METROTOM.Results you can trust.

I n d u s t r i a l M e t r o l o g y f r o m C a r l Z e i s s

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METROTOM.Results you can trust.

Process precision from Carl Zeiss• Highly accurate manufacture of components• Assembly and acceptance testing process:

same as for ZEISS coordinate measuring machines• Precision adjustment• CAA corrected calibration

Radiation safety• Full-protection enclosure • Meets radiation protection ordinance in accordance with

DIN 54113 for full-protection devices (0.5 mr/h on external skin) of this type

Precision mover from Carl Zeiss• In-house manufactured, precision-relevant machine components• Compensation of guideway errors (CAA corrected)

Rotary table on air bearings• Rotary table with direct drive• In-house air bearings• Resolution: 0.044"• Max. load (centric): 500 N• Axial tolerance fa = 0.1 μm• Radial tolerance fa = 0.2 μm

Optimum measuring range• d 300 x h 350 mm

Suitable materials• Dependent on the principle of cumulative material thickness

and composition• Plastics up to 250 mm thick• Light metal alloys up to 120 mm thick (Al, Mg)• Model construction materials up to 200 mm thick

(plaster, wood, bakelite, resin and sand cores)• Ceramics and compound materials

(depending on the density, porosity and composition)• Steel (Metrotomography up to 10 mm,

defect checks up to 15/18 mm)

Key features

Machine technology

Measuring range

Overview

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Micro-focus x-ray tube• High voltage: 10 – 225 keV• Tube power: 5 – 1000 μA• Target performance: 320 W max.• Angle of reflected beam: 50° conical• Angle of useful beam: 30° conical• Size of focal point: > 7 μm

Flatbed detector• Extremely sensitive detector system• 1024 x 1024 pixels at 400 μm2 for 3D-CT• Distortion-free, digital radioscopy

Easy-to-use, precise software• New technology, familiar evaluation environment:

CALYPSO for everyone• All evaluation options: testing and metrology

evaluation with CALYPSO, reverse engineering and geometry comparison

• Unique: automatic recognition of cavities in the evaluation program

• Remote evaluation• Already generated protocols can be reused with CALYPSO

Optimum accuracy• Unparalleled precise results for internal and external

geometries, determined on METROTOM Check• Sufficient accuracies with most aluminum, plastic and

elastomer applications• Exact accuracy verification only after a GR&R

(Gage Repeatability & Reproducibility) measurement on the respective part

METROTOM Edge Scanning• Threshold is continually scanned instead of being

specified once for the entire measurement (as with ISO 50 or ISO 50 with contact measurement)

• Highly accurate edge detection thanks to continuous adjustment of the threshold

• Unparalleled accuracy of the measurements

A step ahead in imaging

Software

Measuring uncertainty and measuring system analysis

A step ahead in measuring technology

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A new world of metrology.

Metrotomography, the fusion of metrology and tomography, offers new possibilities in industrial

metrology. It is now possible to perform highly precise and non-destructive measurements in

areas where only external or destructive inspections or no quality assurance took place in the past

– the interior of highly complex parts.

Principle of 2D x-ray technology

The metrotomography procedure is based on the

principle of x-ray technology. An x-ray source pen -

etrates the respective object with electromagnetic

radiation. This is collected on a detector surface and

recorded in varying degrees of intensity depending

on the geometry and absorption characteristics of

the irradiated object. The result is a two-dimensional

gray-scale image.

Principle of 3D computed tomography

The 2D image generated using x-ray technology

is only meaningful for visual inspection when shown

as a cross section. In the metrotomography pro-

cedure, the component is rotated 360° around its

own axis, resulting in a 3D image of the entire

volume of the workpiece.

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Assembly

checks

Component:Lighter, plastic

Task:Check the correct assembly of all single components

Result:Volume model shows correct assembly

Defect analysis

Component:Chip, plastic with metal parts

Task:Inspection for defects

Result:3D view of the volume model shows no sources of error

Damage analysis

Component:Miniature coil, plastic with wire

Task:Determine cause of failure

Result:Volume model shows wire separation on soldering point

Comparison:Coil size 5 mm

The information provided by quality checks depends on the precision of the image: the more

detailed the display, the more precise the evaluation. Thanks to the highly accurate display

of even complex internal geometries, the metrotomography procedure opens up the entire range

of evaluation possibilities to testing technology.

Inspection of

materials

Component:Ski boot, plastic with metal parts

Task:Inspection of material errors

Result:Volume model and display of material show no possible breakage points

Porosity analysis

Component:Cylinder, cast

Task:Inspection for cavities or inclusions

Result:Susceptibility to breaking as a result of cavities in the casting

Inspection with one look.

Metrotomography –

overview of the advantages

• Inspection analysis of complex parts

• Non-destructive inspection of previously unreachable

internal geometries

• Reduction of product development cycles

through fast and highly accurate analyses

• Efficient prototyping

• Automatic recognition of cavities

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Is “actual” what it really should be?

