For many machined parts, having the specified surface finish is key in
meeting the demand of either a particular application or customer. Whether
the desired surface is due to cosmetic, resistance or critical use reasons,
certain parts demand an exact and reliable surface measurement.
One method of taking an industrial surface measurement is through a physical,
invasive practice usually using a stylus. However, for parts that use
material easily damaged by any physical touch, this choice is not an
option.
EDM Intelligent Solutions’ (EDMIS) customers
needed an improved non-contact vision inspection system that would have
greater functionality and increased ease of use. To meet this need, EDMIS
developed a 5-axis automated 3D metrology center, the MVi5, which uses
non-contact sensors to capture measurements and determine surface finish in
the specified Ra, or the measurement of the surface’s average absolute
deviation from its mean height. Additional surface finish metrics like Rq,
Rt, Rz, Rmax and Sa parameters are also available.
When a workpiece is loaded into the MVi5, the system captures 3D point data
of the part and generates automated form, roughness and dimensional
measurements. The part’s datums are also captured and used to produce
measurements in the part coordinate system which allows for 3D and 2D true
position measurements of the part. Advanced 3D metrology sensors featuring
measurement speeds of up to ≤ 1.7 million points per second and
high-resolutions of 10nm allow the MVi5 to measure form, distance, height,
surface roughness, true position, scan vs. CAD model differences and scan
vs. scan differences all in one rugged multi-sensor platform that is ready
to be installed directly on the manufacturing production floor.
Using the EDMISi measurement programming environment, customized 3D
model-based measurement and inspection programs are automatically generated
off the 3D solid model design of the part to be inspected, simplifying
traditionally complex programming of measurement and inspection tasks.
Offline measurement and inspection programming is also offered through
integration with various CAD/CAM software packages common within
industry.
Metrology equipment typically uses PC-based controls to inspect and measure
manufactured parts. However, because industrial applications, such as in
aerospace, defense and medical device manufacturing, increasingly demand
very precise assessments that are critical to their end use, EDM Intelligent
Solutions decided that their robust 3D metrology machine needed a more
reliable control. The company decided to use FANUC CNC controls due to their well-known
industry leading 50 year plus MTBF.
“While CNCs may require a more complex machine design, FANUC controls
offer less downtime, more efficient production and greater support for
processes down the line.,” says Walter Zic, COO of EDM Intelligent
Solutions. “We made the choice to use FANUC controls because we know
that they will effectively deliver reliable and precise motion control that
will always be supported by FANUC.”
EDMIS was familiar with FANUC because the company had already incorporated
6-axis FANUC robot arms for its robotic measurement
system, the RSH-M10. Their end users were already comfortable with using the
FANUC robot interface and FANUC’s Power Motion i-MODEL A controls have a
very similar look and feel.
“We wanted the metrology center to be very easy to operate,” says
Zic. Indeed, operation of the MVi5 5-Axis 3D Metrology Center is quick and
simple via the touch screen optimized EDMISi human machine interface with
native barcode compatibility.
In addition, FANUC’s Power Motion i-MODEL A has a broad range of
customizable solutions, including integrated LCD screens and sophisticated
handheld displays that are ideal for even novice operators. Zic was also
concerned about his customers having to regularly update a PC-based type of
control, which is not a problem with CNCs.
Another feature that sets the MVi5 apart from other metrology systems is its
ability to be located directly on the production floor. Most metrology and
surface measurement equipment need to be placed in a separate temperature
controller clean area away from production machinery. The MVi5, on the other
hand, is not as temperature sensitive as other metrology systems. The
industrial machine tool base houses a top of the line motion system with
linear travels of 300mm on the X, Y and Z axes along with integrated glass
scales on each. The heavy-duty rotation and tilt unit features a payload of
20kg with a B-Axis tilt range of +/-120° and continuous C-Axis rotation
of 360°, with both axes having integrated absolute encoders.
FANUC provided technical assistance to ensure the controls selected would
deliver the performance needed for precise and repeatable measurements. Now,
the new MVi5 is shipping to customers, such as those in the aerospace industry. Customers are using the 3D
metrology center to measure parts used in new generation aircraft that
reduce their fuel consumption by 15 percent or more. To accomplish this,
these parts must have precisely shaped features, edges and surface finished
to help boost the efficiency of the propulsion systems and control
components onboard the aircraft.
“Industrial form and surface measurements require precision,
reliability and repeatability,” says Zic. “It’s critical
to operations. We knew FANUC would offer the reliable motion control crucial
for measuring parts used in industries like aerospace, defense and medical device manufacturing.”
Click to visit their website for more information about EDM Intelligent Solutions.
Click for more information about FANUC America’s Motion Controls offerings.