prerequisites for successful quality control in the fourth ... · ∙gd&t analysis standards ∙iso...

Prerequisites for Successful Quality Control in the Fourth Industrial Revolution (Industry 4.0)

Quality Assurance in Injection Molding Process Chains

Prerequisites for Successful Quality Control in Industry 4.0 |

Material parameters

CAD / PMI Simulation Tool making & electrode manufacture

Injection-molded parts

Series inspection

Assembly & load test

PresenterPresentation NotesWell, we have heard a lot about using sensors and software for dynamic measurements and 3D shape and dimension analyses within injection molding process chains...

Prerequisites for Successful Quality Control in Industry 4.0 | 3

Quality Assurance in Injection Molding Process Chains

Automated quality control in medical engineering ∙ Automation & support in product development ∙ Standardized QA methods with all suppliers ∙ Central control

Implementation of GPS standardization for plastic components ∙ Geometrical tolerancing and datum systems, DIN EN ISO 5459 ∙ Component alignment and local coordinate systems ∙ Clear results and easily understandable visualization Drawing-free process – 3D Master ∙ Quality features and specifications on the 3D model ∙ “Frontloading” for digital processes ∙ Industry 4.0

PresenterPresentation NotesMr. Lundo showed how full-field metrology enables the implementation of standardized quality assurance procedures and a central control of suppliers in medical engineering. Mr. Panick referred to the challenge in implementing DIN EN ISO 5459. Geometrical tolerancing, datum systems, part alignment and local coordinate systems have to be implemented with expertise in order to ensure clear results and analyses. Mrs. Eisenhardt’s presentation concentrated on anchoring quality characteristics and additional PMI specifications on the CAD data set, which may indicate the first step towards Industry 4.0.

Measurement Planning in the Production Process


Quality control

Material properties



Series inspection

Assembly & load tests

PresenterPresentation NotesWith this scheme, the quality assurance of “off-tool parts” is shifted from a later part of the process chain (ISTR, measuring room director) ...


Quality control

Material properties



Series inspection


Measurement Planning in the Production Process

PresenterPresentation Notes... to an earlier stage, namely into the field of engineering. It is certainly a clever decision to think of the function, measurement and quality assurance already during the CAD development and ideally in cooperation with the engineer

The Evolution of Mechanical Engineering: Changing the Master to a 3D Model


Drawing

CAD + drawing CAD + PMI (drawing-free: 3D Master)

CAD+ drawing (reduced dimensioning)

analog

analog / digital

digital / analog digital

PresenterPresentation NotesAnother trend that we observe among our users is the simplification of 2D drawings coming along with the introduction of full-field measuring techniques. Only functional dimensions are defined via GD&TAll other features are checked via the CAD data set or profile tolerances. Thus, hundreds of single measures can be omitted. The latest (and not yet very common) trend was described by Mrs. Eisenhardt: the anchoring of inspection features and specifications directly digitally on the 3D CAD data set. This is the final step of leaving the analog world behind and entering a completely digital world.

Digitization of inspection features in the CAD software Inspection features/nominal elements semantic “construction” on CAD ∙ Datums ∙ Datum systems ∙ GD&T tolerances ∙ Dimensions ∙ Text annotations ∙ Views

Import of digital inspection features in the GOM software ∙ Import as/of nominal data ∙ Allocation of a measuring principle ∙ Automatic evaluation of actual data


3D Master – Evaluation with 3D Measuring Data

PresenterPresentation NotesThis means that inspection features or nominal elements such as datum systems, GD&T, dimensions etc. are constructed or implemented with the help of a semantic “construction”. At GOM, we are already able to import these features directly into the GOM software and to allocate a measuring principle for an effectively automatic evaluation of actual data (as you will see in the live software presentation held by my colleague Amos Makgoba). Thus, you can save valuable time for the ISTR – the most critical phase (including the tool release and production start-up)

Transformation formats for inspection features ∙ MBD Model-Based Definition (Creo / PTC) ∙ FTA Functional Tolerancing & Annotation (Catia / Dassault Systèmes) ∙ PMI Product Manufacturing Information (NX / Siemens)

Inspection features ∙ Geometrical dimensioning and tolerancing (GD&T) ∙ Dimensions


Measurement Planning on CAD – CAD Software

PresenterPresentation NotesTypical expressions and software packages for which we have developed an interface are: MBD Model-Based Definition (Creo / PTC)FTA Functional Tolerancing & Annotation (Catia / Dassault Systèmes)PMI Product Manufacturing Information (NX / Siemens)

Product manufacturing information (PMI) Gathering and transmitting: Production information / non-geometrical attributes for construction, planning, production and inspection included in 3D CAD data Corresponding information Construction data Manufacturing information ∙ Surface structure ∙ Material properties ∙ 3D notes (text)

Inspection features ∙ Geometrical dimensioning and tolerancing (GD&T) ∙ Dimensions


Tools for Industry 4.0 – PMI Software

© Siemens

PresenterPresentation NotesOne has to keep in mind that these inspection features only constitute a small part of the product manufacturing information besides the construction data and the production information.

