New Software Puts Big Data to Practical, Specific Use

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1 Photo courtesy Heidenhain Metrology Software New Software Puts Big Data to Practical, Specific Use Today s metrology software compared with applications available as recently as the turn of the century is more accurate, has the capacity to analyze bigger data sets, is faster, and makes using it easier. Ilene Wolff Contributing Editor A free update for those who already have Heidenhain s IK5000 Quadra-Check PC-based software makes it possible to use a Keyence LK-G5000 laser for measuring glass and other transparent materials. mind boggling how fast it moves data. And that s really critical to getting your job done, said Ron Rode, past president of the Coordinate Metrology It s Society (Weatherford, TX). Scanning is getting more and more accurate, you re able to take bigger and more dense cloud points, and the software is getting much more robust. Rina Molari-Korgel, current CMS president, agrees: That s where software has been making advances, in taking massive amounts of data and finding geometric entities and edges. Being able to do that kind of intelligent processing is pretty amazing. People say Just scan it, but now I ve got all this data and what do I do with it? Lester Glover, whose company Hexagon Metrology (North Kingstown, RI) released a significant update of its premier software, PC-DMIS in December, has an answer for Molari-Korgel. He said the trend is for software to deliver visual data results in real time, complete with point cloud analysis. August 2015 AdvancedManufacturing.org 49

2 It renders the point cloud and turns it into a color-coded diagram that analyzes not with discrete points, but covered with a point cloud, said Glover, vice president of key account business development for Hexagon North America, adding, The general trend is for all of the software to work together, including the code for the user interface, processing/reporting and calculations/motor control. Rode and Molari-Korgel use metrology software every day he as program manager for tooling and portable metrology at Planet Tool & Engineering (O Fallon, MO) and she as senior applications engineer at Hexagon Metrology (also Weatherford, TX) so Image courtesy Capture 3D both appreciate what Glover s talking about. One of the big things I ve seen in the last five or six years is the software had become easier and easier to use, said Rode, who notes that choosing a function can be as easy as clicking on an icon. It s kind of like filling in a checklist. A critical production environments while promising reliable measurement results. Gear geometry is a science unto itself and is not well understood outside the niche industry that it s in, said Dennis Traynor, sales manager for Gleason Metrology (Dayton, OH). Gear profiles are highly modified for performance reasons, said Traynor. Therefore, very exacting control over the measurement system with customized OEM-specific analysis software, along with machine control/positioning systems to <1 micron, are required to correctly analyze the profile and intended modifications to make the gears perform to their highest levels with low noise and long-term durability and reliability. The integrated systems of Gleason s latest innovation, the 300GMS P Analytical Gear Inspection System, are designed to compensate in real-time for the temperature, vibrations and contamination found on a typical production floor that issue is that people can use this without years of training. Capture 3D s ATOS Professional software is designed to solve simpleto-complex metrology tasks accurately and rapidly with comprehensive reporting. would usually compromise the performance of metrology work. His successor in leading the CMS said ease of use includes making software more customizable and easier to program for repeat measurements. Management thinks that anybody can measure, therefore if you actually know how to do it, you usually have to write some sort of script for a guided measurement process, so almost anybody on the assembly floor can use it. In other words, you have to know what you re doing. Manufacturing Engineering scanned the industry for updates in metrology software, and talked to companies about innovations in measuring gears; glass and other transparent materials; aerospace blisks; and a multipurpose offering used by Tesla Motors. The subsystems are all controlled by a complex suite of software that, in typical production conditions, corrects for the subtle yet ever-changing dynamics of putting such a system in an uncontrolled environment, said Traynor. By having the capability to establish control over the machine and part coordinate systems, and the effects of temperature, humidity, vibration and low egress of contaminates allow the GMS P series machines to coexist in the production environment. The 300GMS P is designed to be turnkey for users in aerospace, automotive and smaller power transmission industries, such as industrial gearboxes, aerospace actuators, gear jobbers for loose gearing, and Tier 1-3 automotive suppliers, Traynor said. This latest addition to the GMS Series (with models available 150 Years of Gears Gleason, in business for 150 years in 2015, introduced a gear metrology system innovation that s been shop hardened with new compensation software that enables it to operate in for gears up to 10' [3.1 m] in diameter) includes features like surface finish measurement and prismatic feature measurement. It also includes the powerful Gleason GAMA 3.0 applications software suite that, like GAMA 2.0, offers users a 50 AdvancedManufacturing.org August 2015

