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TABLE OF
CONTENTS QUALITY MAGAZINE
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MAY 2011
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VOLUME 50
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NUMBER 5
DEPARTMENTS 6
FROM THE EDITOR
Become an Innovator 8
INDUSTRY NEWS
Source: Faro Technologies
New Technologies and Features Pose Challenges for Automakers SME Unveils Annual Innovations List Consumer Reports: Some Used Cars Have Fewer Problems Than New Models
26 FEATURES 50 YEARS OF QUALITY
24 OPTICAL COMPARATORS GO DIGITAL The future is here. Advancements in comparator technology enable higher accuracy and productivity.
16 FACE OF QUALITY
Quality Professionals Must Understand Management 18 OTHER DIMENSIONS
Calibration Mistakes: Plain Plug Gages 20 QUALITY 101
QUALITY MEASUREMENT
26 THE METROLOGY TRAINING DILEMMA To make effective use of a high-precision metrology system, one needs to understand how it works, how to squeeze the best performance out of it, how to choose the optimal one for the application and what to do if something goes wrong.
Force Measurement Explained 22 QUALITY INNOVATIONS
Versatile Gaging 48 CASE STUDY
Testing Out Quality
QUALITY TEST & INSPECTION
32 CUSTOM NONCONTACT SOLUTIONS MEET UNIQUE INSPECTION CHALLENGES Everything is to gain by finding out how to perform a critical inspection better, faster and at the lowest cost.
65 QUALITY PRODUCTS 71 CLASSIFIEDS 72 ADVERTISING INDEX
QUALITY MANAGEMENT
36 THE FUTURE OF ISO STANDARDS
NEXT MONTH
Five common quality ISO standards are examined. Multisensor Measurement
44 SHARPENING THE AXE Bombardier embarks on deploying advanced quality and logistics planning.
Optical Inspection Data Collection Six Sigma
MAY 2011, VOLUME 50/NUMBER 5 WWW.QUALITYMAG.COM
ABOUT THE COVER Proven preventive quality tools such as failure mode effects analysis (FMEAs), process control plans and mitigation approach plans, which have been used extensively in many industries—including automotive, pharmaceutical and medical—have yet to be embraced by the aerospace industry. That is about to change. Source: Bombardier VISIT WWW.QUALITYMAG.COM TO SIGN UP FOR THE QUALITY WEBINAR SERIES 000_a-QM0511cover.indd 1
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Starrett Ride Height Gage in use by Porsche Motorsport.
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Basics of X-Ray Tomography for Precision Measurement Recent developments in computer tomography now provide high-precision measurements, even on internal features, using X-ray technology. Success with Training Modules Off-the-shelf training software helps a plastics company address the training need of a dispersed workforce and adhere to safety and compliance training in manufacturing. Training modules customize the program to suit the needs of the plastics company and allow for the software to grow with the company as it progresses. Off-Topic Quality: 3-D Imaging Software Helps Researchers Understand 19th Century Painting Techniques The characterization of the porosity of ground layers in easel paintings through 3-D imaging software was a first step toward understanding nature’s role in material transport in 19th and early 20th century paintings.
How Can Optical Measurement Improve Industrial QC? May 12, 2:00 p.m. ET Reducing Warranty Costs Through Quantification of Machined Lead Angle and Surface Characteristics of Rotary Seals May 17, 2:00 p.m. ET Eddy Current Testing: Its Many Benefits and Applications June 14, 2:00 p.m. ET
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IMTS Revisited • Carl Zeiss • Marposs • Micro-Vu • Nikon Metrology • S-T Industries
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FROM THE EDITOR
BECOME AN INNOVATOR
WHERE THERE'S STRUGGLE OR DISCOMFORT, THERE'S ROOM FOR INNOVATION.
I GILLIAN CAMPBELL
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just returned from an enlightening and informative three days at the 2011 Quality Conference, held in collaboration with University of North Carolina—Charlotte and the Charlotte Research Innovation Center. The conference kicked off with a tour of Joe Gibbs Racing. We had the opportunity to check out the facility and learned that it costs more than $80,000 to build an engine and approximately three-and-a half weeks to put together a car to compete at the NASCAR level. After two workshops, several keynote addresses and myriad presentations, Praveen Gupta, president of Accelper Consulting (Schaumburg, IL) closed out the conference with, “Beyond Quality—A Roadmap for Innovation.” Gupta addressed the audience by saying that we live in an age of mass customization so we all need to be innovative. Of course he’s right. We have fast food chains that tout that you can have it your way. Coffee is available in any size or flavor imaginable. No longer is it necessary to buy an entire CD for $15 in hopes that you like more than the first single released. Now we can download a single song for around $1 and then further customize our music choices into categories: workout, shake your groove thing and in an effort to please my jedis-in-training, Star Wars music. Don’t accept anything less than perfect. “Innovation without excellence is a waste,” Gupta stressed, “and excellence without innovation is dumb.” Gupta further explained that innovation is the new face of quality—it is a new characteristic of quality. No longer is innovation something addressed only
within the fours walls of large companies. It starts with the individual. Contrary to many of our own hang-ups, Gupta said that everyone can become a great innovator, but it is a conscious decision that we need to make on an individual basis. Where does one begin? “Where there’s a struggle or discomfort, there’s room for innovation.” Gupta said. “Develop something that you customers would love to have.” Innovation can be as simple as combining two things. The cell phone industry exploded by merely combining the telephone and portability. On another level, here at Quality we have a Webinar series that combines the need for education, accessibility of computers, and the comforts of your home or office to deliver need-to-know information. Perhaps, most importantly, innovation should be fun. It’s fun to think without boundaries. Remember when you were a kid and your imagination took you to places long-forgotten by adults? It’s time to revisit that part of your life to get the innovation ball rolling. Are you ready to accept Gupta’s challenge to become an innovator? Where will you start? Share your thoughts with me at
[email protected], or with other members of the Quality community at the Quality Magazine LinkedIn Group page, the Quality Facebook page and on Twitter at http://twitter.com/QualityMagazine. * * * * * A special thanks to all of our sponsors and speakers who participated in the 2011 Quality Conference. Gillian Campbell is editor of Quality Magazine. Gillian can be reached at
[email protected].
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COMING EVENTS JUNE 6-9 HEXAGON 2011, Orlando, FL Hexagon, (800) 730-4647 www.hexagonconference.com 7-9 MD&M EAST, New York, New York UBM Canon, (310) 445-4200 www.canontradeshows.com
BUSINESS NEWS | COMING EVENTS | PEOPLE NEWS | MERGERS
JULY 25-29 CMSC PHOENIX, Phoenix Coordinate Metrology Society, (888) 320-7011, www.cmsc.org SEPTEMBER 13-15 MATERIALS TESTING 2011 Telford, United Kingdom British Institute of Non-Destructive Testing www.materialstesting.org 20-22 QUALITY EXPO, Chicago UBM Canon, (310) 445-4200 www.canontradeshows.com/expo/qexpo11 OCTOBER 16-20 MATERIALS SCIENCE & TECHNOLOGY 2011 Columbus, OH, ACerS, (614) 794-5894 www.matscitech.org 24-28 ASNT FALL CONFERENCE AND QUALITY TESTING SHOW, Palm Springs, CA The American Society for Nondestructive Testing, (800) 222-2768 www.asnt.org/events/calevents/ calevents.htm
PEOPLE CHRIST MAKRIS has joined Baumer Ltd. (Southington, CT) as a product marketing manager. In his new position, Makris will develop internal and external marketing and training strategies to support and promote Baumer’s inductive, capacitive, magnetic photoelectric, laser and mycom sensor lines. Makris brings 20 years of marketing and engineering experience—with a strong focus in the industrial automation and controls market—to the role. MASAHIRO OGAWA has been named CEO of Yaskawa America Inc. (Waukegan IL). Ogawa has worked at Yaskawa for 24 years. He was most recently the vice president of research and development for the Yaskawa robotics division in Japan. He led the company’s development of the world’s first dual-arm robot as a high-volume product. Photonic Products Group Inc. (Northvale, NJ) has appointed AMY ESKILSON to the role of vice president of sales and marketing. Eskilson, who was with Thorlabs Inc. prior to joining PPGI, served as director of business development for the photonic components catalog.
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QUALITY | May 2011
J.D. POWER AND ASSOCIATES: NEW TECHNOLOGIES AND FEATURES POSE CHALLENGES FOR AUTOMAKERS WESTLAKE VILLAGE, CA—Overall vehicle dependability has improved from 2010, with automakers succeeding in reducing problem rates in many traditional areas, but experiencing some challenges in overcoming problems with newer technologies and features, according to the J.D. Power and Associates’ 2011 U.S. Vehicle Dependability study. The study, which measures problems experienced during the past 12 months by original owners of three-year-old vehicles, includes 202 different problem symptoms across all areas of the vehicle. Overall dependability is determined by the level of problems experienced per 100 vehicles (PP100), with a lower score reflecting higher quality. The study is used extensively by vehicle manufacturers worldwide to help design and build better vehicles, which typically translates to higher resale values and higher customer loyalty. It also helps consumers make more-informed choices for both new-and-used-vehicle purchases. Among new-vehicle shoppers, perception of quality and dependability is the most influential factor in their decision to purchase a specific vehicle model, according to J.D. Power and Associates. In 2011, overall vehicle dependability averages 151 PP100—the lowest problem rate since the inception of the study in 1990—and improves from 170 PP100 in 2009. Between 2009 and 2011, annual improvement for the industry has averaged 6%, which is slightly lower than historical rates of improvement. During the past decade, industry improvement has averaged 8% each year.