Product lifecycle management (PLM) Integration of data, processes, business systems and persons from the entire business environment Management of information arising from brainstorming, engineering and production Associated functions and technologies ∙ Product data management (PDM) ∙ Computer-aided design (CAD) ∙ Computer-aided manufacturing (CAM) ∙ 3D computer-aided engineering (CAE) and simulation ∙ Mechatronic system simulation (behavioral simulation) (1D CAE) ∙ Finite element analysis (FEM/FEA) ∙ Modal analysis ∙ Digital manufacturing ∙ Manufacturing operations management (MOM)


Tools for Industry 4.0 – PLM Software

PresenterPresentation NotesAnd these, however, need to be integrated in superordinate information management systems which allow the integration and administration of data, processes, business systems and persons involved in brainstorming, construction, production and marketing. An essential condition for this kind of data management is, of course, that all information is gathered and transmitted digitally and always kept up to date.

PMI: Product and Manufacturing Information + PLM: Product Lifecycle Management + CPS: Cyber-Physical System = Industry 4.0

Industry 4.0

11 Prerequisites for Successful Quality Control in Industry 4.0 |

PresenterPresentation NotesOnce there will be the possibility of a reasonable and comprehensive transfer of product and manufacturing information, and companies will have a digital product lifecycle management system, cyber-physical systems will ultimately initiate the transition into Industry 4.0


Industry 4.0 – Internet of Things Machines Communicate with Data Systems

© DFKI

PresenterPresentation NotesFollowing discoveries and developments such as steam power, electricity and automated production, that would be the fourth industrial revolution.

“In the future, a manufacturing order could be automatically controlled in line with the value chain. Drawings would be exchanged between manufacturing plants in order to organize the order sequence as well as maintenance requirements.”*

13

Industry 4.0

*Fraunhofer IAO study on Industry 4.0

Prerequisites for Successful Quality Control in Industry 4.0 |

Mutual management / control

Material properties

CAD / PMI Simulation Series inspection Tool making & electrode manufacture



Quality control

PresenterPresentation NotesThus, Industry 4.0 could have the effect that, instead of humans reading and interpreting measuring results for an appropriate troubleshooting, production plants as well as service and maintenance will be organized in a self-regulating process based on the measuring results.

Consistent “language” in inspection & quality assurance for shape and dimension analysis Clear information Functional demands on products Efficient production and verification Less possibilities of interpreting inspection features differently Time saving

Standardized Inspection Language


B A GG

B A GG

PresenterPresentation NotesBut, there is still a long way to go, at the moment, we are struggling to find a consistent “language” for inspection and quality assurance in the field of shape and dimension analysis, so that inspection features are less likely to be interpreted differently and people are able to clearly communicate beyond departments and country borders.

Standardized inspection language GD&T (Geometrical Dimensioning and Tolerancing) GPS (Geometrical Product Specification) ♦ GPS / GD&T ♦ ISO / ASME Standards

Alphabetization & communication for ∙ Engineers/designers ∙ Production engineers ∙ Measurement engineers ∙ ...


GD&T & GPS

PresenterPresentation NotesWe think that GD&T and GPS are good options, but Mrs. Eisenhardt from Continental reported on the problems concerning the alphabetization of engineers and other departments, which is not an unknown problem (as during GOM Conference in 2015, SRAM reported on similar challenges). … that’s why we have recently begun to offer GD&T training modules

Full-field digitization of the actual state ∙ Parts ∙ Tools

Adaptive machining ∙ Measuring data is used as a basis for CNC machining Standardized inspection language software & training ∙ GD&T analysis standards ∙ ISO 1101 ∙ ASME Y14.5 (high relevance of ASME)

Digital interface for inspection features from CAD ∙ Direct import and evaluation (FTA, MBD, PMI)


Industry 4.0 – GOM 3D Metrology

PresenterPresentation NotesAt GOM, we observe all these trends and take them into account for our developments: Only with the full-field digitization of the actual state of parts and tools, for example, could Industry 4.0 be initiated. Some companies use our measuring data as a basis for CNC machining – keyword: adaptive machining – which also can be seen as a type of Industry 4.0. Furthermore, we contribute to improving the prerequisites for a standardized inspection language by offering a software module and training courses. And, we implement the trend regarding the digital transmission of inspection features on the CAD (which was initiated by companies such as Continental, SRAM and Braun) by providing 3D measuring data.

Digitization of parts and tools Digital interface for inspection features from CAD Standardized inspection language (GOM software module & training) Digitization of inspection features Storing of inspections features in the CAD Standardized inspection language (implementation in companies) Alphabetization (e.g. GD&T & GPS) Communication between engineer, production, measurement engineer ... PLM Cyber-physical systems ... Prerequisites for Successful Quality Control in Industry 4.0 |

Industry 4.0 – Trend & Reality?

17

PresenterPresentation NotesOf course, it is rather in your hands than in ours, if this trend will be made a reality.What are your requirements for companies developing CAD software concerning the digitization and storage of inspection features?What kind of “inspection language” is set in your departments?How do you alphabetize engineers, production and measurement engineers?Which opportunities do you have regarding information management systems?When will cyber-physical systems exist?