3 Image courtesy Capture 3D Capture 3D s GOM Inspect version is a free download from the company s web site. highly intuitive user interface and simple input screens for programming of workpiece and cutting tool data. GAMA 3.0 also includes tutorial information on the gear features with wording, pictures and videos that are user editable. Those features, combined with ease of setup, a state-ofthe-art remote input/output controls system and improved movement optimization, significantly reduce the cycle times required for the complete inspection of almost any gear or gear tool. The advanced operator interface puts a number of powerful tools at the user s disposal, including an environmental monitoring station to record temperature and humidity as well as video telephony; note pad and voice mail messaging capability; Gleason Connect, for enhanced remote diagnostic support; creation of standard work instructions; online training tools; multilingual communication; and more. Measuring Transparency At Heidenhain (Schaumburg, IL), a free update for those who already have its IK5000 Quadra-Check PC-based soft- METROLOGY SOLUTIONS NEW TAKE CONTROL OVER QUALITY. SOLUTIONS FOR DIMENSIONAL INSPECTION ON SHOP FLOORS. DIMENSIONAL INSPECTION SOFTWARE AdvancedManufacturing.org August 2015

4 ware makes it possible to use a Keyence LK-G5000 laser for measuring glass and other transparent materials, said Stuart Graham, product specialist for metrology. With the metrology market moving towards multisensor machines of all types, adding support for the Keyence laser was an easy decision, said Graham. Now the software can be used with both Optimet and Keyence LK-G5000 lasers. Lasers have had exponential growth in metrology over the last decade, and it s expected to continue to rise, especially in multisensor machines, Graham said. We also improved the speed of our 3D profile part fits by up to 5 and added the ability to export measured features into the STEP file [2D/3D] format, he said. This provides our customers with essential speed and flexibility for use on modern measuring machines. Graham also pointed out a basic feature of the IK5000 Quadra-Check software that should appeal outside of the quality control area to both a company s numbers crunchers and human resources departments. We are literally measuring anything that can be measured on our cars here at Tesla thanks to Capture 3D s metrology solutions. It s extremely versatile, and can be used with CMMs, optical comparators, video measuring machines, microscopes, and any combination of machines, increasing its value. It makes the company s workforce more versatile at the same time. One of the best things about the IK5000 is if you train one operator, he can use it with different machines and applications with just a little bit of retraining, Graham said. If your CMM operator is out, but you have cross-trained on applications using the IK5000, your very expensive CMM can be run by your comparator operator, rather than being down until your CMM operator is back. Improve machine utilization. Even in the dark. Rotary Loading System RLS Your Entry into High-Efficiency Production Economical A basis for the cost-effective machining is optimizing the feeding of parts in and out the machining center Flexibility With its modular design, the Liebherr RLS Rotary Loading System offers a high degree of flexibility User-friendly The proven Soflex PCS cell controller is user-friendly and offers integrated order planning Quality and Reliability Quality is the top priority for Liebherr. When producing our products, every stage is monitored ensuring world-class products with the highest reliability and service life See us at Gear Expo 2015 Booth 1809 Liebherr Automation Systems Co Woodland Drive Saline, Michigan Phone.: info.lgt@liebherr.com The Group August 2015 AdvancedManufacturing.org _004_LVT_007_RLS_USA_GB_außerhalbMP-2.indd :1

