner acquires surface point clouds at a rate of 120,000 points per second. This is a massive multiple of the number of points that are measured using classical tactile inspection. The result is a full 3D scan of the part, while tactile scanning only provides individual points or scan lines. This detailed 3D digital copy provides not only full shape or section information, but also deep insight into the surface waviness and tooth wear, hardly detectable by tactile measurement.
Hypoid gear
Inspection of all tooth surfaces on an automotive bevel gear can be done in only 5 minutes
Profile error/lead error indication
Powerful acquisition software combined with advanced analysis The main HN-C3030 software features acquisition and analysis tools for optimum scanning of various sizes, shapes and surface conditions. Comparison of acquired point clouds to original CAD file provides colourful, easy-to-interpret 3D deviation reports. However, for more advanced gear inspection, dedicated gear software enables easy creation of teaching files and gear tooth analysis in the same format as with conventional contact gear measuring systems.
The highly operable solution for a variety of applications. The HN-C3030 particularly excels in the measurement of highly detailed, complex shapes such as hypoid, bevel, helical and all other types of gears with a maximum diameter of 300mm. It is also suitable for inspection of impellers, blades, oils seals, hob cutters etc. The HN-C3030 system isn’t restricted to use inside of temperature controlled rooms. At facilities such as production sites, the HN-C3030 can be used as a shop floor system when equipped with the optional thermal regulator.
Bevel gear
Helical gear
Benefits • Dense 3D scan provides better insight into complex shapes (part-to-CAD comparison, waviness, wear) • Laser scanning offers high measurement speed • Non-contact eliminates the need for probe tip compensation • Higher resolution than tactile measurement • Reveal surface defects (e.g waviness) not detectable by tactile probes • Measure small parts or features impossible for tactile probes
Compressor wheel for automobile turbo charger
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Case study
Nikon microscope allows highly efficient rock sample categorisation
Dr Simon Schneider using the Nikon Metrology SMZ18 stereomicroscope at CASP. The screen is showing a close-up of the bivalve image, showing the shell formed by calcite, and, on the right side, part of the surrounding limestone matrix.
CASP researchers use advanced stereomicroscope for geological research CASP is a non-profit, charitable trust carrying out field-, literature- and analysis-based geological research in prospective hydrocarbon basins. Funding comes entirely from subscriptions by the oil and gas industry. CASP members of staff publish the results of their research in internationally renowned peer-reviewed scientific journals after a suitable delay.
Fieldwork forms the core of CASP’s work. This not only involves field descriptions and photographs of rock outcrops, but also the collection of samples for analytical work back in Cambridge. In the CASP laboratory, microscopy is a core element of the research work to enable the samples that have been collected to be studied and categorised.
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When it was established in 1975, CASP focused on geological research in sedimentary basins of the Arctic, but its activities are now worldwide, with current active projects in Russia, Greenland, Canada, the Black Sea, the Adriatic and Ethiopia, among other locations. Another area of research is the North Atlantic Margins, for which Dr Simon Schneider is project leader. He received a
PhD in palaeontology in 2010 from LudwigMaximilians-University, Munich.
The importance of efficient microscopy Dr Schneider explained, “The fossil specimens that we analyse are often a few centimetres in width and similar in height. In addition, we look at a lot of 30- to 70-micron rock thin-
Cyanobacteria (the feathery structures in the central part of the left) encrusting a potential plant stem (the dark element in the lower left corner). The actual plant has mostly rotted away and been replaced by diagenetic cements. The cyanobacteria are in turn encrusted by layers of travertine. The width of the sample is 3.5 mm.
sections made using a diamond saw and grinding machines, and these also measure several centimetres across. To view some of the fossils satisfactorily under a microscope, we need a range of different magnifications and more importantly a reasonable working distance. We had a couple of binocular microscopes here on which the transmitted and incident lighting was less than satisfactory. The instruments also took a long time to set up.” The alternative was to use a powerful Nikon monocular microscope that had been in use at the laboratory for many years, but its x200 to x2,000 magnification range was too high to allow Dr Schneider and his colleagues to assess the larger samples in detail and to characterise easily the mineral and fossil content of the rocks. The latter instrument was fitted with a Nikon digital microscope camera, so when CASP’s researchers looked for a more efficient, lower power stereomicroscope for their needs, the prospect of a model from the same manufacturer was attractive, as the same camera could be used on both microscopes. Nevertheless, a number of different makes was reviewed before a Nikon SMZ18
Magnified 600 times, this photomicrograph shows biogenic calcite crystals of a bivalve shell (grey) and their organic interlayers (brownish) viewed in cross section. The compound of crystals and organics is what makes shells both durable and elastic.