The slowdown in improvement is largely attributable to increased rates of problems with electronic features in vehicles, including audio, entertainment and navigation systems and new safety features, such as tire pressure monitoring systems. “Automakers, as a whole, have made significant improvements in reducing traditional problems, particularly with vehicle interiors; engines and transmissions; and steering and braking during the past several years,” says David Sargent, vice president of global vehicle research at J.D. Power and Associates. “However, as manufacturers add new features and technologies to satisfy customer demand and new legislation, they face the potential for introducing new problems.” According to Sargent, as newer technologies become more widespread, enhancing the dependability of these features has become an important point of differentiation among automakers. HIGHEST-RANKED NAMEPLATES AND MODELS For the first time since the inception of the study, Lincoln leads the overall nameplate rankings in 2011. Lincoln improves by 13 PP100 from 2010. Lexus follows Lincoln in the nameplate rankings. Rounding out the top five nameplates are Jaguar, Porsche and Toyota. The Porsche 911 has the fewest problems in the industry, with just 68 PP100. Toyota Motor Corp. continues to perform well in long-term dependability and garners seven segment awards—more than any other automaker in 2011—for the Lexus RX, Scion xB, Toyota 4Runner, Toyota Prius, Toyota Sienna, Toyota Tacoma and Toyota Tundra.
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Ford Motor Co. receives four model awards for the Ford Fusion, Ford Mustang, Lincoln MKZ and Lincoln Navigator. General Motors (Buick Lucerne, Cadillac DTS and Chevrolet Tahoe) and Honda Motor Company (Acura RL, Honda CR-V and Honda Fit) each received three awards. In addition, the following models also received awards: BMW X3, Mazda MX-5 Miata and Mercedes-Benz CLK. The study finds that while domestic brands have closed the gap in initial quality with import brands, there is still a considerable difference between the two in vehicle dependability, with import brands outperforming domestic brands by 18 PP100 in 2011. This is consistent with findings of the 2008 Initial Quality Study, which examined the models included in the 2011 VDS after 90 days of ownership. While domestic brand cars have fewer problems (135 PP100, on average) than import brand cars (147 PP100, on average), trucks and crossover vehicles of import brands have considerably fewer problems than those of domestic brands. In addition to affecting brand image and brand loyalty, long-term dependability also has a notable effect on dealership service and customer service spending. As the number of problems experienced increases, owners are increasingly likely to use non-dealer service facilities for paid service work. In addition, as the number of problems increases, the percentage of owners who say they “definitely will” return to their dealer for service diminishes. Among owners who indicate they have experienced no problems, 76% indicate they “definitely will” return to the dealer for paid service. This proportion decreases to 42% among owners who say they experienced six or more problems. The 2011 Vehicle Dependability Study is based on responses from more than 43,700 original owners of 2008 model-year vehicles after three years of ownership. The study was fielded between October and December 2010.
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SME UNVEILS ANNUAL INNOVATIONS LIST 301 Armstrong Blvd., St. James, MN 56081 Phone: 1-800-326-2039 Fax: 507-375-4503 Internet: www.stindustries.com E-mail:
[email protected] DEARBORN, MI—Honoring both innovation and manufacturing, the Society of Manufacturing Engineers (SME) announced the 2011 List of Innovations That Could Change the Way You Manufacture.
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TEKTRONIX SERVICE SOLUTIONS (Beaverton, OR), a provider of instrument calibration, repair and related services, is opening an instrument services lab in Santa Clara, CA. The new facility provides enhanced service options and added flexibility for central California companies that rely on test, measurement and control instrumentation for day-to-day operations. HEXAGON METROLOGY INC. (North Kingstown, RI) announced a new strategic distribution partnership with FORD TOOL & GAGE CORP. (Milwaukee, WI). The company will serve as an authorized distributor of Hexagon Metrology’s Sheffield Measurement and Optiv product lines in Wisconsin and upper Michigan. The new partnership leverages the strong suits of both companies to address the technology needs of manufacturers producing complex, precision parts. At TOYOTA MOTOR CORP.’S (Aichi, Japan) 2011 Global Supplier Convention in Nagoya, Japan, automotive safety system company AUTOLIV INC. (Stockholm, Sweden) was honored for its contributions during 2010. Autoliv was selected as a winner of the global Toyota Excellence Award for outstanding performance in value improvement. Autoliv supplies Toyota in all regions with airbags, seatbelts and steering wheels. In addition, Autoliv’s tech centers in Japan, North America, Europe and China support Toyota with design engineering expertise in automotive safety and with crash testing capabilities. CALIBRATION DYNAMICS LTD. (Andover, UK) has recently opened a fully traceable calibration laboratory at its headquarters in Andover, Hampshire in the United Kingdom. The new laboratory is equipped with WIKA primary standards accurate to 0.008% of reading. A fully automated calibration system has also been installed, significantly reducing instrument turnaround and customer downtime.
KISTLER (Farmington Hills, MI), a worldwide supplier of precision sensors, systems and instrumentation for engine, chassis and vehicle development, as well as vehicle component manufacturing systems, announced that construction is underway for a new North American technical center in Novi, MI, to complement the existing sales support and manufacturing activities of its Amherst, New York-based corporate headquarters. Precision component manufacturer MILWAUKEE MACHINE WORKS (Milwaukee, WI) has purchased a Leitz PMM-G ultra-accurate coordinate measuring machine from Hexagon Metrology (North Kingstown, RI). The Leitz measuring machine has a measuring capacity of three meters wide by four meters long, and two and a half meters high. The PMM-G is a gantry configuration machine that allows large scale parts up to 30,000 pounds to be moved inside for precision measurement. PALMER WAHL INSTRUMENTATION GROUP (Asheville, NC) is celebrating 175 years of manufacturing industrial instrumentation in 2011. Originally founded in Cincinnati, in 1836 by James Foster Jr., Palmer Wahl says it developed the first thermometer made in America—the Foster Cup—in 1852. Currently, the company’s customers include the National Space Program, Proctor & Gamble, Anheuser Busch and the U.S. Army, Navy and Air Force. CREAFORM (Levis, Quebec) has announced results for the 2010 fiscal year. The company has had its best year since inception, with annual sales of $27.3 million, which makes for a growth of 25% through 2009. 2010 Q4 sales of $9.6 million have set a new record in the history of the company, representing a 49% increase from Q4 of 2009.
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This annual list showcases new and emerging technologies that are making a difference in manufacturing. This is not the usual list of emerging technologies. These are innovations that can be used today or within a few months and have already shown some successful implementation. “Not only has innovation enabled us to make better things at lower costs,” says Boris Fritz of Northrop Grumman Aerospace Systems and vice chair of SME’s Innovation Watch Committee, “but innovation also leads to the development of things we couldn’t even dream of just a decade ago.” Among this year’s innovations are: • Graphene, which is said to be not only the strongest known material ever developed at a oneatom-thick sheet of carbon, also is lightweight and electrically conductive. Fifty times stronger than steel, graphene is being used for extremely sensitive sensors, electronic switches, aircraft braking systems and touch screens. Companies using graphene include IBM and Bell Helicopter, and is available from companies such as Angstron Materials.
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• Programmable magnets open the door to self assembling. The ability to manipulate magnetic fields lends itself to many applications from precision switches to snowboard bindings to spinal implants. Using heat to erase a magnetic field, the material can be reprogrammed to have multiple north and south poles of differing strengths. They are available from Correlated Magnetics. • The committee also recognized the Build to Demand (BTD) process as something that can change the way things are manufactured. BTD, an alternative to the Toyota Production System, which works well for suppliers that experience variable demand and are seeking to increase customer service rates while reducing inventories and production costs. Limited or no capital investment is required to implement BTD. John Deere Horicon Works developed BTD in the early 2000s with assistance from the University of Wisconsin-Madison. • Microstructured molding tools will impact manufacturers of products that could benefit from enhanced surface capabilities. Created as square or custom inserts for injection or compression molds, the innovation adds several capabilities to any molded product: superhydrophobic, reduced friction, reduced fluid drag, increased heat transfer and more. This approach reduces microstructure manufacturing cost by 83% to 98%. Developed by Hoowaki, microstructured tooling has been available since the spring of 2010. • Programming light with quantum dots is an innovation that promises not only to change the way things are
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NEWS Grady Cope, President of Reata Engineering & Machine Works, (Englewood, CO), was appointed to the role of 2011 Chairman of the NATIONAL TOOLING AND MACHINING ASSOCIATION (NTMA) on March 5, during The Manufacturing for Growth (MFG) Meeting in Chandler, AZ. Grady is currently a member of the University of Colorado–Denver Engineering Advisory Board, and has served on the University’s Alumni Board. At the last NADCAP (Warrendale, PA) meeting in Barcelona in February, several individuals were recognized for their commitment to aerospace special process and product quality through their involvement in Nadcap. Nadcap is a worldwide continuous improvement cooperative of major companies within the aerospace industry. Four outgoing members of the Nadcap Management Council (NMC) who were not in attendance were recognized for their service on the NMC: • Mark Crevier • John McBrien • Peter Feind • Michel Pierantoni • Doug Matson of the Boeing Co., Michael Brandt of Alcoa Inc. and John Ewing, a PRI auditor/instructor, received recognition awards for their contributions related to Pyrometry issues. • Scott Patterson of Goodrich received a recognition award for his service as Nonconventional Machining and Surface Enhancement Task Group Chair. • Philippe Pons of Airbus received a recognition award for his service as Electronics Task Group Chair. • Dale Harmon of Cincinnati Thermal Spray received a recognition award for attending 35 consecutive meetings. Harmon has not missed a meeting in 10 years. • Kevin Ward of Goodrich received a Leadership Award for his service as NMC Standardization Sub-Team chairperson.
