manufacturing metrology 2020 - fast, accurate, safe and

Trends in Manufacturing Metrology Fast, Accurate, Safe and Flexible

Jochen Weinisch

Carl Zeiss Industrial Metrology GmbH

Regional Sales Manager China/Taiwan

24/10/2014 2 Carl Zeiss IMT GmbH, Jochen Weinisch

“System of Interchangeable Parts” in Industrial Production

Unit System

for a unique definition of

product

characteristics

Machines

for production

according to the

definition

Metrology

for determination and

check of characteristics

100 years ago: 2/3 of produced parts had to be manually adjusted to fit to each other

Today: Separated production of parts, but all fit to each other during assembly

WHY?? …Because of global standards:

3

Industrial Products

What do these

products have in

common?

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www.presseanzeiger.de

24/10/2014 Carl Zeiss IMT GmbH, Jochen Weinisch

4

They stand for global boosters

Globalization

Resource efficiency

Mobility

Energy

Electro-mobility

Connection of fare apart places

Global communication

and networking

Change in the energy market

Health and fitness


5

Megatrends like are the key driver of production trends

Globalization

Resource efficiency

Mobility

Global megatrends

Increasing

Individualism

Insecure trouble spots

Demographic change

Climate change

Boundary conditions

Energy

Efe

cts

Resource efficiency

(energy, raw materials, capital)

Flexibility (compensate market

fluctuation, individualization)

Transparency

(predictability, directed quality

control)

New Processes

(control of new processes)

Trends in production


6

Productions Trends and their Influence on Challenges and Trends in Manufacturing Metrology

Resource efficiency Flexibility Transparency New Processes

Trends of production

Fast increasing

integration

reducing measuring

time

automatic data

processing

Accurate reducing measuring errors / uncertainty

Challenges and Trends in Manufacturing Metrology

Safe verification of measuring uncertainty

Flexible increasing variety of

measuring techniques increasing information density


Fast

Lightning-fast systems

make lightning-fast mistakes.

Stanislaw Lem

7 24/10/2014 Carl Zeiss IMT GmbH, Jochen Weinisch

8

Inetegration of metrology in production lines allows fast results

Function

Direct installation of CMM in production

Integration into the automatic material and information flow

Performance

Fast adjustment to part variants by changing CNC programs without mechanical changes

Comparable results to measuring room within temperature range: 18-40°C


9

Fast trough intelligent Software in metrology

Fly-scan with Performance pack

16 Scanning elements

Complex programming

Measurement time: 75 sec

1 Scanning element

Simple and quick programming

Saving: 69% of time / 52 seconds

Conventional


Accurate

Anyone who doesn't take truth seriously in small

matters cannot be trusted in large ones either.

Albert Einstein


11

Examples for the large Range of Metrology

Horizontalarm-

CMM

Multisensor-

CMM

Coordinate Measuring Machines

0,001

0,01

0,1

1

10

100

0,0000001 0,000001 0,00001 0,0001 0,001 0,01 0,1 1

„Length“

[m]

„Accuracy“

[mm]

atomic

diameter 1 m

human hair

90 m 1 m

0,00001

0,0001 Transmissions-

Electron

Microscope

Profilometer Confocal

Microscope

Surface Measuring

Electron Microscopy

Bridge-CMM


Transmissions-

Electron

Microscope

Electron Microscopy

Confocal

Microscope

Surface Measuring

12

Examples for the large Range of Metrology

0,001

0,01

0,1

1

10

100

0,0000001 0,000001 0,00001 0,0001 0,001 0,01 0,1 1

„Length“

[m]

„Accuracy“

[mm]

atomic

diameter 1 m

human hair

90 m 1 m

0,00001

0,0001

Profilometer


Horizontalarm-

CMM

Multisensor-

CMM

Bridge-CMM


Horizontalarm-

CMM

Multisensor-

CMM

Bridge-CMM


Horizontalarm-

CMM

Multisensor-

CMM

Bridge-CMM


Safe

There is no safety in numbers,

or in anything else.

James Thurber


14

Safe: Conformity Evaluation, Tolerance and Measuring Uncertainty

OT/UT = upper/lower tolerance, U = measuring uncertainty

The tolerance is

reduced by the

measurement

uncertainty.

The tolerance is not reduced if the

uncertainty does not exceed 10 .. 20%

of the tolerance. OK

Not OK Not OK

U U U U

Tolerance

(Specification)

"Golden Rule" "Decision Rule" (ISO 14253)

(Small) exceeding of tolerance by the

measurement uncertainty is allowed.

Exceeding of the tolerance by the

measurement uncertainty is not allowed.

T

U U

OT UT

UT-U

U U

OT+U T

U U

OT UT

UT-U

U U

OT+U


15

Safe: The Cost of Measuring Uncertainty 安全：测量不确定度的成本

quality level

cost

total cost

error cost

quality cost

T

U U

OT UT

UT-U U U

OT+U

Golden Rule, Measuremente System Analysis

T

U U

OT UT

UT-U U U

OT+U

Decision Rules

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Measuring MachineMachine geometry

SensorsMeasuring standard

Accuracy (MPE)

Measuring range

Measuring software

Error correction (CAA)

Qualification normalIlluminationTelecentricitySensor limitsHysteresis, dynamics

...

Inspection TaskApplication orientation

Tolerance orientation

Process and cycle time orientationTask-oriented reports

Volume orientation...

OperatorEducation/trainingUse of toolsClamping check

Alignment checkStylus qualificationMeasurement planning

Avoiding of collisions

Stylus assemblyShaft probing

Machine monitoringCare and cleanliness

Motivation...

Measuring StrategyInspection planning

Sensor

Measuring methodFilter setting

Outlier eliminationAnalysis strategyClamping/fixturing strategyAlignment strategyIllumination strategyZoomNumber of measuring points

Distribution of measuring points

Probing force

Scanning speed

Usage of rotary table

...

EnvironmentTemperatureTemperature gradientTemperature driftThermal radiationContamination, dust

VibrationsHumidityAir draftLight reflections

...

WorkpieceForm error

DimensionWeight

MaterialLinear expansion

SurfaceBrightness/reflectionPart temperaturePart contaminationElasticity/plasticity

Drawing/CAD...

measuring

resu

lts

Safe results are hard work Influences on the measuring results


Flexible

Stay committed to your decisions,

but stay flexible in your approach.

Tom Robbins


18

The Application determines the equipment


19

Carl Zeiss Industrial Metrology We offer a wide and flexible portfolio of products

Bridge-type CMMs Production CMMs

Horizontal Arm CMMs Computer Tomography Form and Surface Inspection Systems

Multisensor CMMs Gantry CMMs


20

Summary: Trends in Manufacturing Metrology 2020

Fast

Accurate

Safe

Flexible


2011 21 Carl Zeiss im Fokus

manufacturing metrology 2020 - fast, accurate, safe and

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