Transforming Quality Control with Fast In-Line Production Measurement
In fast-paced manufacturing, precision and efficiency are paramount. Quality control is often viewed as a non-value-added operation. Manufacturing engineers, production, and plant managers often have a fractious relationship with the Quality Control department, which often slows down production, bottlenecks information, and struggles to provide relevant feedback to drive process feedback in manufacturing. ZeroTouch Metrology® changes this paradigm.
ZeroTouch enables shop floor inspection, in-line or nearline focused on providing immediate and relevant dimensional inspection and analysis. The shop floor gauges can sit directly in the manufacturing area and are often integrated in line with the manufacturing process. Pass fail is established in cycle with non-conforming parameters specifically reported out to MES systems, PLC, a printout, or viewable onscreen. Linear dimensions, diameters, GD&T callouts, etc on the blueprint can be measured. Defects such as dents, porosity, and non-cleanup can be caught in cycle eliminating the need for secondary visual inspection by an hourly operator. Additionally, this data provides real-time process trends establishing when processes are trending out of control before scrap or rework is made. The machine drives real-time feedback on the quality of components without the need for hands-on measurement or operator intervention.
Data can be presented the same as other metrology tools with a visual representation of error as well as color mapping of the part to show variation in material position and magnification of features such as flatness and runout.
Non-Contact Measurement Laser Technology
ZeroTouch uses cutting-edge non-contact measurement laser technology, relying on advanced sensors to capture a high-precision point cloud digital twin, from data individual feature measurements are extracted. A combination of lasers is deployed in order to fully characterize the part, all synchronized together in one highly accurate coordinate system enabling the capture of a digital twin each cycle.
A laser configuration allows to fully cover features intended to be inspected. Lasers have the appropriate stand off to maximize data coverage with a deep stand off and captures as many 4,000 points across each individual laser stripe trigging at 200Hz. The resultant is a full digital twin of millions of points.
Fast cycle times, as low as 12 seconds for measuring an automative brake rotor with capture and analysis the part in cycle with a definitive pass fail recorded at end of cycle.
CAD models with model-based definition (MBD) can be used as well as features measured in accordance with the parts blueprint. The inspection program has the same evaluation criteria as an offline CMM program without the need to manually walk the part over to the CMM Inspection Lab.
Sub 10% Repeatability and Reproducibility
Typical features measured with sub 10% Repeatability and Reproducibility (GR&R) performance include Distances, Diameters, Flatness, Parallelism, Runout and Thicknesses.
ZeroTouch Key benefits include:
Speed: Obtain results instantly,without the delays of traditional measurement methods.
Accuracy: Achieve micrometer-level precision ensuring top-notch product quality.
Simplicity: No need for complex setup or extensive training – it’s a user-friendly solution
Efficiency: Save time and reduce errors in the quality control production process.
ZeroTouch Metrology is a game-changer for industries including aerospace, automotive, medical devices where high-precision measurements are critical. Part family with common features made in high volume processes are excellent candidates to consider the implementation of ZeroTouch.
For more information: www.zerotouchmetrology.com