ATOS ScanBox Series 8

RGC Engineering & GOM Cooperation

RGC Engineering is the GOM distributor for South Africa. RGC Engineering is responsible for the following aspects: • Installation of the GOM Equipment and Software. • Training on the use of the GOM Equipment and Software by the company client’s employees. • All related support pertaining to GOM. • We also offer service work for companies that can not yet afford to buy their own systems and

support them until such a stage that they see the benefit of having their own system on hand.

Benefits of Service Work • First Tooling Inspection Reports • Critical measurements or full inspection reports for supplier qualification. • Problem solving instead of only measurement. • Full process control: prototype, 1st off, production, tool, mold, fixture and final inspection. • Support for SMME’s. • Reverse engineering for startups.

ATOS ScanBox Series 7 and 8 | GOM

GOM Optical Measuring Machine


ATOS ScanBox Optical 3D measuring machine for automated dimensional inspection Suitable for different applications and part sizes

GOM Solutions for Automated Metrology


Optical 3D Measuring Machine Automated system for single or repetitive measuring tasks ∙ Full-field data collection ∙ Analysis ∙ Reporting Accurate and traceable measuring results High measuring speed and throughput Flexible solution in regard to measuring objects

Industrial, robust metrology system for production environment

Auto Teaching for minimized programming effort Simplified Kiosk Interface for shop floor workers Eliminating the influence of human error through automation Reliable information for statistical process control

ATOS ScanBox


Optical 3D Measuring Machine Single source solution Short delivery times Quick installation and start-up Worldwide availability Worldwide transfer of programs to other ATOS ScanBoxes Local support through a worldwide network Upgrade options ∙ Add rotation table module(s) to your Series 8

ATOS ScanBox


New GOM Concept for Large Parts Measure complete car bodies ∙ From above ∙ From below ∙ From the side ∙ From inside

New 8-Axis Kinematic

Comparison: Reach of small robot and large robot


New GOM Concept for Large Parts Measurement of complete car bodies ∙ From above ∙ From below ∙ From the side ∙ From inside

Small robot on vertical lift to increase reach



New 8-Axis Kinematic for exterior measuring



New 8-Axis Kinematic for interior measuring



Duplex mode possible ∙ Simultaneous, coordinated operation of two robots in one measuring cell ∙ Creation of one common data set ∙ Operation in one common coordinate system Independent measurements of two robots on two different parts also possible

Double Robot Setup


Parts Casted blank, finished tool Typical Applications Full-field digitizing of casted blanks ∙ Material allowance control ∙ Reduction of CNC machining times

Quality control of milled tools ∙ Spring back compensation ∙ Pro-active wear control / tool life extension ∙ Archiving of working dies Tool repair ∙ Fast root cause analysis ∙ Rapid copy milling of broken dies ∙ Localization and marking of welding/repair areas (back projection)

Automotive Tool Shop


Parts Assemblies (hood, door, trunk lid, body-in-white) Typical Applications Analysis in Meisterbock & Cubing ∙ Complete analysis measurement (flush & gap, hemmed edges, deviation visualization, inspection sections, …) ∙ Virtual assembly ∙ Analysis of character/design-lines Production quality control ∙ Capturing of all inspection features and functional dimensions ∙ Trend analysis and statistical process control (SPC) ∙ Export of measurement results and reports to internal server and databases

Automotive Body Shop

Flush & Gap

Complete analysis measurement


New ATOS ScanBox

Thank you for your attention. [email protected] www.gom.com

GOM – Precise Industrial 3D Metrology


PresenterPresentation NotesI, for my part, wonder if we will witness this fourth industrial revolution or not...... with that thought in mind, I would like to start the lunch break.

Prerequisites for Successful Quality Control in the Fourth Industrial Revolution (Industry 4.0)�Quality Assurance in�Injection Molding Process ChainsQuality Assurance in�Injection Molding Process ChainsMeasurement Planning�in the Production ProcessMeasurement Planning�in the Production ProcessThe Evolution of Mechanical Engineering: Changing the Master to a 3D Model3D Master – Evaluation with 3D Measuring DataMeasurement Planning on CAD – CAD SoftwareTools for Industry 4.0 – PMI SoftwareTools for Industry 4.0 – PLM SoftwareIndustry 4.0Industry 4.0 – Internet of Things�Machines Communicate with Data SystemsIndustry 4.0Standardized Inspection LanguageGD&T & GPSIndustry 4.0 – GOM 3D MetrologyIndustry 4.0 – Trend & Reality?�ATOS ScanBox Series 8RGC Engineering & GOM Cooperation GOM Optical Measuring MachineGOM Solutions for Automated MetrologyATOS ScanBoxATOS ScanBoxNew 8-Axis KinematicNew 8-Axis KinematicNew 8-Axis KinematicNew 8-Axis KinematicDouble Robot SetupAutomotive Tool ShopAutomotive Body ShopNew ATOS ScanBoxSlide Number 32

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