Quality Expo 2013

Here’s a snapshot of some of the gages, quality software, calibration, CMMs, data collection, electronics test and non-contact inspection equipment that will be exhibited on the show floor at McCormick Place in Chicago on September 10-12.

3D INSPECTION PROFILING FOR PARTS MEASUREMENT
Offering a new 3D Profiling capability to inspection measurement, the versatile IK 5000 QUADRA-CHEK PC software system from Heidenhain Corporation (Schaumburg, IL) now gives operators the ability to quickly measure and determine parts profiles within desired tolerance zones. This optional 3D feature compares the actual measured part to a three-dimensional model within the PC software, making inspection a breeze, especially useful on CMMs.

To utilize the 3D Profiling, the operator first imports a computer-generated 3D model using IGES or STEP formats and then takes measurement points on the desired part. This new function fits and compares the two within the IK5000, and then both the overall profile and the individual point results can be toleranced, printed, and/or exported for evaluation.

The measurement and evaluation routines of 3D contours using the IK 5000 makes inspection on CMMs and multisensory measurement inspection machines an easy process. These part programs can then be used to take measurements of subsequent parts either manually or in an automated measuring process depending on the machine design.

Other functions of the 3D Profiling option include the ability to orient and align the model in all possible degrees of freedom, as well as to apply profile tolerances for any of the lines and surfaces either as an overall tolerance or specific to individual features or surfaces.

The IK5000 software is a PC-based inspection software and hardware package, used for 2D and 3D measuring tasks. The 3D Profiling add-on option is integrated into the standard operating software of the IK5000, allowing use of the entire software package as normal and turned on when needed.

The IK 5000 QUADRA-CHEK with 3D Profiling is an equally suitable choice on new inspection equipment as well as for retrofitting onto an older inspection platform. Available in versions for 3 and 4 axes, the optional expansions make it ready for all coordinate measuring technology applications. www.heidenhain.us

MODULAR MULTI-GAGE SYSTEM QUICKLY SOLVES COMPLEX INSPECTION
Mahr Federal, Inc. (Providence, RI) has introduced Standard Elements, a new modular-based gaging system with standard components that allow users to configure and implement simple to complex gaging solutions quickly and cost effectively. They provide the flexibility and versatility of a general gage, yet can also combine to provide the speed and accuracy of a custom or dedicated gaging solution.

The system is designed to meet the ID, OD, and length measurement needs of today’s manufacturing environment where short runs and quick changeovers are becoming the rule.

“These systems are not expected to replace traditional gages,” said George Schuetz, the Mahr Federal director of precision gages, “but to add another dimension to the gaging paradigm. The idea of the multi-gage is to turn all the elements found in high precision comparative gaging into modular components. These elements include good solid reference anvils or contacts, a sensitive contact, part references (or backstops), and a readout, all tied together with a robust frame for stability.”

The use of these Standard Elements allows multi-gage measuring devices to be designed and assembled for the widest possible range of workpieces. And since they are constructed of all common elements, they can easily be re-configured for similar or different applications. “So where a traditional comparative gage may have been built for one size shaft with five diameters,” said Schuetz, “a new multi-gage can easily be adjusted for five different shafts having different diameters at different locations.”

Just as there are different levels of performance and robustness in the design of standard handheld comparative gaging, Mahr Modular Multi-Gage components employ a similar “good, better, best” design philosophy. Multi-gage elements can be configured for the simplest parts or even the most complex and demanding workpiece geometries.

And because the modular components are all designed to be as small as possible, a high number of measuring points can be inspected within a small area of the workpiece. All multi-gage systems can be constructed by the customer from standard catalog elements and then, if needed, changed later by the end user.

Mahr Modular Multi-Gage configurations are robust enough to withstand demanding shop floor environments, and offer a number of economic benefits as well. Once manufacture of a particular type of workpiece has ceased, elements used in the test equipment can be reused for a different type of workpiece.

A choice of different readout systems can be used, as well as different mechanisms for guiding the moving part of the stylus, according to the accuracy requirements of the measuring task. This flexibility reduces both development and implementation time.

When the performance of electronic gaging is required, Mahr Modular Multi-Gage systems offer the same flexibility in selecting input and computation options. These include creating multiple inputs from different sensors (LVDTs, digital probes, analog or air sensors) and the use of gaging computers with gaging software for multiple part programs, part classification, and data storage and analysis.

