Robotic 3D Optical Inspection of Large Castings
Based in Krefeld, Germany, Siempelkamp Giesserei is the largest hand-molding foundry in the world. It produces large and heavy castings with a weight of up to 320 tons for the fields of energy conversion, raw material processing as well as press construction and mechanical engineering. The company has a longstanding history and experience in foundry technology and attaches great importance to safe work processes, environmental protection and high product quality.
Siempelkamp is an important global supplier for the industry. To ensure a smooth production process for top-quality castings, the company relies on measuring technology from ZEISS. The ZEISS ATOS LRX 3D scanner enables Siempelkamp to carry out an effective quality assurance while increasing energy efficiency and using valuable resources sustainably by minimizing scrap.
Metrology is part of a comprehensive digitalization strategy. Full-field measurement data enable the company to digitally track the part geometry of all products throughout the entire process – from the model to the casting mold to the final cast part.
No Limits: Innovative Processes For Measuring Parts of All Sizes
ZEISS ATOS LRX is specialized in 3D scans of large-volume parts. The sensor provides full-field data with a highly detailed resolution in next to no time. Thanks to its ultra-bright laser light source and the large measuring area, significantly fewer scans are required. In a single scan, ATOS LRX captures 12 million individual measuring points. With a dustproof and splashproof housing, this solid system is designed for rough production conditions and thus perfectly suited for industrial use.
Thanks to the specifically developed project measuring cell, Siempelkamp Giesserei can now also use ZEISS ATOS LRX as an automated solution. Based on the captured measuring data, the software automatically visualizes surface deviations between the 3D actual coordinates and the CAD data. These results help to quickly identify, analyze and resolve quality issues. Due to the full-field measuring data, the company has a continuous digital quality control.
“To achieve precise manufacturing of such large components, it is essential to ensure the accuracy of the details, which, of course, cannot be achieved without the use of high-precision metrology” commented Dr. Georg Geier Managing Director at Siempelkamp Giesserei GmbH & Siempelkamp Metallurgie GmbH.
Effective Inspection Software
ZEISS ATOS LRX is equipped with the powerful ZEISS INSPECT Optical 3D software. From full-field data acquisition to mesh processing to trend analysis and digital assembly, the software supports every process step. Scanning, inspection, and reporting in one single software.
Back projection is a feature that is frequently used for the processing of cast parts to directly project grain points from the software on the part. Thus, large cast parts can be marked quicker and more precisely. Providing a continuous workflow and user-centered operation, the software is intuitive and user-friendly. Smart features allow for a quick and automated programming of the measuring cell, minimizing the required effort.
Next Generation Laser Light Source
ZEISS ATOS LRX is equipped with an advanced, ultra-bright laser light source allowing for 3D scans even in challenging ambient light conditions. By capturing large measuring areas, the system is the first choice for fast scanning of large surfaces, even if they are dark or shiny, and delivers precise, high-resolution data. The sensor is designed for industrial applications with its robust housing protected against dust and splash water. To work reliably and precisely even in harsh production environments, the system self monitors its calibration status.
For more information: www.zeiss.com/metrology