research stereomicroscope was purchased in the spring of 2015 from Nikon Metrology, Derby (www.nikonmetrology.com). The microscope has macro and micro imaging in one manually controlled instrument for convenient viewing and manipulation of samples. A high performance lens provides clear images with uniform brightness across the entire field of view. Dr Schneider confirmed, “The SMZ18 is a brilliant microscope. It has 18:1 manual zoom and our binocular eyepiece provides a 22 mm field of view. The magnification range up to x270 and the 60 mm working distance of our objective are perfect for what we need. The quality of the optics is world renowned and the other crucial factor is the effective episcopic (reflected light) and diascopic (transmitted light) illumination of our samples.”
extracting zircon grains from mineral samples for radiometric dating purposes. Another regular user is Dr Li Guo, who received a PhD from Cardiff University, and mainly studies the composition and genesis of travertines, which are limestone deposits formed by hot springs. Dr Guo has recently used the camera to obtain photomicrographs of a 3.5 mm wide sample of fossil cyanobacteria, which obtained their energy through photosynthesis and thus grow in shapes similar to algae. The bacteria colony studied was encrusting what appears to be the stalk of a plant. However, this stalk has mostly rotted away and been replaced by diagenetic cements. The cyanobacteria are in turn encrusted by layers of travertine, the above mentioned, layered limestone.
The Nikon SMZ18 as a multidisciplinary tool Simon Schneider is not the only researcher at CASP to benefit from the new microscope. Dr Michael Flowerdew, who received his PhD from University College Dublin, is a geologist specialising in geochronology and isotope geochemistry. He uses the instrument for
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Case study
Mindful distraction: Therapeutic art created with mineral photomicrographs
Stereoscopic microscope fitted with high resolution full frame camera delivers superior image quality
Professor Richard Weston, a renowned architect, lecturer and author of numerous books on architecture and mineralogy has also formed the Richard Weston Studio. The Richard Weston Studio specializes in creating aesthetic designs and artworks from small specimens or minerals, fossils and stones. In 2011 he was described by a UK newspaper, the Independent on Sunday, as “the breakout star of Britain’s Next Big Thing”, a BBC2 TV series in which the buying teams of three high street giants asked the public to supply them with the next bestselling products.
His success stemmed from a series of images of natural materials he captured using a high resolution document scanner to produce designs for a collection of silk scarves. Introduced in 2010 to the shelves of the Liberty department store in London, the scarves quickly became one of the shop’s best-selling lines. Two years later, four of Prof Weston’s photographs enlarged to five metres by three metres graced the entrance to accommodation in the Olympic Village in Stratford during the London Olympic Games. Outside the fashion industry, his high resolution digital images and 3D models offer a vast range of possibilities in architecture and the design of urban spaces, gardens and interiors, from printing or etching tiles and digitally weaving rugs to decorating a wall or an entire building. The work has led to increasing international recognition, with recent magazine articles appearing in the USA, The Ukraine and The Netherlands and two books on textile design published in the UK. Current work at the studio (www.richardwestonstudio. com) is a far cry from early attempts to capture decent pictures of a £143 ammonite specimen Prof Weston bought in 2003 from a local crystal shop in Cardiff, south Wales. He recalled, “My scanner cost less than the
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Prof Weston’s photomicrograph of an agate sample
ammonite and resulted in a disappointing, muddy brown picture�. In 2014, following a conversation with a colleague at Cardiff University, he was convinced that a Nikon based photomicrography station was ideal, leading to the purchase of an SMZ1270. The stereoscopic microscope is equipped with a Prior moving stage and a Z-axis drive, both with a positioning accuracy of one micron, a Nikon camera and sophisticated NIS-Elements frame selection and stitching software, all supplied by Nikon Metrology (www.nikonmetrology.com). The scope of projects that could be carried out increased dramatically and so did the quality of the images produced. The highly controllable set-up allows a sample to be illuminated with a combination of transmitted and incident light to bring out the best in a crystal structure. As the absorption and reflection patterns of natural specimens are different, it is possible to vary the light sources so that two scans can be obtained from the same mineral sample and it is nearly impossible to detect any similarity between the two images. Individual frames taken of a specimen are joined in Nikon Metrology’s advanced NIS-Elements imaging software, which helpfully selects the best focal plane for each
Prof Robert Weston, wearing a shirt printed with one of his ammonite fossil photographs, examines the agate crystal on the screen of the linked PC.
photomicrograph. The process generates very high definition composites with file sizes from tens or hundreds of megabytes up to several gigabytes. Before processing, nearly all minerals and rocks are coated in a light oil, imparting a flat surface that can be photographed without light scattering from the rough-sawn surface, saving the time and costs associated with having samples polished. The other big advantage of this approach is that there are no remnants of polishing powder on the surface to remove digitally, a procedure that is time-consuming and sometimes impractical. Each resulting image is subtly colourful, intricately patterned and unique. Following a recent discussion between Prof Weston and a professor in the neurosciences department at the Swedish University of Agriculture, it appears there may be a health benefit from viewing pictures of minerals in our busy modern world. Apparently, there is a therapeutic effect when looking at these natural fractal patterns. They reduce stress by engaging one part of the brain to create a state of mindful distraction or fascinated attention, similar to meditation, allowing the tired prefrontal and parietal cortexes to restore themselves more quickly after a period of prolonged concentration.