Mahr Standard Elements are available with or without integrated pneumatic probe retraction, spring blade or ball guidance, measurement strokes up to ±2.5 at ±10 mm accuracy to 0.5 µm. Download the full Millimar Modular Measurement Catalog for complete Multi-Gage standard element details. [email protected], www.mahr.com

AUTOMATIC VIDEOS FOR RAPID REPETITIVE MEASUREMENTS
Starrett Kinemetric Engineering, Inc., a subsidiary of L.S. Starrett Co. (Athol, MA) announces its new AVR Series of CNC automatic video metrology systems. These systems are designed for applications where repeat measurements are required on a run of parts with the speed and accuracy of non-contact video edge detection (VED). Two sizes are offered: model AVR200 with 8 in x 4 in x 8 in of XYZ travel and model AVR300 with 12 in x 8 in x 8 in of XYZ travel.

The AVR Series features a granite base for stability and precision and recirculating ball linear guides for smooth stage motion. The level of the stage glass can be adjusted mechanically, as well as in software. Computer-controlled Quadrant LED ring lighting, LED sub-stage lighting, and optional through-the-lens LED lighting meets the most challenging illumination requirements.

The AVR is coupled with a 21.5 in all-in-one touch screen PC that runs MetLogix M3 software under Windows® 7 Professional. All electronics other than those in the PC are housed in the Z-column, avoiding external components and ensuring a clean system installation with a minimal footprint.

The basic M3 metrology software supports 3-axis measurements and 2D geometrical constructs (such as points, lines, angles, rectangles and slots) and corrections for level, skew and datum origin. Touch screen functionality with a pinch, swipe and a touch provides intuitive operation for all users.

With the M3 DXF/FOV option pack, DXF CAD files can be imported over a network, DXF drawings can be overlaid on the live video image, and error whiskers can be displayed for portions of the live video that do not fall within tolerance limits. High-speed measurements can be made within the field-of-view (FOV) of the camera optics and can be seamlessly integrated with X-Y encoder readings for larger parts.

With the M3 CNC option, closed loop control signals for X, Y and Z motion and optical zoom and illumination are generated for repetitive measurements, boosting productivity.

The AVR Series systems include a digital video camera with either 6.5:1 or 12:1 motorized zoom optics or a choice of six telecentric lenses. The telecentric lenses provide micron-level resolution and optical distortion down to 0.001 percent for accurate FOV measurements. Such measurements can encompass a small part up to 2.00 in x 1.50 in or a feature of a larger part.

“Our AVR Series represents the next step in the evolution of CNC vision metrology systems with state-of-the-art hardware and software for unmatched flexibility, accuracy and ease of use,” stated Mark Arenal, the general manager of Starrett Kinemetric Engineering. www.starrett.com

SNAP™ MEASURES ENTIRE PARTS INSTANTLY – WITH NO FIXTURING
The QVI® SNAP from RAM Optical Instrumentation (Rochester, NY) completes entire part measurements in seconds with no moving parts, using its large-field optical system and high resolution, digital zoom camera. SNAP’s digital measuring technology with simple, one-button operation makes it the fastest automatic measuring system available.

SNAP excels at measuring small parts with lots of features, and its exclusive Zoom Anywhere™ technology allows instantaneous zooming to any location in the field of view.

SNAP includes three lighting systems to ensure the perfect illumination for every part, including a backlight for profile projection, square-on top light for looking into bores and cavities, and an 8-sector bi-color ring light for highlighting surface features.

SNAP’s telecentric optics, with their large depth of field, eliminate tedious focusing. Measure-X® 2D software with its unique AutoCorrelate function eliminates the need for manual setup, enabling fast measurement of parts without fixturing, regardless of part orientation.

With SNAP, staging parts is eliminated, calibration is automatic, and complete measurements are virtually instantaneous. SNAP is a compact benchtop unit rugged enough for the shop floor, with the reliability and accuracy that you expect from RAM. [email protected], www.ramoptical.com

CMM MEASURES PRODUCTION ON THE SHOP FLOOR
Zeiss Industrial Metrology (Maple Grove, MN) will be featuring the DuraMax Shopfloor cordinate measuring machine. With a number of additional components and functions, this compact CMM is now even better suited for shopfloor measurements and can also accommodate several workpieces at once. www.zeiss.com/metrology

HIGH QUALITY MEASUREMENT INSTRUMENTS
An innovative world leader in the field of high quality measurement technology, Fischer Technology, Inc. (Windsor, CT) offers a full range of instruments for coating thickness measurement, material testing, micro- and nano-indentation measurement and material analysis to serve many diverse industries such as automotive, marine, aerospace, electronics, powder coating, plating, military, solar and many others.