5 Photo courtesy Capture 3D The IK5000 can operate on 32-bit or 64-bit PCs with Microsoft 7 or 8 operating systems. Even though 3.1 just came out in November, Graham said in May that version 3.2 may be ready for release by the time you read this article. It includes ease-of-use features, such as adding more reporting features for traceability needs as well as user profile management. Faster to Market ATOS Professional and GOM Inspect Professional software from Capture 3D (Costa Mesa, CA), updates of which the company released in January, are designed to solve simple-to-complex metrology tasks accurately and rapidly with comprehensive reporting. This allows users to identify and determine optimal corrective action, if necessary, eliminating unnecessary redundant processes and minimizing iterations to help reduce manufacturing costs, waste, and cycle times to speed up time to market, said Catherine Kim, marketing manager. ATOS Professional software is used in conjunction with Capture s ATOS noncontact blue light 3D scanners. The ATOS Core 3D scanner uses structured blue light technology for accurate and fast noncontact measurement of complex, shiny and/or colored surfaces. GOM Inspect Professional is a stand-alone that can be used with various measuring systems, e.g., CMMs, laser scanners, CT scanners, structured light scanners, etc. The software provides a number of metrology functions and has been tested and certified by The National Metrology Institute of Germany and the US National Institute of Standards and Metrology, placing it within the class of smallest deviations. Capture 3D s software is used worldwide in such industries as aerospace, power generation, medical, casting, sheetmetal, injection molding and automotive. We are literally measuring anything that can be measured on our cars here at Tesla thanks to Capture 3D s metrology solutions, said M.J. Tribble, product excellence blue light specialist at luxury carmaker Tesla Motors (San Carlos, CA). The ATOS 3D scanning technology has given us the luxury, with its mobility, of using one piece of equipment to perform accurate and detailed inspection analysis and reverse engineering on closures, assembly sets, interiors, and more. We also use TRITOP Photogrammetry [another Capture 3D product] to perform vibrations tests, certifications, and 180 deformation analysis. A cloud of tip center data points is generated over the entire airfoil and root surfaces. The software is traceable for process safety and includes: polygonization of 3D point clouds, mesh processing, parametric inspection, CAD comparison, 2D inspection, part-to-part inspection, golden mesh (average mesh), CAD/ measurement plan importation, standard and custom alignments, local coordinate systems, GD&T, trend analysis/spc, airfoil inspection, sheetmetal inspection, material thickness calculation, silhouette inspection, cluster evaluation, colormap reporting, CMM-type reporting, and more. Additional modules can be added for optical tracking, back projection of features onto the physical part, deformation analysis, photogrammetry, and automation. The automation module, Virtual Measuring Room, offers automatic ATOS 3D scanner robotic sensor positioning for offline and online inspection programming, with an optional kiosk interface for touchscreen operation. Engineers design ATOS Professional and GOM Inspect Professional for real-world applications, and new features are frequently added. Capture 3D notifies users of any updates, and each release is documented with notes about particular enhancements. This software allows companies to use the same interface throughout multiple departments and between suppliers and their customers for uniformity that promotes collaboration, and faster process throughput and optimization. The free GOM Inspect version, which has been downloaded 45,000 times, according to the company s web site, is available for immediate download at gom-inspect. 54 AdvancedManufacturing.org August 2015

6 Image courtesy Renishaw Up in the Clouds Renishaw introduced a line of metrology software that s specifically designed for aerospace blades. It s used with the company s five-axis measurement system. The software suite includes APEXBlade planning software for sweep scanning and DMIS programming; MODUS airfoil analysis for calculating and reporting of blade section profile and airfoil characteristics; and SurfitBlade to aid in reverse engineering the complete airfoil. Renishaw has a line of metrology software that s specifically designed for aerospace blades that s used with the company s five-axis measurement system. Shown here is the application SurfitBlade. I ve seen planes made in the '70 s still running, and many didn t have CAD files to rework or the company didn t have data stored from when the blade was built, said Chad Willis, CMM technology manager for Renishaw (Hoffman Estates, IL) So, reverse engineering can be done to make sure each blade is the same and can be fixed or reproduced. The other advantage is that you can use the reverse engineered CAD model for finite analysis. Engineers can use the actual blade surfaces and analyze engine performance based on the real manufactured part as opposed to nominal models. Historically, blades were measured in sections because measurement techniques were so slow. But the new line of Renishaw hardware and software allows for the entire blade to be inspected quickly and accurately, allowing unlimited section (to compare with the CAD file or to comply with government regulations) or full-surface analysis based on high-precision contact probe data. Unlike lasers or optics that only have a line of sight to measure the blade, our REVO system can get inside the part or between the blades to get accurate data, explained Willis. Also, unlike laser and optic systems, a REVO is not concerned about the reflectivity of the material or sharpness of the leading and trailing edges. APEXBlade quickly generates collision-free programs that drive the REVO measurement system to carry-out complex sweep scans that collect point cloud data from across the complete surface of the blade. The CAD model is imported into the virtual REVO CMM environment prior to the measurement plan being automatically generated. Once the operator is happy with the program, he generates a DMIS file to execute within the MODUS metrology software. A key advantage of the new Renishaw approach to blade measurement is that a cloud of tip center data points is generated over the entire airfoil and root surfaces, said Willis. The MODUS point cloud sectioning function then allows on surface sections to be constructed by intersecting any defined plane with the captured point cloud. This can be carried out at the time of measurement, or in the future if further sections at different locations are required, without the need for re-measurement of the blade. MODUS then allows the operator to take the nominal airfoil sections available from the CAD model and the actual sections from the point cloud sectioning to report blade section profile and airfoil characteristics. Furthermore, the software has comprehensive graphics for reporting profile measurement results. The graphics can be integrated with all other feature measurement reports, which are formatted as a.pdf file. For designers and developers doing reverse engineering, SurfitBlade is an offline application used to generate NURBS blade surface forms for use in downstream processes. These might include computational fluid dynamics and finite element analysis, said Willis. It also allows the average blade geometry to be computed from a series of blade results.?capture 3D / Coordinate Metrology Society / Gleason / Heidenhain / Hexagon Metrology (855-4-HEXMET) / Planet Tool & Engineering / Renishaw / 56 AdvancedManufacturing.org August 2015

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