ASSOCIATION NEWS • John Haddock of BAE Systems received a Leadership Award for his service as NMC Oversight Sub-Team chairperson. • Mark Rechtsteiner of GE Aviation received the NMC Chairperson’s Award for his leadership and vision as NMC chairperson. • Lisa Ippolito of PRI received a recognition award for dedication and hard work and playing an instrumental part in the Nadcap Meetings over the last nine years. THE ASSOCIATION FOR MANUFACTURING TECHNOLOGY (AMT, McLean, VA) has elected its 2011-2012 officers and directors at its 2011 annual meeting in Chandler, AZ. The board of directors of the association, which represents more than 400 American manufacturers of machine tools, manufacturing machinery and related products, elected Eugene R. Haffely Jr., general manager, Dayton Facility at ATW Automation (Dayton, OH), to chairman. Haffely follows Daniel D. Janka, president, MAG Global, Hebron, KY. Janka will now serve the association as an ex-officio member of its board of directors, along with Ronald F. Schildge, president, Eitel Presses Inc. (Orwigsburg, PA). The board elected Timothy B. Dining, president and CEO, Greenerd Press & Machine Co. (Nashua, NH), to serve as first vice chairman in the coming year. Also elected was R. Stephen Flynn, president, Optical Gaging Products Inc. (Rochester, NY), to serve as second vice chairman and treasurer. Kim W. Beck, president and CEO, Automatic Feed Co. (Napoleon, OH), will continue to serve as secretary. Newly elected to a three-year term as a member of the association’s board of directors are Larry G. Schwartz, president and COO, Okuma America Corp. (Charlotte, NC) and Richard L. Simons, president and CEO, Hardinge Inc. (Elmira, NY). Both R. Stephen Flynn, president, Optical Gaging Products (Rochester, NY), and Michael Powell, president, Master WorkHolding Inc. (Morganton, NC), will be returning for a three-year term.
manufactured, but also change the way we light our homes and offices. Quantum dots are nanoparticles of a semiconductor material that range from 2 to 10 nanometers in diameter. The ability to control the size of a quantum dot enables a manufacturer to determine the color of light emitted. Quantum dots are currently providing brighter images, lower power consumption and improved color purity for electroluminescent displays. Companies manufacturing quantum dot-enabled products include QD Vision and Weinberg Medical Physics. • Controlled through a Web-based application, a remote-presence robot allows a telecommuting worker to remotely attend meetings, drop into the offices of colleagues and otherwise collaborate with people in another office. With cameras in the eyes to capture video, speakers and microphones to relay sound and a laser pointer “finger,” the user sees what the robot sees and directs it around by using a computer’s arrow keys. Companies such as Procter & Gamble are using these remotepresence robots to increase the
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efficiencies of teams working across the world. • Ten times stickier than Velcro and reusable gecko-inspired glues, Super Velcro is an extremely strong adhesive that comes apart when heated. Using shape-memory polymers, General Motors researchers created a product that allows a strong but alterable bond that replaces liquid adhesives requiring lengthy oven curing, which consumes a lot of energy, or foam tapes that do not provide high adhesion strength. Super Velcro is being used for interior and exterior automotive trims with potential applications for furniture, toys and buildings. In reviewing submissions for the Innovations That Could Change the Way You Manufacture, the committee also highlights an Innovation Watch List. These technologies are showing great promise but, as yet, are unproven in the manufacturing setting. “Because most people use common, everyday products that are frequently
outsourced, they think that manufacturing in America is dead,” says Fritz. “Innovations like those identified today should be a reminder that American manufacturing has moved beyond the production of commodities and is one of the most technologically advanced sectors of our economy.” The Innovations That Could Change the Way You Manufacture will be a focus of the Manufacturing Velocity: SME Annual Conference scheduled for June 5-7, 2011, near Seattle. The conference brings together manufacturing professionals and leaders who are interested in innovations and exchanging ideas in one place.
CONSUMER REPORTS: SOME USED CARS HAVE FEWER PROBLEMS THAN NEW MODELS YONKERS, NY—With the average new car losing 47% of its value in the first three years of ownership, buying a used car can be the best way for consumers to get the most vehicle for their money, according to Consumer Reports’ annual auto issue.
Consumer Reports found eleven 2008 models with about the same or even fewer problems than similar 2010 models in the same class. Among the most trouble-free 2008 models were the Toyota FJ Cruiser and Yaris with 11 and 12 problems per 100 vehicles, respectively. The average 2010 car had 13 problems per 100. While the FJ Cruiser and Yaris did not score well in Consumer Reports road tests, some of the other most reliable 2008 models, such as the Honda CR-V and Fit did, making them better overall choices. Overall, Japanese cars are the most trouble-free, with Honda and Toyota far ahead compared with older vehicles made by other major manufacturers, particularly 2006 and earlier models. Some models have an alarming problem rate even when they are still fairly new. More than one in four owners of the 2009 four-cylinder Toyota Tacoma pickup reported a problem with the radio in the 12 months covered by the survey. For now, it is being replaced free under Toyota’s basic war-
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May 2011 | QUALITY 13PM 1/13/09 2:05:07
IND IN DUSTRY
NEWS American Machine Tool Distributors’ Association (AMTDA) and The Association for Manufacturing Technology (AMT). This total, as reported by companies participating in the USMTC program, was down 16.3% from December but up 188.3% when compared with the total of $128.82 million reported for January 2010. These numbers and all data in this report are based on the totals of actual data reported by companies participating in the USMTC program. “Despite the slight decline in orders from December, the January USMTC report confirms that U.S. manufacturers are reinvesting vigorously to improve productivity,” says Peter Borden, AMTDA president. “As equipment deliveries grow longer and commodity prices increase, factories may continue to make these investments before inflation and other factors raise prices further.” The United States Manufacturing Technology Consumption (USMTC) report, jointly compiled by the two trade associations representing the
ranty, which expires after three years or 36,000 miles. The survey also found that fiveyear-old models can be good bets for used-car buyers, although problem rates, on average, are worse than rates of three- or four-year-old cars. While three-quarters of the three-year-old vehicles in Consumer Reports’ survey were problem free, so were two-thirds of the five-year-olds. The most problem-free five-year-old model was the 2006 Toyota Highlander V6, which had 19 problems per 100 vehicles. Consumer Reports’ survey also found that cars older than five years are not so trouble-free. Only half of the nineand 10-year-old vehicles had gone 12 months without a reported problem.
JANUARY MANUFACTURING TECHNOLOGY CONSUMPTION 188% HIGHER THAN JAN. 2010 MCLEAN, VA and ROCKVILLE, MD—January U.S. manufacturing technology consumption totaled $371.41 million, according to the
production and distribution of manufacturing technology, provides regional and national U.S. consumption data of domestic and imported machine tools and related equipment. Analysis of manufacturing technology consumption provides a reliable leading economic indicator as manufacturing industries invest in capital metalworking equipment to increase capacity and improve productivity.
CORRECTION In the March 2011 issue of Quality, the phone number for Jeff Bibee of Werth Inc., author of X-Ray Tomography: The Basics, was missing a digit. The correct number is (860) 399-2445. Quality regrets the error.
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FACE OF QUALITY
QUALITY PROFESSIONALS MUST
UNDERSTAND MANAGEMENT MAYBE THE REAL PROBLEM LIES WITHIN THE QUALITY PROFESSION.
A JIM L. SMITH
recent discussion in my quality management class reminded me of the 2010 ASQ World Conference on Quality and Improvement in which I was a session speaker. The issues most people wanted to discuss were their relationships with management, or more accurately, their lack of relationships. Many wanted advice about how to deal with long-standing conflicts between managers and employees. In fact, many were surprised when I informed them that the real problem likely rests with us, the quality professional, not with management. Since I retired as a senior leader in a Fortune 50 company and consider myself a quality professional, it gave me a unique perspective. It isn’t that managers don’t care about quality; the vast majority really does care. Many managers just don’t understand quality and don’t know how to use it as an advantage, rather than view it as a problem. Their primary job is to create a reliable organization, and quality lies at the core of that task. Unfortunately, many quality professionals haven’t done an adequate job communicating the importance of quality to an organization’s management. The following may be some reasons why ineffective quality professionals are having problems: 1. Quality professionals don’t understand the language of management. Managers talk about customers, marketing, sales, and profit and loss. All of these code words have specific meanings and numbers that are used to measure progress toward meeting targets. 2. Quality professionals don’t understand the language of quality. Quality is not an adjective, it’s a noun. It doesn’t mean goodness—it means doing what you said you would do. Management turns away from those who talk about relative goodness. No action anywhere in business comes from a packaged set of procedures. As an example, managers will generally accept ISO 9000 as a marketing necessity. Quality professionals who try to convince managers that third-party accreditation makes a difference in the conformance and the output, typically lose credibility. As the late Philip B. Crosby repeatedly said, “Managers think in terms of numbers; they only understand and drive quality when told the price of non-conformance.” For some managers, the cost of quality is viewed as a tax. Managers are extremely busy people, just like everyone else, so they expect their functional
16
QUALITY | May 2011
leaders to be able to explain what they do in a few sentences. In other words, plan your approach, know what you need to say and get to the point. 3. Quality professionals can struggle with low self-image. In many organizations, the quality staff can take a lot of abuse and are under constant pressure of justification, elimination or downsizing—even in good economic times. This takes its toll on the psyche. Quality professionals need to take charge of making their organizations reliable. They will get a lot of the credit for this and their efforts will be appreciated. 4. Quality professionals don’t learn well from the nontechnical experience of others. With a nontechnical degree, I rose from an entry-level factory position to retire at a senior management position in a large company. Along the way, I also acquired several ASQ certifications, an ASQ Fellow and two quality professional of the year awards. Success came because I was useful and reliable to my company. It is the ability to weave the quality knowledge with management acumen and willingness to help your organization and customers succeed that makes the difference. Remember that becoming a team player who consistently delivers value and takes business risks will be noticed and rewarded. 5. Quality professionals think quality is a technical and procedure entity. Sometimes quality professionals concentrate on corrective action rather than prevention. Quality certifications are certainly valuable, but they need to be coupled with building relationships and delivering value, every day. The solution to the problems of the quality profession doesn’t require a meltdown and reconfiguration of management, or a new set of procedures. The solution just might lie in our own hands. Remember we serve at the discretion of management, so we must learn their language if we want to help our organizations succeed, and help ourselves along the way. What’s the first thing you intend to do after reading this column? It might be to take a different approach. Take time to think about where you are going or you may not like where you will ultimately end up. Jim L. Smith has more than 45 years of industry experience in operations, engineering, research & development and quality management. You can reach Jim at
[email protected].
www.qualitymag.com
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OTHER DIMENSIONS
CALIBRATION MISTAKES:
PLAIN RING GAGES WARD OFF SOME COMMON CALIBRATION MISTAKES WITH A LITTLE KNOW-HOW. Editor’s note: This is the third installment in a four-part series on common calibration mistakes.