A plan/actual comparison is the ideal tool to effectively and precisely control the creation of

a product. Development, design, tool-making and production use the same data and can analyze

it very quickly. This makes it possible to detect potential sources of error early on and directly

implement appropriate corrective measures. Processes that took weeks in the past, are completed

by METROTOM in one hour.

How it works:

1. Import the CAD data

2. Import the point cloud

3. Rough alignment

of the data sets

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4. Define and align base system

5. Plan/actual comparison

6. Plan/actual comparison in cross section

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Speed: Initial sample test report in one hour.

Creating an initial sample test report usually requires several hours. With CALYPSO, you can generate

the measurement plan offline and start it immediately after completion of the metrotomography

procedure. Duration of the entire process: just a few minutes. Efficient planning puts the initial sample

test report in your hands in one hour.

1. Import the features and orientation from the drawing or the CAD data set and specify a measurement strategy

2. Generate orientation on a CAD model

3. Create a CNC measurement plan from the CAD model

4. Generate the CNC run from a previously loaded point cloud and create records

Metrotomography –

overview of the advantages

• Initial sample test report in only

a few minutes

• Fast, highly accurate results

• Metrology inspection of workpieces that

could not be measured in the past

• Familiar evaluation environment

• Reuse of existing CALYPSO records

How it works:

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Test reports are required in all phases of product development, tool-making and regularly in quality

assurance for volume production. Creating these documents is often very time-consuming with

traditional measuring technologies. METROTOM saves up to 80% off of the time that was needed

in the past – without sacrificing precision. Another benefit: you can display the report in exactly

the form you need it.

Fast and informative: test reports with METROTOM.

Metrotomography –

overview of the advantages

• Test reports for everything in 20% of

the time previously required with standard

procedures

• Fast, precise and solution-oriented

implementation

• Customer-specific outputs:

standard output protocol, VDA initial sample

test report, excel report, sectional view,

plan/actual comparison

This includes:

Standard output protocol Excel report

VDA initial sample test report

Plan/actual comparison

Sectional view

Roundness protocol

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How much time is saved with METROTOM

at Gaudlitz?

• Total development times

for plastic parts:

reduced by about 20%

• Highly precise samples:

within one day

• Part and tool development

times:

reduced by about 20%

• Complete capture of a part:

approx. 40 minutes

• Plan/actual comparison:

approx. 20 minutes

From experts for experts: recommended by experienced experts.

METROTOM has been successfully used for several years. Well-known customers, from corporations

to mid-sized enterprises, utilize the benefits of METROTOM for a wide variety of applications.

See for yourself why metrotomography from Carl Zeiss is the perfect measuring solution for you.

How long has METROTOM been in operation?

Gaudlitz GmbH, a supplier of plastic parts, has relied

on metrotomography from Carl Zeiss since 2006.

Why did Gaudlitz choose METROTOM?

As a highly innovative company, Gaudlitz continu-

ously develops new plastic products. The company

invested in this new technology to increase the

precision and efficiency of its development and pro -

duction processes. With METROTOM, Gaudlitz

achieves extremely short measuring times and an

unparalleled amount of information.

More efficiency with METROTOM – Gaudlitz GmbH

Experts rely on METROTOM

Automotive/electronics –

Robert Bosch GmbH

Mobile communications –

Motorola

Automation –

Festo AG

Plastics technology –

Gaudlitz GmbH

Consumer goods –

Braun GmbH

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Measuring system analysis with METROTOM – at Robert Bosch GmbH

How long has METROTOM been in operation?

Robert Bosch GmbH has been using metro-

tomography from Carl Zeiss since 2004.

How was the measuring system analysis

of METROTOM performed?

• Inspection of dispersion and position

of the measured values on the calibration

standard and on the volume part

• Comparison measurement with PRISMO

and other coordinate measuring machines

Why did Bosch choose METROTOM?

Robert Bosch GmbH uses METROTOM for the

efficient, cost-optimized and precise development

of innovative products. As an industrial supplier,

Bosch relies on ZEISS technology to optimize the

product creation process and product quality.

Metrotomography –

the most precise solution

• METROTOM from Carl Zeiss guarantees

maximum accuracy

• Quality from ZEISS: assembly and acceptance

testing process the same as with ZEISS coordinate

measuring machines, precision adjustment,

CAA corrected calibration, precision mover from ZEISS

• Dynamic threshold procedure:

continuous scanning of the threshold, resulting in

high-precision edge detection

• Image calibration procedure

• Acceptance testing procedure: METROTOM check

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Carl Zeiss

Industrielle Messtechnik GmbH

73446 Oberkochen/Germany

Sales: +49 (0) 1803/ 336-336

Service: +49 (0) 1803/ 336-337

Fax: +49 (0) 7364/ 20-3870

E-mail: imt@zeiss.de

Internet: www.zeiss.com/imt