The FISCHERSCOPE® X-Ray Fluorescence Instruments utilize an energy dispersive X-ray fluorescence analysis (ED-XRFA) method for simultaneous high precision coating thickness measurement or exact material analysis of even complex coating systems, with or without calibration standards.

Fischer also offers solutions to measure the electrical conductivity of metals, the ferrite content of welds and quick and simple measurements of anodic coatings on aluminum. Other measurement methods include handheld coating thickness measurement, beta backscatter, magnetic induction, eddy current, phase-sensitive eddy current, and coulometric and the necessary certified foils and standards needed for the calibration of all our instruments.

Visit Fischer at the Quality Expo to see our instruments up close and learn how we can help you with your applications. [email protected], www.fischer-technology.com

EXCLUSIVE LIFETIME WARRANTY BLUETOOTH INDICATORS
Fowler/Sylvac’s new Mark VI Bluetooth indicators from Fred V. Fowler Company, Inc. (Newton, MA) are available in both 1/2 in and 1 in travel. Both feature a resolution of .00005 in/.001mm with an accuracy of ±.00006 in (1/2 in model) and ±.00008 in (1 in model).

Integrated Bluetooth Technology offers output without the hassle of cables or antennas hanging from the indicator. Your USB port is all you need. The Mark VI indicator is one of several Fowler/Sylvac products that offer the “Fowler Exclusive Lifetime Warranty.” [email protected], www.fvfowler.com

BENCH TOP COMPARATOR AT ATTRACTIVE PRICE
Dorsey Metrology International, Inc. (Poughkeepsie, NY) welcomes attendees to visit with them and see their new Benchmark 14H comparator, and is focusing this new addition to its product line at an attractive price point between Dorsey’s entry level 14HE model and its very popular 16H model bench top comparators.

Like Dorsey’s other models, this machine is built to last, is designed for shop floor use and made in the USA.

Also featured will be a new line of light weight carbon fiber gages, along with a full line of dimensional measurement instruments. These products consist of Dial Indicators, Bore Gages, Snap Gages, Comparator Stands, Large Diameter ID/OD (Fixed or Adjustable Models), Ring Gages, Groove Gages, Bench Gages, Depth Gages, Set-Masters, Countersink Gages, Chamfer Gages and much more for industrial metrology applications in markets such as aerospace, automotive, medical and energy.

Besides a comprehensive line of comparators and dimensional measuring instruments, Dorsey also offers gages for customer’s special applications, whether the products are a modification from it’s standard product line, or custom designs to meet their customers special applications. www.dorseymetrology.com

CMM COVERS ALL SHOP FLOOR APPLICATIONS
Wenzel America, Ltd. (Wixom, MI) will showcase the updated version of their popular X-Orbit entry level coordinate measuring machine that can be used in all application areas, from goods inwards to final inspection. It’s simple to use with a host of features you have come to expect from Wenzel.

The new XO CMM design incorporates improved dynamics, newly styled covers and a skirt around the machine base. The XO is available in three bridge sizes – 5.5, 8.7 and 10.7 – and represents the best price/performance ratio on the market.

The XO CMM is manufactured from granite to give thermal stability in all applications as well as self cleaning and wear free air bearings on all axes. The X-Orbit is available with a range of Renishaw sensors and is fully capable of checking simple geometry to scanning free form surfaces. www.wenzelamerica.com

MULTISENSOR CMM INCREASES MEASUREMENT VOLUME AND MORE
Hexagon Metrology, Inc. (North Kingstown, RI) announced the release of the Optiv® Classic 443 tp, the newest model in the Optiv Classic series. Each unit comes touch probe-ready and includes a high-resolution CCD (charge-coupled device) camera for multi-sensor applications with micro- to nano-scale precision measurement requirements.

The Classic 443 tp boasts a first term accuracy of 1.9 microns, making it ideal for the inspection of small scale features and parts like micro-hole dies, sieves, filters, fiber optics and inkjet nozzles as well as complex, densely populated precision parts from the medical, aerospace, electronics or automotive industries.

This entry level, high-capacity multi-sensor CMM (coordinate measuring machine) provides over five times the measurement volume of its smaller brother, the Optiv Classic 321GL tp.