M HILL COX
any of the mistakes made in the calibration of plain plug gages also are found in the calibration of plain ring gages so it is wise to review them. As with plug gages, the simple nature of plain ring gages leads to the mistaken assumption that the devices used for their calibration are as well. While the instruments may appear to be pretty basic, their technical characteristics are not always that obvious so it’s time to take a look at the equipment involved.
EQUIPMENT A mistake that is often made when selecting the right device for calibrating plain rings is to assume that a device that sells for $5,000 is as good as one that sells for $25,000 or more. Too often, technical criteria Too often, technical criteria lose out to price and when lose out to price and when the the performance doesn’t measure up on the simperformance doesn’t measure plest of functions no one can figure out why. up on the simplest of functions Two different types of instruments with no one can figure out why. similar resolution are considered equals by some, a mistake that ignores the fact that the electronics are only part of the device. The mechanics are the most critical part, for without sound design and construction, the digital display merely presents impressive fairy tales. Internal comparators are the most popular device for calibrating plain ring gages. Basically, they incorporate a table on which the ring is placed. A slot in the center of the table allows two contacts or probes to protrude above the table surface to contact the bore of the ring. The contacts can be adjusted for different sizes and are finally set using a gage block buildup for each size to be checked. Some models have a longrange measuring head to reduce the need for a buildup for each size. A significant mistake in using this type of equipment is to assume that you can plop the ring on the table and, after centering it, measure away. This would be more or less true except for the fact that the bore of the ring may not be square to the face resting on the table—a very common situation. Instruments that are specially designed for this work incorporate a
18
QUALITY | May 2011
mechanism that tilts the probes so this condition can be detected and accounted for. Instruments without this function require the technician to manipulate the ring or simply assume the problem won’t arise—a big mistake in its own right. The spherical contacts on all ring gage calibration instruments are crucial to accurate measurements but often only receive a cursory visual examination when the equipment is calibrated. This mistake can cause all manner of mayhem down the road. It could be argued that this won’t matter so much since the instrument is set to each size it will measure and any “flats” on the contact surface will be incorporated in the setting. This is true but you have to remember that the instrument is being set using flat, parallel surfaces off a gage block buildup and will contact radial surfaces for measurement. Flats on them will span a portion of the diameter being measured and not give a true reading of size. Another problem in this area is misalignment of the contacts vertically and horizontally. MASTERS As mentioned earlier, a buildup of gage blocks is the setting master of choice for short range internal comparators. All of the notes regarding their use as masters for plain plug gage calibration apply when used for plain ring gage calibration, plus one other problem. When setting an external measuring device, the blocks are being pushed together by the instrument they are setting. The reverse applies when an internal comparator is involved. Some technicians will use a gage block holder or cage to keep the buildup together. Nothing wrong with this except for the mistaken belief that wringing can be avoided since the blocks are going to be clamped together. Doing so introduces changes in the overall dimension of the buildup that are not good. Avoid these problems by ensuring the blocks and any accessory jaws are properly wrung together. If the blocks won’t stay that way when used without clamping them together, you need better blocks or reduced measuring force—or both. And don’t forget to leave the buildup on a normalizing plate after wringing so any heat generated by the process or handling of them can dissipate. Hill Cox president of Frank J. Cox Sales Ltd. (Brampton, Ontario, Canada). He may be reached at
[email protected].
www.qualitymag.com
F
A
E
G
B
C
H
D
QUALITY 101 Electronic instruments are used more often for higher accuracy measurements. Source: Ametek
when it is pushed together or crushed. This type of measurement is useful in understanding how much force it will take to open a door, to compact a box and open a blister-package.
FORCE
MEASUREMENT EXPLAINED
Regardless of the technology employed, the desired result of force measurement is the same—measure the force applied to capture a reading for validation or further analysis. BY SCOTT A. C RONE
F
orce measurement is used in many differing types of applications and may be accomplished with devices utilizing differing technologies. Typical applications include measurements of tension and/or compression and are directed at capturing properties such as strength of a material, component or a bond. The technologies include mechanical measurements utilizing calibrated springs or electronic measurements using strain gages that employ the piezoelectric effect to capture the effect of force on a load cell or strain gage. Regardless of the technology employed, the desired result is the
20
QUALITY | May 2011
same—measure the force applied to capture a reading for validation or further analysis. Tension measurements are typically used when there is a desire to obtain information on the behavior of a product or material when it is pulled apart. This is a useful measurement for understanding how strong an adhesive bond is, which is relevant, for example, when a handle will support the weight of what is contained in a case, or if a child can break off a small part of a toy. Compression measurements are typically used to obtain information on the behavior of a product or material
VALIDATION, TESTING AND RESEARCH These measurements can be used for validation, testing and research. One particular group of measurements is even used to test and evaluate muscle strength. Measurements may be done in validating samples of a product such as testing a button or joint. These types of measurements are most often simple procedures performed in the production environment. Researchers and design engineers also require such measurements as they work through product development or selecting materials and parts for use in manufacturing. The goal would be to have proper materials used in a product or package, or for the components to behave in a certain way. These measurements are typically performed in a lab or even may be done by a specialized testing company. The testing that is performed may be done to reach a certain value based on the criteria established by engineering, scientists or a governing agency such as the American Society for Testing and Materials (ASTM). The acceptable result could be a value of tension or compression and may involve ensuring that there is no damage. This is called nondestructive testing (NDT). In some cases, the test is done to cause a failure: this is destructive testing. Both would fall under the broad term of force measurement. Mechanical instruments are typically used for lower accuracy measurements or measurements in conditions that are hazardous or detrimental to electronic instruments. These instruments are usually rugged and use calibrated springs and gearing to gage and display force readings. Applications such as flight line testing, product validation on the production floor and muscle strength evaluations may use a mechanical device for force measurement. Electronic instruments are used more often for higher accuracy mea-
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surements. Electrical instruments typically offer more flexibility for the operator in that they may have communications capability for data transfer, changeable load cells for different measuring ranges, remote load cells for testing in limited spaces and incorporated functions such as statistical analyses. However, electrical instruments may not be designed for some environmental conditions and are more susceptible to damage from the elements. Some applications such as tearing force of a cloth, sampling of raw materials, plastics testing and puncture force may use an electronic instrument for force measurement. In any case or application, one key thing to remember is that the device is only a part of the test. Many applications require repeated tests or may have to be performed several times at a specified interval. For consistency, the sample needs to be tested in a specific manner. If it is not, then the data or result becomes questionable. There are many methods available to ensure a proper and consistent test result. A basic requirement is to ensure proper calibration of the device. Even within the calibration cycle, if the device has been overranged, it should be calibrated. The other requirements are wrapped into test setup and performance. Using such devices as test stands, travel limits, load (force) limits and programmable systems are tools that are used to ensure consistency in the test setup. Performance consistency
www.qualitymag.com
Compression measurements are typically used to obtain information on the behavior of a product or material when it is pushed together or crushed. Source: Ametek
may involve such items as specific fixtures or tips for the device, using the same operator and applying the force to a specified location on the sample. All of these factors play a part in ensuring that the results are repeatable and are valid for the test that is being performed. CONSISTENCY IS KEY The selection of the device and peripheral set-up options are a function of the requirement to perform the test. If the test is being used for quality verification and has a go/ no-go result, the test setup may be very simple and use a basic device to capture the results at the end of production. If the test is being used to gage the acceptability of raw materials for use in producing an end item,
the test may be much more complex and require a higher level of accuracy and repeatability so a test stand, digital gage and data capture may be in order. There are many variables to consider and the selection is most often based on the need for compliance to a standard and/or a design criterion and the type of test being performed. In all cases, consistency is the key to capturing good data and readings and will always play a large part in obtaining valid and useable results. Scott A. Crone is product line manager and sales and support manager at Ametek Test & Calibration Instruments (Berwyn, PA). He can be reached at
[email protected] or (727) 538-6007. For more information, visit www.ametekcalibration.com.
May 2011 | QUALITY
21
INNOVATIONS The Equator uses a parallel kinematic structure for high-speed scanning and repeatability. Source: Renishaw
VERSATILE
GAGING The new Equator is a single gage that can be used for an unlimited amount of applications. BY KARI O’ROURKE, MANAGING EDITOR
E
arlier this year, Renishaw (Hoffman Estates, IL) kicked off its first gaging product line with the new Equator—a versatile gaging system capable of inspecting multiple parts. The patented system can be reprogrammed within minutes depending
on changes to part designs or if new parts need to be measured, using Dimensional Measuring Interface Standard (DMIS) programming. The Equator’s unusual appearance is the result of a stiff parallel kinematic structure that allows for easy scalability while maintaining stiffness for point-
to-point reliability. High scanning can be achieved by this patented concept along with fast moves between features. “Equator is unique in its design and method of operation and has already changed the thinking of hundreds of production engineers, making it the new gage of choice,” says David Emmet, business manager, CMM and Automated Measurement Products. “The versatility and repeatability Equator offers look set to change the world of gaging.” Installation of the Equator gaging system is quick and easy and can be out of the box and operating in less than 20 minutes. Only single-phase power is required with no air supply necessary. Also, with its lightweight design weighing in at roughly 55 pounds, crowded factory spaces are not an issue for the Equator. According to Emmett, the Equator systems are available with two levels of software, a programmable version for production engineers to create DMIS programs and, at a lower price, a shop floor system that allows those programs to be executed but prevents operators from making modifications. Both software levels include Modus Organizer operator front-end software. “In the programmable version, Modus Equator programming software allows engineers to rapidly create gaging routines for any part—simple or complex, prismatic or free-form,” says Emmett. “Modus Equator features the ability to easily program scanning measurements and touch points, using the industry-standard Renishaw SP25 compact scanning probe. Scanning allows thousands of data points to be taken to define a feature for true form analysis.”