This image was taken from a sub-millimeter specimen using the Z-axis capture function of the Nikon Metrology microscope.
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Case study
Nisan Engineering reduces inspection time by a factor 5
Subcontractor installs new ALTERA CMM and retrofits Mitutoyo machine with CMM-Manager software Dinesh Prajapati, a director of Leicester-based subcontract machinists, Nisan Engineering (www.nisanengineering.co.uk), takes the view that there is no point machining a component if you cannot check that it is within tolerance. The problem was that parts were becoming increasingly difficult to inspect after the company, which traditionally used 3-axis CNC machining centres, installed a 4-axis horizontal-spindle model and a 5-axis vertical machining centre.
Much more complicated components were being produced on these machines and some of the features were impossible to inspect on the company’s manual coordinate measuring machine (CMM), which dates back to the 1990s. If the features were critical and could not be inspected by hand using other conventional metrology equipment, work had to be turned away, as in most instances there would not have been time to send the parts out for checking. Purchase of an ALTERA 8.7.6 CNC CMM in early 2015 provided the solution. It is able to inspect the most complex parts that Nisan produces and in addition, all parts are measured in a fraction of the time that was previously needed on the manual machine. While the new CMM was being installed, Nikon Metrology retrofitted identical control software, called CMM-Manager, to the manual Mitutoyo BH504 CMM. It considerably increased the speed with which components can be inspected on what was rapidly becoming an
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With the Altera CMM the same process takes just 9 minutes – less than one-fifth of the time - and extra measurements are taken resulting in a more comprehensive inspection. Mr Prajapati, director of Leicester-based subcontract machinists, Nisan Engineering
outmoded facility, giving it a new lease of life. Mr Prajapati gave a couple examples of the significant benefits obtained using the new CMM and the upgraded machine. The first refers to a part produced on the 5-axis machining centre that could not previously be inspected at all, whereas it is an easy process on the Altera. The second concerns a 4-axis machined component that is now inspected more comprehensively and faster on the new CMM as well as on the Mitutoyo with Nikon Metrology software.
5-axis machining productivity maintained The 5-axis job is an aluminium housing measuring 172 mm in diameter by 52 mm high that forms part of a turbine used for renewable energy generation. After CNC turning of the bore and outside diameter (OD), the part goes onto a German-built Spinner 5-axis VMC for a substantial amount of milling and cross-drilling at various oblique angles. One hole is at 30 degrees, another at 45 degrees and a third at 52 degrees. All are of 0.8 mm diameter and intersect at a point. These holes could not practically be measured on the manual CMM, even with the new software, whereas it is an easy process on the Altera using a very fine touch probe in the Renishaw PH10T motorised indexing head. The entire part is checked in two automatic
cycles taking a total of 10 minutes, including automatic probe exchange, during which time the operator is free to do other tasks. Tightest tolerance is 10 microns total on the OD and bore. Mr Prajapati said, “Repeatedly repositioning the head by hand on the manual CMM takes half an hour each time. Doing this three times to inspect the holes plus several more times to access other features would take five or six hours, far too long to be a viable method of inspecting the turbine component. Additionally, it would risk introducing inaccuracies. Then for example if a drill breaks during production and needs to be replaced, rechecking those machined features would hold up production, further raising the cost per part of manufacture.”
Comparison of CNC and manual inspection Examining the measurement of a family of EN8 steel components that have been produced in the Leicester factory for the past two and a half years on an Akari twin-pallet, 4-axis HMC sheds light on the significant advantages of retrofitting Nikon Metrology’s CMM-Manager software to the manual Mitutoyo. The gas flow meter cylinders are machined in 10 sizes from solid billets measuring from 74.5 to 145 mm in diameter and 270 to
The aluminium turbine component being inspected in a cycle time of 10 minutes at Nisan Engineering, Leicester.
557 mm long. A bore of between 34 and 65 mm diameter is machined during the first operation, followed by drilling, tapping and milling around the periphery during op 2. Bores have to be accurate to 37 microns total and other dimensions to between ± 0.1 and ± 0.2 mm, while the faces of the component are tied up to the bore to within 50 microns concentricity and parallelism. Using the manual CMM and pre-existing Mitutoyo software, inspection took 40 minutes. It was followed by conventional handgauging of a threaded hole and manual inspection of certain other interrelated positional features that could not be included in the CMM procedure, which added a further 10 minutes. With the Altera CMM the same process takes just 9 minutes – less than one-fifth of the time - and extra measurements are taken resulting in a more comprehensive inspection. The cycle has to be programmed the first time, but on all subsequent occasions it is available for immediate reuse.
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