Thickness and surface area measurements in free space. Jan Reinder Fransens December 4, 2013

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1 Thickness and surface area measurements in free space Jan Reinder Fransens

2 Overview Introduction Irmato Contactless measurement Current system Control software White light sensor Free form measurement Challenges Possible methods Demo system Future developments Precision Fair Free form measurement 2

3 Profile Multidisciplinary engineering company, from R&D to Realisation for product development, factory automation and machine building. Branches in Stramproy, Aachen (G), Steinheim am Murr (G), Kinrooi (B), Drachten, Groningen, Eindhoven, Veldhoven, Mierlo and Veghel. Over 350 employees. Customers in the following branches: Automotive, Aerospace, Electronics, Medical, New energy, High Tech Drachten Kinrooi Groningen Veghel Eindhoven Stramproy Aachen Steinheim Am Murr Precision Fair Free form measurement 3

4 Competences and products Mechatronic systems Prototyping Engineering Assembly systems Measurement Solutions Vision inspection Automation; Robotics & Linear transfers Research & Development (P)ECM Process & Production systems Precision Fair Free form measurement 4

5 One-stop-shop 4. Engineering 5. Release For Production 6. Realization 7. Factory Acceptance Test 8. Shipping 9. Installation 3. Requirements Definition 10. Site Acceptance Test 2. Process Research 1. Customer Request 11. Service Precision Fair Free form measurement 5

6 Thickness and surface area measurements in free space

7 SW correction Contactless measurement Why Contactless? Increasingly complex products Higher measuring speeds possible Forceless -> no product deformation No stylus error correction needed Stylus sphere Measure XY R torus Precision Fair Free form measurement 7

8 Contactless measurement White light sensor Focus depends on λ Only one λ in focus Spectrometer determines λ with highest intensity Distance d follows from λ d table range Z-resolution lateral resolution opening angle frequency 100µm 25mm 3 800nm µm samples/s Precision Fair Free form measurement 8

9 Contactless measurement ICMM test set-up volume sensor 100x100x100mm optical white light resolution sensor 20nm z-axis 50nm xy-axes 50nm accuracy 0.2 µm frequency tot 14 khz max. speed z-axis 25mm/s xy-axes 200mm/s Precision Fair Free form measurement 9

10 Contactless measurement Control software Layered software structure Scripting language to define measurements MATLAB fitting routines 3D viewer to visualize data Precision Fair Free form measurement 10

11 Free form measurement Why free form? No limitation for angles on work piece Larger work pieces are possible Higher flexibility Precision Fair Free form measurement 11

12 Free form measurement Challenges Accurately measuring the Tool Centre Point (TCP) position Synchronization between robot and sensor Positioning of the sensor w.r.t. the work piece ABB data IRB1600 6/1.2 Position repeatability 0.02mm Path repeatability 0.13mm TCP positioning error 0.36mm * * Nubiola and Boney 2013 Precision Fair Free form measurement 12

13 Free form measurement Possible methods Precision Fair Free form measurement 13

14 Free form measurement Ranking of methods nr. method 1 use 2 cameras and an accurate grid as background to determine the TCP 2 use cables on the robot to determine the joint positions, calculate the TCP 3 use 3 cameras to determine the TCP position (3D vision) 4 determine the joints with laser distance measurement, calculate the TCP 5 use an optical laser system with spatial artefacts to determine the TCP 6 use a laser tracker system with retro reflector to determine the TCP [3] 7 use a precision trigonometrically method with cables to determine the TCP Precision Fair Free form measurement 14

15 Free form measurement Demo system ABB IRB 1600 robot system Precitec CHRocodile E with probe Precision Fair Free form measurement 15

16 Free form measurement Demo system results Movie Precision Fair Free form measurement 16

17 Future developments Next steps Implement selected measurement method Increase accuracy Sensor perpendicular with on surface Synchronization between sensor and robot Autonomous scanning of objects Link with CAD data Increase scanning speed Precision Fair Free form measurement 17

18 Acknowledgements For their work on demo system and pictures Arno Douma Bas Triemstra Peter Landman Precision Fair Free form measurement 18

19 Thanks for your attention Questions? Please contact Irmato: +31 (0) or visit our booth number 120

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