SPECIFICATIONS » Working volume X Y Ø 300 millimeters
» Fixturing requirement: ±1 millimeter
» -Z 150 millimeters
» Machine air supply requirement: No air required
» Comparison uncertainty: ±0.002 millimeter » Maximum scanning speed: 100 millimeters per second » Maximum movement speed: 500 millimeters per second » Scanning rate: 1,000 points per second
» Operating temperature: 10 C to 40 C » Storage temperature: -25 C to 70 C » Relative humidity operating range: 20 to 80% » Maximum power consumption: 750 watts
» Probe type: Renishaw 3 axes SP25 analog scanning » Fixture plate: 305 millimeters by 305 millimeters aluminum » Maximum workpiece: weight 25 kilograms » Machine weight: 25 kilograms » Machine dimensions (W x D x H): 570 millimeters by 500 millimeters by 700 millimeters
» Typical power consumption: 110 watts
» Scale resolution: 0.0002 millimeter
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QUALITY | May 2011
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Shown here is the Equator gaging a medical component. Source: Renishaw
Full programming functionality is provided by taking the dongle that comes with the programmable system and plugging it into a shop floor system. Engineers can then adjust programs while retaining control. Prior to the product launch, the Equator was put through a testing phase with several leading companies in the aerospace, automotive and medical fields. One company that participated in the prelaunch was Meyer Tool (Cincinnati), an aero-engine component maker. Since
implementing the Equator, Meyer Tool has been able to eliminate at least four expensive hard gages in a new work cell. “And that’s just the beginning of the impact the company anticipates for its inventory of custom hard gages, which can cost up to $20,000 each to design, build and maintain,” says Beau Easton, quality manager, Meyer Tool. “Down the line, design changes can add another $3,000 to $10,000 to reconfigure and qualify an existing gage.” The Equator is capable of measuring a variety of parts including, shaft cylinders, hip joints, blade and root form, and molding. An entire Equator system includes a port stylus changing rack, SP25 probe system, controller, one fixture plate and stop button or joystick kit—all at the running cost of $26,000. Accessories also are available.
BALL GAGE INSTEAD OF A CYLINDRICAL PLUG GAGE. Save time with the self centering spherical surface of the ball gage. When measuring a large number of holes it can be 100 times faster. Put one or two flats on the ball and find any out-of-round holes. Measure how parallel the space is between two surfaces and or the size. You can get into inside diameters or inside spherical surfaces of rod end bearings.
Renishaw Inc. 5277 Trillium Blvd. Hoffman Estates, IL 60192 (847) 286-9953 www.renishaw.com
Bend the stem to reach inaccessible
locations,
in
confined areas, down in a hole, inside a cavity or in a buried feature which cannot be seen. Mount the ball on a wire for flexibility to go around corners in pipe and tubing, for example. Easily measure the width of grooves or the surfaces of spherical and toroidal features. Accurately
measure
the
pitch diameter of bearing races, threaded surfaces and of gears. Bal-tec Division Micro Surface Engr., Inc.
AM
1550 E. Slauson Ave Los Angeles, CA 90011 323-582-7348 www.precisionballs.com
www.qualitymag.com
May 2011 | QUALITY
23
50 YEARS OF QUALITY
Optical
Comparators Go Digital
The future is here. Advancements in comparator technology enable higher accuracy and productivity. BY PATRICK BEAUCHEMIN, P.ENG. PH.D.
I
ntroduced in the 1940s, optical comparators are still being actively used to verify that manufactured parts are within tolerance, including those with complex geometries. Comparators are used throughout the plant including the shop floor, metrology and quality control labs. Optical comparators are
versatile and robust, and provide an easy-to-use and cost-effective measurement solution for many applications and industries. Up until recently, comparators have been the easiest way to quickly compare a part to its drawing to allow the operator to make an overall pass/fail determination.
A digital optical comparator overlays the part’s CAD drawing onto the live video image of the part, in this case, the part is a knee implant. Source: VisionX
24
QUALITY | May 2011
TODAY Now, new digital advancements in comparator technology offer significant benefits. For example, new digital optical comparators offer the ability to digitally compare a part to its computer-aided design (CAD) data quickly and easily, at exceptionally high accuracy. This data also can be archived and documented electronically. In contrast, traditional optical comparators require Mylar overlay charts that are time consuming to use, less precise, error prone and difficult to document. Also, because the CAD drawing can move with the part on a digital comparator, operators can compare a part to its CAD drawing beyond the optical field of view. With conventional optical comparators, the overlay is fixed on the screen and does not move when the stage carrying the part moves. Further, a digital optical comparator will automatically produce an operator-independent pass/fail result, and display any deviation from specification by comparing a part against bidirectional tolerances at user-specified control points. New digital comparator technology combines the capabilities of an optical comparator, video coordinate measurement machine, machine vision and vision system. Similar to a coordinate measuring machine (CMM), digital optical comparators produce highly accurate measurements in both manual and full automated modes. The latest comparators feature an extensive set of machine vision tools to carry out pattern matching, color
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verification and defect detection. Very high-resolution imaging systems are now available, which provide detailed inspection of subjective properties, such as surface finish verification, digital image collection, annotation and electronic distribution. Today, operators can capture a very high resolution and geometrically exact image of the part by using a highresolution digital camera and low distortion telecentric lens. And they can easily view the high contrast images in full daylight. Monitors also are improving. Highresolution quad monitors produce images with an on-screen resolution better than that of traditional 30-inch optical comparators. Digital comparator technology is appropriate for a range of industries including orthopedics, medical device manufacturing, automotive, aerospace, energy, precision mechanical components and assemblies. It also is appropriate for higher magnification and very high accuracy applications such as micro electro-mechanical systems (MEMS) device manufacturing, electronics and semiconductor. For example, in the orthopedics industry, 100% of parts must be inspected and compared to their CAD data during the manufacturing process, directly on the shop floor. These are implants with complex geometries and tight tolerances. The higher accuracy that digital comparator technology provides is a key benefit. Also, because parts can be made in small batches, there is a constant need to change the overlay. With traditional optical comparators, this involves removing the overlay, walking over to the overlay storage area, finding the correct overlay, walking back to the machine and positioning the overlay. With digital technology, the operator only needs to scan in the work order’s barcode or press a button on the screen to automatically call up the correct overlay, which comes up already correctly positioned over the image of the part. MOVING FORWARD As comparator technology continues to evolve to address market demands, data collection and automation are vital considerations. Operators will require that optical comparators have much more extensive data collection capabilities.
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A composite view of a horizontal and vertical configuration a digital optical comparator is shown. Source: VisionX
And obviously, it will be expected that the data be in electronic form. Up until now, optical comparators have not had any built-in data collection capability. As a result, the records of most inspection operations carried out using optical comparators are information-poor and of uneven quality. This is understandable as many of these inspections are carried out directly on the shop floor, by machine operators whose primary function is to manufacture parts. Inspection records kept in these circumstances often consist of a checkmark or two on a paper report, indicating that the necessary inspection has indeed been carried out successfully. These types of records are not up to today’s documentation and record keeping standards. With digital optical comparator technology, when the operator scans in the barcode on the router that accompanies the parts to be inspected, not only does the system automatically load the correct CAD file, but all of the relevant information—for example, lot and job numbers, work order and operator identifier—also is directly linked. The system can then be used to quickly obtain a high accuracy auto pass/fail result to compare the part to its CAD file. This operator-independent result, along with any measurements of criti-
cal dimensions and other notes can be saved along with a very high-resolution image of the part and its CAD file overlay, and a time/date stamp. And all of this is done on the shop floor, as the parts are being inspected at the different stages of the manufacturing process. The quality of the information being collected is tremendously increased, and at the same time, the cost of collecting this comprehensive information is reduced. Automation also is of significant importance. Manual comparator systems can produce results that may vary from operator to operator. Fullyautomated operations provide much higher accuracy results and eliminate variation due to operator dependency. There are a number of benefits and no downsides to better, more extensive data collection and increased automation. With the growing requirements made on manufacturers today for higher yields and ever-increasing quality, electronic data collection and automation are the way of the future for optical comparators. Patrick Beauchemin, P.Eng. Ph.D. is president of VisionX (Pointe-Claire, Quebec, Canada) For more information, e-mail
[email protected], call (514) 694-9290 or visit www.visionxinc.com.
May 2011 | QUALITY
25
MEASUREMENT
Metrology The
Training Dilemma
To make effective use of a high precision metrology system, one needs to understand how it works, how to squeeze the best performance out of it, how to choose the optimal one for the application and what to do if something goes wrong. BY STEPHEN KYLE
Editor’s note: This article is an excerpt from Stephen Kyle’s white paper presentation given at the 2010 Coordinate Metrology Systems Conference (CMSC).
