addition to speeding up the production ramp. CMMs aretypically located in environmentally controlled inspectionrooms, which o;en impact machine availability. If the partsare to be inspected in the metrology room during the production process, part “queues” are to be expected, due to limitedmachine availability coupled with long CMM setup times.
Zero Touch has been designed precisely to mitigate theseissues by being fast, ;exible, easy to use, and compatible withthe manufacturing environment.
Zero Touch enables 100% part inspection. In addition, theZero Touch is characterized by its ease of use. By giving theoperator an easy-to-use tool, di;erent types of parts produced on di;erent lines can be quickly inspected. Suchcapability will enable the rapid quali;cation of manufacturing lines and speed up production ramp.
Zero Touch’s unique architecture features 5 independentaxes; a rotating bridge–Gonio like–equipped with multiple,
non-contact sensors, including lasers and chromatic confocal sensors, which dramatically increase inspection speedsin measuring the entire part surface, as there is no sensorchange time. ;e sensor bridge is con;gurable allowing forthe most optimal and appropriate sensor selections to suitpart geometries and surfaces, in addition to the complexdimensions being measured. Such innovations associatedwith a horizontal rotary table and 3 translation axes result inhigher throughput of parts and increased capacity, enabling
100% in-line inspection rather than just sampling.
;e innovative design of Zero Touch presents a remarkableimprovement in surmounting the challenge of repeatability ina hostile manufacturing environment. Since it can performmultiple measurements in parallel using di;erent sensors,parts and assemblies can be analyzed signi;cantly faster than aconventional CMM.
“;e sensors can be con;gured to the speci;c GD&T mea-
surements and the part, and in one scan the system can capture
data points to create a high-density 3D model,” says Mendez.
“;is makes it possible to measure objects made of a wide vari-
ety of materials with complex geometries, including holes, un-
dercuts, bevels, and surfaces, quickly and with micrometer
precision. At the same time, the system provides very high re-
producibility and repeatability of results.”
;e various non-contact sensors on the metrology bridge can
be easily calibrated by so;ware directly via the metrology plat-
form. Further time is saved by the simplicity with which parts
and assemblies can be placed on the measuring table, instead of
requiring complex positioning ;xtures. ;is not only decreases
the metrology preparation time but also enables direct cost sav-
ings in ;xture design, development, and management.
“It was also important that ZeroTouch shows no signs of
wear, and delivers the same performance year a;er year,” says
Mendez. “So we gave it a planar air bearing system.” ;e mov-
ing parts, such as the measurement platform and sensors, gen-
erate virtually no friction during the measuring process. Part
inspection plans can be created within a few hours and stored
in the manufacturing execution system (MES) for manage-
ment and retrieval. “;e user is assisted by menu-guided in-
tuitive tools, making deep programming knowledge super-
;uous now,” says Mendez. “Instead, inspection plans can be
prepared using drag-and-drop functions.”
Measurement data for each component is retained to ensure
data integrity. ;erea;er, component-speci;c plans can be ac-
cessed in the MES for fast measurement. Optionally, compo-
nents or assemblies can be given barcodes to be read by an
onboard barcode reader. ;e respective inspection plan is then
automatically loaded from the MES. ;e control so;ware pro-
vides high personal safety by ensuring that the system does not
move as long as the doors of the switchgear cabinet are open or
if the system light curtain has interference.
;e three-dimensional point cloud can be analyzed immediately a;er the measurement process. Integrations toproven analysis tools enable the accurate comparison of thescan results with part CAD models or a reference part previously scanned and measured to not only check for geometric and dimensional tolerances but for other previouslyundetected issues such as surface aspect defects. Using statistical process control (SPC), faults or outside-tolerancedeviations can be quickly detected and appropriate reporting can be sent back to the MES. ;is could enable the adjustments of process parameters in upstream manufacturing processes to minimize rejects downstream.
;e current system measures 240 x 150 x 190 cm (L x W x H)and weighs 3,550 kg. It can measure parts measuring up to 300x 300 x 300 mm and weighing up to 10 kg. It uses a high-performance GPU PC with Intel Core i7-7700T Processor and twocapacitive industrial monitors with touchscreens.
The various non- contact sensorson the metrology bridgecan be easily calibratedby software directly viathe metrology platform.
Further time is saved by the simplicity with which parts and assemblies can be placed on the measuring table, instead of requiring complex positioning fixtures. Thevariety of available sensors allows 3D measurement or any kind of surfaces including mirror-like ones.
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DWFritz Automation developed the Zero Touch metrology platform to dramati-
cally improve part measurement and inspection times. The system uses multiple
non-contact sensor technologies to capture the measurements in three dimensions
and in real time.