Highlights of the Classic 443 tp’s innovative vision technology include calibrated lighting, a high resolution color CCD camera, and a multi-segment LED triple angle ring light to create better contrast for edge detection. The multi-sensor CMM features a 12x CNC motorized zoom for continuous adjustment of field of view and resolution, and an LED status indicator providing a quick visual check of the machine’s status.

The Classic 443 tp comes standard with PC-DMIS® Vision image processing software and optional online 3D CAD capabilities for live programming of the machine to compare measured values to nominals. The software includes the groundbreaking MultiCapture feature which finds all 2D characteristics in the field of view, regardless of their type, and measures them simultaneously.

MultiCapture then moves the camera to the next cluster of features and measures them. This sequence continues until the inspection program is complete, and is automatically optimized by creating the most efficient path with the fewest number of stage movements. Inspection speeds increase by 50% or more, depending on feature size and density, which can significantly raise throughput.

“The Classic 443 tp offers increased capacity, without sacrificing accuracy, in a truly innovative multi-sensor CMM,” states Dan Farnsworth, a product manager for Hexagon Metrology. “The increased measurement volume makes it ideal for palletized parts and offers good accessibility to the measuring table from all sides. It is the perfect fit for high-volume measurement of small, tightly toleranced parts.” www.hexagonmetrology.us

EXTENDED HEIGHT GAGING FOR TALL, FIXTURED AND AUTOMATICALLY LOADED PARTS
The extended space below gaging system’s measuring volume allows fixtured parts to be transferred onto the gage and enables use of automated systems such as robots and conveyors.

Renishaw, Inc. (Hoffman Estates, IL) extends the product line, and the height, of its revolutionary Equator gaging system with the new Equator 300 Extended Height comparative gage. The new system doubles the space below the measuring volume of the original model, providing a 300 mm height to accept tall parts or those attached to machining fixtures.

The additional space also facilitates automated part handling with robots and conveyors. The system can inspect features on parts up to 300 mm tall, with rapid changeover to smaller parts using an extended fixture plate spacer.
Equator is a radical alternative to traditional dedicated gaging, filling a gap in the market never before addressed.

The patented low-cost design, unique in construction and method of operation, is capable of high-speed comparative gaging for inspection of high-volume manufactured parts. Equator is a lightweight, fast and highly repeatable gage that operators can use with push-button simplicity, and the system can switch between parts in seconds, making it ideal for flexible manufacturing processes or accepting parts from multiple machines.

Equator systems have been installed in multiple automotive, aerospace, medical and electronic plants across the world, and users cite advantages of reduced maintenance and fixture costs, plus the ability to gage multiple parts and re-program for design changes.

By using fixturing that positions parts to within 1 mm of where the master was measured, there is no significant effect on system repeatability, and the need for expensive precision fixtures is removed. The Equator fixture plate can be easily exchanged for other plates, each mounted to the Equator base using highly repeatable three-point kinematic seats. The plates can also be exchanged for fixture plate spacers, allowing smaller parts to be gaged in the same measuring volume.

Equator’s innovative and highly repeatable gaging technology is based on the traditional comparison of production parts to a reference master part. Re-mastering is as swift as measuring a production part and immediately compensates for any change in the thermal conditions of a shop-floor environment.

The calibrated absolute accuracy of CMMs, which are often located in remote temperature controlled rooms to ensure accuracy, can be extended to the shop floor to provide calibrated traceability to Equator measurements. With the calibration file loaded into the Equator software, measurements made in the Equator system can be referred back to the CAD or drawing nominals.

An Equator-specific stylus changing rack, included with the system, adds versatility and allows automated in-cycle changing of SH25 stylus holders. The SH25 holders couple to Renishaw’s SP25 probe, allowing Equator users to swap the stylus configurations without re-qualifying each time. Up to six stylus combinations can be loaded into the rack at any time and they can be used on a single complex part or with multiple parts of varying geometries.

Since the launch of the Equator gaging system in 2011, many users have taken advantage of the turnkey programming service offered by Renishaw and its partners. Reflecting the international nature of manufacturing, Equator users can take advantage of Renishaw’s extensive network of Equator support engineers.

Projects initiated in one country or region can be easily transferred and locally supported in multiple locations. Renishaw has nearly 70 regional support offices and multiple approved partners, covering every industrialized area of the world. www.renishaw.com/gaging