I
n the realm of metrology, there is a wide variety of instrumentation used for portable coordinate
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measurement (PCM) and large volume metrology (LVM). A precision mechanical arm captures accurate 3-D points and surfaces from a race car. A laser beam tracks a wireless probe, held by the operator and used to check critical dimensions on an automobile body. A photogrammetry
system inspects the three-dimenthree dimen sional features of an aircraft door. A handheld laser line scanner is tracked by an imaging system as it builds up the surface shape of a car door. These high-precision dimensional measurement systems can be brought on site to help build, check and reverse engineer a wide range of large, manufactured objects. These measurement technologies are not new. Many mobile optical systems delivering 3-D shape were developed by shrinking down mapping systems configured to measure large land masses and optimizing them for car bodies and aircraft wings. This shrinks down
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Verifying the position of aerodynamic parts on race cars was a difficult task before Andretti Autosport began using a precision mechanical arm. Source: Faro Technologies
Last year, the CMS made a survey of the error, too, and produces systems of knowledge. Their tools are critiindustrial users, which produced the which can accurately measure to a few cal to manufacturing success, but to interesting result that tenths of millimeters or a make effective use of a high-precision around 66% of users who few tens of micrometers. metrology system, one needs to underTECH TIPS responded came from Early applications of stand how it works, how to squeeze » High-precision dimensionthe aerospace and 20% industrial photogrammethe best performance out of it, how to al measurement systems from the automotive try (precise measurement choose the optimal one for the applicacan be brought on site sectors. That may cover from multiple images) or tion and what to do if something goes to help build, check and most of the applicaindustrial surveying (prewrong—which never ever happens at a reverse engineer a wide range of large, manufactions at present, but it cise measurement from good time, does it? tured objects. leaves plenty of room for multiple theodolites) date Customers also get demanding. growth in other smaller from around 1970. They want proof that a manufacturer » There is a need to know sectors where there are Developments in can deliver on the promise to measure how to test a system’s challenging tasks in electronic imaging and dimensions smaller than the average performance, calibrate it if necessary and demcoordinate metrology. processing have since human hair, so there is a need to know onstrate that its output We can expect portable turned industrial phohow to test a system’s performance, calcan be traced all the way coordinate metrology to togrammetry into a ibrate it if necessary and demonstrate back to the standard unit increase its base. range of sophisticated that its output can be traced all the way of length. vision metrology tools back to the standard unit of length, » A detailed knowledge of and extend the multhe meter. A big help here would be THE METROLOGY the technology has not tiple imaging methods certification and some independent TRAINING DILEMMA been easy to come by. into structured light recognition that people have the skills Is there a problem and triangulation systems to do this. can it be solved? Yes, for detailed measurement of surface These issues are only solved with a there is. And, yes, it can. PCM and form. Surveying systems have moved detailed knowledge of the technology. LVM now encompass a large body from multiple theodolite intersection systems to widespread use of single instrument systems based on indus® trial total stations (theodolites with built-in laser distance measurement) and the more recent developments, in the 1990s, of laser trackers and large volume spherical scanning systems. The 1970s and 1980s also saw the development of articulated arm coordinate measuring machines (AACMMs), often called more simply CMM arms. The very high accuracy of conventional 3-axis coordinate measuring machines (CMMs), housed in specially built, climate-controlled rooms, was then complemented by the lower accuracy but more flexible CMM arm which could be taken to an operator’s workbench. More choice is provided by systems Made in the USA such as the indoor Global Positioning System (iGPS) and the automation of With Direct-to-Video integrated CCD cameras what, until recently, have been mostly Hawkeye® Rigid Video Borescopes eyepiece. When used with optical quality of Hawkeye® Pro manually operated systems. offer the convenience and image our Portable Video Monitor, or Rigid Borescopes, including Clearly these are high-tech systems quality of video, built right into the a computer, image and video patented e2 endoGRINs® relay in regular use in high-tech and highscope! Comfortable onscreen capture is as easy as the touch lenses, delivering bright, crisp, viewing puts an end to long days value industries. The biggest profesof a button. These scopes have clear images. of straining to look through an all the features and excellent sional group to concern itself with the technologies of PCM and LVM is the Visit us at: Booth 3235 gradientlens.com Coordinate Metrology Society (CMS), Springfield, MA 800.536.0790 May 17 - 19, 2011 based in the United States.
Hawkeye Rigid Video Borescopes
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MEASUREMENT Unfortunately, it has not been easy to find a course of instruction or a good book from the library in order to acquire this. For most experts, it is onthe-job training and a certain amount of learning by trial and error. This is not efficient, nor cost effective, but things are looking up. The CMS itself has a committee working to define the body of knowledge covered by PCM and LVM. This
does not, for example, give the details of how a particular system works, but does identify the areas to be filled by a database of detailed knowledge. On a more direct level, one member organization of that committee launched an entry-level course of instruction in portable coordinate measurement systems (PCMS) last year. This is the UK’s National Physical Laboratory (NPL), like NIST in the
A handheld laser line scanner is tracked by an imaging system as it builds up the surface shape of a car door. Source: Leica Geosystems/Hexagon Metrology
United States and the PhysikalischTechnische Bundesanstalt (PTB) in Germany, is responsible for maintaining national metrology standards. BASIC TRAINING COURSES NPL develops training courses in metrology, both dimensional and nondimensional, at four distinct levels. • Level 1 is an entry-level course for users of metrology who learn to question what they do. • The second level is designed for appliers of metrology who must select and implement solutions. • Level 3 is tailored for developers of metrology championing new solutions to problems. • Level 4 training is for definers of metrology who create those new measurement solutions. Level 4 gets a little stratospheric, and is fine for a master’s degree or advanced technology workshop, so most of the training is focused on levels 1 and 2. NPL has already developed courses at level 1 and 2 for core dimensional metrology. These teach the important basics: measurement uncertainty,
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QUALITY | May 2011
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tracking, single camera systems, hybrid and automated systems. The presentations finish with a discussion of the performance evaluation of systems. Practical work is likely to be difficult to achieve with more specialized systems and perhaps increased use of video presentations is required. These are open issues still to be decided. The core metrology courses and the PCMS Level 1 have all achieved accred-
standards and traceability, coordinate systems and the use of simple, everyday instruments such as micrometers. The training curriculum progresses to full 3-D and the detailed understanding of portable coordinate measuring systems. NPL has now created a new two-day PCMS Level 1 course that is already operational. The first day of the course consists of presentations mixed with system demonstrations or videos. Day 2 of the course concentrates on practical tasks. This course takes a 3-D view of the world and introduces the most commonly used PCMS tools. These have been identified as CMM arms, laser trackers and some vision metrology systems. The practical work is defined in outline, not in detail, and its actual implementation is decided by the training course deliverer who sets up to three tasks for the students. In gaining this valuable hands-on experience, the students also learn to evaluate the working environment and plan, execute and report on a measurement job. PCMS Level 2 is not yet operational, but the presentation material has been drafted. Level 2 completes the overview of current PCMS with background material on legacy theodolite systems and a review of a range of specialized technologies such as iGPS, 6-D laser
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itation and, in the UK at least, students who successfully attend the courses obtain a formal qualification. There are several ideas for courses at Level 3. One hot topic is the measurement of surface form for which many systems of different design and concept exist. The technology is still undergoing extensive development and performance measurement of surface scanners, for example, is currently lim-
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MEASUREMENT
A photogrammetry system inspects the 3-D features of an aircraft door. Source: Geodetic Systems Inc.
al igin ® r o the rf Get ket Su SA c Po e in U d Ma
ited and in need of improvement. This would certainly be a worthwhile topic at Level 3. Good reference material is still in short supply and an accessible knowledge base of PCMS would be an excellent tool to complement training courses, support self-learning and provide the basic material behind the body of knowledge defined by the Coordinate Metrology Society.
Pocket Surf®
If portable coordinate metrology is your business, join the party and contribute your ideas. Q Stephen Kyle works independently, and as an honorary senior research fellow at University College London, on the application and development of PCM and LVM. For more information, e-mail
[email protected] or
[email protected].
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TEST & INSPECTION
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QUALITY | May 2011
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Custom
Noncontact Solutions
MEET UNIQUE INSPECTION CHALLENGES with a black wear-resisting compound that make them very difficult to image with standard equipment. The consultant devised a system that incorporated custom optics, part handling, lighting and camera combinations, and customized software that made a qualitative analysis and documentation of these unavailable. More often than not they are. They have just not been assembled parts faster and more reliable. and integrated into an off-the-shelf prodOn a high-resolution screen, the uct that will meet the particular need. inspector views the part as it is manipulated into various positions and with Most manufacturers do not have experts who have mastered the multiple lighting combinations to make surface disciplines needed to design and assemflaws readily detectable. If questionable ble an elegant custom noncontact meaareas are found, the operator can adjust surement solution. There are, however, camera software settings, lighting and magnification to optimize their visibility. organizations within the manufacturing industry that do have the expertise or If a flaw is detected, the operator the project management experience neccan capture the image, differentiate essary to offer such services at a favorwith color, measure the area occupied by the defect and mark able cost or benefit ratio. BENEFITS it up with drawing and » On a high-resolution annotation tools so that DIFFICULT-TOscreen, the inspector views engineers can quickly IMAGE PARTS the part as it is manipuunderstand and review Black is wonderful for lated into various positions any problems. When purposes of camouflage, and with lighting combinathe operator is finished, but not ideal if one needs tions to make surface flaws an electronic archive to image the surface of readily detectable. is created to preserve a black parts to detect » Custom noncontact inspeccomplete record of the flaws or measure feation solutions may be inspection process. tures. A manufacturer qualitative, quantitative or This solution reduces of high-stress internal a combination of both. eyestrain, neck fatigue combustion engine com» If there is a measurement and other discomforts so ponents had some critical or inspection problem, nonthat operators can perparts that had to be 100% contact or otherwise, that form at a high level for inspected for surface seems to defy a standard longer periods. It also credefects that were a potensystem or existing tool soluates a highly accurate and tial source of failure. tion, do not hesitate to call meticulously documented Unfortunately, these in an expert with custom systems capabilities. inspection process. metal parts are coated
Everything is to gain by finding out how to perform a critical inspection better, faster and at the lowest cost. BY MARK ARENAL
T
oday there is no lack of noncontact inspection tools. There are highresolution video cameras, optics, multiple illumination sources, laser scanners, white light sensors, high-resolution displays, precision motion platforms, linear stages, along with computers and software packages that are used to control the inspection systems, capture the data, analyze it and store it in appropriately accessible formats. Noncontact and multisensor measurement system manufacturers have made good use of these components to design standard products for measuring and inspecting parts that, due to the small size, fragility, deformability, inaccessibility or multiplicity of their features cannot be measured efficiently by conventional tactile equipment. For most parts that benefit from noncontact or multisensor inspection, there is typically a selection of measurement systems that will do the job well. However, as designers push manufacturers to make parts that are smaller, more intricate or incorporate unique materials, the specialists who need to measure these components will inevitably encounter new challenges that standard noncontact measurement systems cannot easily handle. It is not that the pieces needed to meet the challenge are
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TEST & INSPECTION
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SMALL FEATURE FLAW DETECTION AND MEASUREMENT Custom noncontact inspection solutions may be qualitative, quantitative or a combination of both. A medical manufacturer needed to inspect a small plate with hundreds of precisely machined perforations. Multiple quality issues needed to be addressed during a relatively high-speed 100% inspection process matching the pace of production: Were all the holes in the part model present? Were all the holes clear of dust or debris created during the manufacturing process? Did each of the holes conform to precise size and tolerances? Finally, were all of the orifices in the plate in proper relation to each other? In this case, the recommended solution is a standard measurement platform, adapted so that both qualitative and quantitative evaluations can be performed rapidly and automatically with one setup on the same equipment. At a low magnification level, the camera takes a picture of the plate so that the software can confirm the presence of all the holes and that there are no partial blockages in them. Additional pictures are taken at a high magnification level, allowing software to verify the size and location of the holes. By exception, the system also is capable of performing high-precision measurements of individual holes at this level. FLEXIBLE AND DEFORMABLE COMPONENTS A company that manufactures illuminated display panels for aircraft was frustrated by the unwieldiness of trying to measure them on their coordinate measuring machine (CMM). The parts were large, flat, soft and flexible—attributes that tactile measurement systems are not well equipped to deal with. Vision would be the ideal solution, but purchasing a system with a large table to measure these particular parts would be very expensive. The dilemma was handled quickly and at minimal cost by adding an optical probe to the Z-Ram of the CMM giving noncontact optical-video measurement capabilities whenever required. In this case, the consultant installed the optical video head, integrated the video with appropriate measurement software and provided the operator with
some initial measurement programs for some of the most common applications along with training. The CMM was more fully utilized and the cost of adding a new vision system was avoided. INSPECTING THE INSPECTION SYSTEMS Not all measurement applications that can benefit from some expert consultation are complicated. One customer simply wanted to know if his existing vision inspection equipment was adequate for his company’s immediate and short-term needs. The consultant did a walk through of the company’s lab and examined the equipment. Then they had a detailed conversation about the types of evaluations that were being performed using vision. In this case, the mechanical platform of the primary vision system was reaching the end of its useful life, but the optics were of high quality and had almost no wear. Therefore, the customer was able to mount existing optics on a new X-Y-Z motion platform to improve the performance of his system and save money. EVERYTHING TO GAIN If there is a measurement or inspection problem, noncontact or otherwise, that seems to defy a standard system or existing tool solution, do not hesitate to call in an expert with custom systems capabilities. Everything is to gain by finding out how to perform a critical inspection better, faster and at the lowest cost. There are independent consultants who can perform this service. A small number of companies also are willing to serve customers in this manner. They can provide the operator with a standard solution if possible, but branch into a custom solution if necessary. Q Mark Arenal is managing director of the Starrett Kinemetric Division (Laguna Hills, CA). For more information, call (949) 348-1213, e-mail
[email protected] or visit www.starrett.com.
QUALITY ONLINE For more information on noncontact inspection, visit www.qualitymag.com to read the following: • “Extending the Frontiers of Noncontact Surface Inspection” • “Noncontact Inspection: From Shadowgraph to Multisensor” • “Noncontact Inspection Keeps Pace with Production”
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MANAGEMENT
The Future of Quality
ISO Standards Five common quality ISO standards are examined. BY GENEVIEVE DIESING, ASSOCIATE EDITOR
I
all systems together so that a quality system can exist and handle many different standards. “The other part of that is moving toward more competence, impartiality and inconsistency,” Morr continues. “[ISO is] trying to make standards where organizations and businesses who operate off of them practice those three THE FUTURE OF ISO tenants so openly in their process.” As industries evolve, so do the stanThis is just good business, and it dards that have informed them. This is helps remove international trade barparticularly true for ISO riers, Morr notes. When standards, which rouBENEFITS businesses across the tinely undergo revisions. » ISO 9001 will continue to set globe recognize the same Craig S. Morr, directhe tone to how ISO stanquality standards, they tor, Quality & Safety, at dards are formed. are on a more level playNSF International (Ann » ISO standards are moving ing field. Arbor, MI), says that as toward more of a standardJeff Rodgers, senior all ISO standards change, ized format. lead auditor with RMS they are eventually head» It is becoming more common LLC (Detroit, MI), says ed in the same direction. for companies offering more this is exemplified in how “Most of the ISO stanthan laboratory services to ISO 9001, a now universal dards are moving toward be certified to ISO 9001 quality management stanmore of a standardized while the laboratory within dard, has been revised and format,” he explains. the organization is accredchanged over the years. “The reason is to align ited to ISO/IEC 17025. SO 9000, AS 9100, TS 16949, ISO 13485 and ISO 17025 are five common quality standards. As ISO standards as a whole become increasingly focused on competence, consistency and impartiality, these five stand to become more subject to future revision.
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QUALITY | May 2011
9001 has moved away from the prescriptive, documentation-heavy side of stantive documentation-h dardization and embraced measurement and increasingly subjective definitions. Rodgers says its revisions have enabled companies in any industry to adopt it, making it a prime model for other ISO revisions and an indicator of how they will change in the future. By using what Rodgers and the ISO community call the process approach—or measuring tasks within a company alongside coordinated goals— organizations can examine the efficiency of their processes more closely by identifying “the weakest link” in a set of sequential activities. “Because the 9001 standard went to the process approach, all the requirements ever imposed on an organization go into each one of those processes,” Rodgers says. Rodgers envisions that 9001 will continue to set the tone for how ISO standards are formed. When it was revised in 2008, no new requirements were added, but rumor has it that some of the wording changes were aligned closely to ISO 14001, an environmental standard that is set to be revised in 2013, Rodgers says. While there is no hard evidence, he says this would not be surprising as ISO
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ISO 9001 ISO 9001 specifies requirements for a quality management system where an organization needs to demonstrate its competence to regularly meeting customer and regulatory requirements. It seeks to improve customer satisfaction by applying processes for continuous improvement and by ensuring conformity to regulatory requirements. These requirements are general and are intended to be universal. ISO 9001 was last revised in 2000. ISO 17025 ISO/IEC 17025 is the primary standard used by testing and calibration laboratories. It was originally issued by the International Organization for Standardization in 1999. While it is similar to ISO 9000, 17025 incorporates the concept of competence. It applies directly to testing and calibration results. 17025 specifies the general requirements for the competence to carry out tests and/or calibrations, including sampling. It includes testing and calibration performed using standard methods, nonstandard methods and laboratory-developed methods. It is appropriate for all organizations performing tests and/or calibrations, such as first-, second- and third-party laboratories. Management requirements and technical requirements comprise ISO 17025’s two main sections. Management requirements are related to the quality management system within the laboratory, while technical requirements have factors that apply to the tests and calibrations performed in the laboratory. “Since the early ’90s, there has been a big push in the industry from regulatory bodies—they pushed labs to get 17025 accreditation,” says Rodgers. “It has done wonders. The competency of our calibrations, our tests and our inspection results produced were very high.” ISO 17025 was published in 1999; it replaced ISO Guide 25. ISO 17025 was reissued in 2005 with wording that better reflected the quality system words of the 2000 version of ISO 9001.
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The most significant changes included more emphasis on the responsibilities of senior management, and specific requirements for continual improvement of the management system itself, particularly in regard to communication with the customer. The result was an improvement in competence for test inspection and calibration for both internal and commercial labs, Rodgers says. “There is
now more accurate and precise reporting of calibration test and inspection,” he notes. ISO 17025 VS. ISO 9001 While these two standards share similarities, they are not interchangeable. ISO 9001 applies to an entire organization. It is useful as a management evaluation tool, but this standard does not have enough technical content to
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standards on the whole are evolving in order to be more harmonious.
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Eddy Current Testing: Its Many Benefits and Applications June 14, 2011 | 2pm EDT M o d e rator Gillian Campbell Editor Quality Magazine
S p eake rs Eric Blackwell Sales Engineer GA / SC / Western NC / Eastern TN / North FL Territory Olympus NDT
Lee Nye Technical Support – Americas Olympus NDT
This webinar provides an introduction to the multitude of nondestructive testing applications that are possible using eddy current testing (ECT) techniques. During this webinar, key market areas will be presented with highlights of some of the applications that are being tested today using ECT. These markets include the automotive, medical, petrochemical and even sporting goods areas. With sample applications from these markets, the possibilities of ECT will be discussed including highlights of the simplicity and speed of a basic eddy current test using a portable flaw detection instrument. Finally, this webinar will help to introduce where ECT can replace many current inspection techniques in a nondestructive yet environmentally friendly manner. Brought to you by
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MANAGEMENT provide an assurance that test, inspection or calibration data are accurate and reliable. Laboratories that do not manufacture products and perform calibration or testing as primary functions will normally need to meet the accreditation requirements of ISO/IEC 17025 and not necessarily the certification requirements of ISO 9001. It is becoming more common for companies offering more than laboratory services to be certified to ISO 9001 while the laboratory within the organization is accredited to ISO/IEC 17025. Ideally, the company would achieve ISO 9001 certification through an accredited certification body and ISO/ IEC 17025 through an International Laboratory Accreditation Cooperation (ILAC)-recognized accreditation body. AS 9100 AS 9100 was developed using ISO 9001 and AS 9000. It builds on these requirements to produce a global standard that meets the requirements of aerospace companies. It was the first standard available for use across the global aerospace community, and it adds the additional requirements necessary to address both civil and military aviation and aerospace needs. AS 9100 was released in October 1999, by the Society of Automotive Engineers and the European Association of Aerospace Industries. AS 9100 replaces the earlier AS 9000 and fully ISO 9000, while adding additional requirements relating to quality and safety. Revision C of the standard was released in 2009. TS 16949 TS 16949, in conjunction with ISO 9001, identifies the quality management system requirements for the design and development, production, and installation and service of automotive-related products. ISO/TS 16949 can be applied throughout the automotive supply chain. It is applicable to sites of the organization where customer-specified parts are manufactured. The standard was last revised in 2009. ISO 13485 ISO 13485 specifies requirements for a quality management system for the
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medical device industry. Organizations use this standard to demonstrate the ability to provide medical devices and related services that consistently meet customer requirements and regulatory requirements. The standard was designed to give consistent medical device regulatory requirements for quality management systems. This means it includes some requirements for medical devices and
excludes some of the requirements of ISO 9001 that are not suitable as regulatory requirements. Because of these exclusions, organizations whose quality management systems match this standard cannot claim conformity to ISO 9001 unless their quality management systems conform to all the requirements of ISO 9001. ISO 13485 has not been revised since it was introduced in 2003. Q
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ABSOLUTE BASE a wide and stable work holder plate to support masses beyond 2000 kg eliminate the anvil ling instability problems and eliminate maintenance and adjustment. For large or very irregular test pieces which cannot be easily received by the regular bench hardness tester, you will not need any portable model thanks to the Affri System® it is a really Rockwell standardized test ASTM E18.
CERTIFICATION AFFRI® Systems are supplied with certificates traceable to the latest edition of ASTM E18 AFFRI® is the perfect system for your production department and the best reference for your laboratory Contact us for a demonstration or an immediate quote: Email:
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Practical Methods to Improve Your Manufacturing Processes
nondestructive testing including materials test
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The Practical Use of NDT and Materials Test Technology
Real-World Application of Vision and Sensor Systems, Components, Software and Services
Contact your Quality Marketing Manager today! Group Publisher Barbara Grim Bill DeYoe Buck Bicek Darrell Dal Pozzo (856) 358-4800 (704) 822-6434 (630) 971-0904 (847) 405-4044 Fax: (856) 358-0900 Fax: (704) 822-6834 Fax: (248) 502-1086 Fax: (248) 502-1024
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[email protected] M NA MA MANAGEMENT N GE G ME M NT N
Sharpenin Bombardier embarks on deploying advanced quality and logistics planning. BY CHUCK NADEAU
A
braham Lincoln once said that if he had six hours to cut down a tree, he would spend four hours sharpening his axe. This philosophy was the key focus for members of Bombardier’s CSeries commercial aircraft and Learjet 85 business jet Quality and Logistics Development teams during a course on advanced quality planning (AQP) and the deployment of the advanced logistics planning (ALP) strategy. Bombardier currently uses Six Sigma and Kepner-Trego methodologies to achieve its quality objectives
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QUALITY | May 2011
and has successfully delivered more than 500 aircraft during the past two years. However, proven preventive quality tools such as failure mode effects analysis (FMEAs), process control plans and mitigation approach plans, which have been used extensively in many industries— including automotive, pharmaceutical and medical—have yet to be embraced by the aerospace industry. That, according to Sandra Perron, director, quality and logistics, CSeries, Bombardier Commercial Aircraft, is about to change.
CHANGES In October 2010, several Bombardier facilitators, including members from Montréal, Belfast and Wichita, KS, graduated from an intensive 10-day AQP course provided by a specialized external consulting firm. They are now spearheading this quality initiative with a first wave of seven suppliers who also are embracing this methodology to identify potential areas of risk in their processes. On the logistics side, the team also is deploying FMEAs, as well as material and information flow analysis (MIFA) and capacity analysis training, to the same seven suppliers. Together, they will “plan for every part,” identify areas of potential risk and mitigate those risks with logistics process controls.
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Source: Bombardier
Source: Bombardier
ng the Axe ““We “W We consistently cons co nsiistently talk about the need for flawless execution. The secret ingredient to the recipe for flawless execution is to mitigate risks before they impact production, and the best way to mitigate those risks is by identifying them first,” says Perron. “The ALP tools that Bombardier is deploying are tailored to do just that. FMEAs provide both Bombardier and its suppliers with the ability to target potential failure modes as far upstream as possible, and subsequently implement process controls, such as error-proofing and poke-yokes, that will prevent those failures from occurring rather than having to deal with them after they’ve happened.” Bombardier also is utilizing the AQP toolset to adopt a proactive culture with
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regards to all internal manufacturing processes. Taking an extended valuestream approach ensures that the entire life cycle of the manufacturing process has been reviewed and that all risks have been identified and mitigated with robust improvement plans in place. Brad Riffel, director of quality assurance at Bombardier Learjet, is a supporter of the AQP program and is excited to witness the shift in continuous improvement thinking within the aerospace industry.
TECH TIPS » The secret to flawless execution is to mitigate risks before they impact production, and the best way to mitigate those risks is by identifying them first. » Bombardier is utilizing the AQP toolset to adopt a proactive culture with regards to all internal manufacturing processes. » FMEAs will be deployed on a wider scale throughout all of Bombardier, and there are indications that the aerospace industry as a whole is adopting this strategy, as well.
Julie Bélanger, a mechanical engineer and quality manager who participated in the training, also agrees that this is the right way to go. “The time is right for implementing advanced quality planning principles and concepts,” she says. “This training enabled me to push beyond my paradigms and to explore the use of these proven tools, which focus on a more proactive approach. I strongly believe this training will have a positive impact on current
May 2011 | QUALITY
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MANAGEMENT
Source: Bombardier
and future development programs, and that it will be instrumental in pioneering a new quality benchmark throughout Bombardier.” According to François Minville, vice president of manufacturing for the CSeries aircraft program, what is imperative to the deployment of this training is that it is not a flavor of the month. FMEAs will be deployed on a wider scale throughout all of Bombardier, and there are indications that the aerospace industry as a whole is adopting this strategy as well. Suppliers have been very receptive to the training thus far and are embracing this paradigm shift with understandable enthusiasm. Once deployed, these tools will enable both Bombardier Aerospace and its suppliers to identify and eliminate potential quality issues far upstream in the process, prevent their impact earlier on and ultimately reap the rewards of a streamlined production system which can focus on “building in station,” a key factor in the automotive industry’s quantum leap in quality and logistics.
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QUALITY | May 2011
DeFelsko Corporation • Ogdensburg, New York Phone: +1 ( 315 ) 393-4450 •
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AIRCRAFT PROGRAM INFORMATION » CSeries aircraft. The CSeries family of aircraft will be the gamechanger in the 100- to 149-seat single-aisle jet market. The 110seat CS100 and 130-seat CS300 aircraft will combine operational flexibility—short-field performance with longer range—with advanced technology, widebody cabin comfort and cash operating costs that provide 15% advantage over the competition in their size class. The very low noise and environmental footprint of the CSeries aircraft will make them the greenest single-aisle aircraft in their class. The CSeries aircraft family is being designed to anticipate airline needs for 2013 and beyond.
» Learjet 85 aircraft. The Bombardier Learjet 85 aircraft, launched on October 30, 2007, is the first Bombardier Aerospace business jet with both fuselage and wing built primarily from carbon composites and designed for type certification under U.S. Federal Aviation Administration FAR Part 25. The new jet, with a customer-driven clean-sheet design, will be positioned between the midsize Learjet 60 XR aircraft and the supermidsize Challenger 300 jet, redefining the midsize market segment.
Both ALP and AQP participants recognized that once embraced on a larger scale, across the company’s supplier base as well as within its manufacturing plants, these advanced planning tools would help Bombardier reach its long-term quality and logistics goals. The vision is simple—perfect parts, on time, every time. Q
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Chuck Nadeau is senior quality engineer, Learjet 85, Bombardier Business Aircraft (Wichita, KS). For more information, e-mail chuck.nadeau@ aero.bombardier.com, call (316) 946-7622 or visit www.bombardier.com. Source: Bombardier
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[email protected] May 2011 | QUALITY
47
CASE STUDY The Faro GagePlus is is ideal for on-machine inspection. Source: Faro Technologies Inc.
TESTING OUT
QUALITY With a minimal investment and no risk, an aerospace parts manufacturer was able to test an inspection gage and prove its ROI before purchase.
E
of removing a part from a tooling xpress Manufacturing (Acton, machine while in-process. Despite Ontario) is a manufacturer of aluthe best of efforts, it was difficult, if minum, mild steel and wood parts not impossible, to set a part back into for the aerospace industry, specifia machine for retooling cally landing gear. The comexactly as it was before. pany focuses on jobs with BENEFITS In addition, simply smaller quantity outputs, » The Faro Gage reduced removing the part from which enables it to do what Express Manufacturing’s a production machine it does best—work quickly lead times from five weeks for inspection and veriwith accurate parts. to three weeks. fication was, in itself, Express Manufacturing » The Faro Gage saved both time-consuming often must inspect bearing Express Manufacturing and expensive. surfaces and mating sur$15,000 in materials and faces with tight tolerances. labor costs because it Until recently, the comTO THE RESCUE verifies part quality before pany achieved this solely Inspecting parts parts are removed from by using micrometers and directly on the the machine. electronic height gages, machine produc» The FaroTechnology Test which ultimately wasted ing them not only Drive enabled Express time and money. increases productivity, Manufacturing to evaluate Express Manufacturbut also quality. Onthe equipment on its own ing’s goal to maintain high machine inspection shop floor and determine accuracy also was hindered allows the machine its return on investment before purchase. by the inherent difficulty tool operator to quickly
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QUALITY | May 2011
and easily inspect parts directly on the floor while the part is being machined, resulting in tighter tolerances with fewer errors and rework. Express Manufacturing was looking for a solution that would give it true on-machine inspection. That tool is the Faro GagePlus from Faro Technologies Inc. (Lake Mary, FL). The gage is a highly accurate—up to 0.0002 of an inch—and easy-to-use measurement arm. It is designed to be used directly on the shop floor and is ideal for onmachine inspection. “On-machine inspection is where the t Faro gage shines and it really helps us,” says Eric Wenger, owner h of o Express Manufacturing. Express Manufacturing says it will still “double M check” with its height gage during c operation, but the company is now o confident in a part before it takes it off c the t machine. This saves the company time, material and frustration. t RETURN ON INVESTMENT Express’ first introduction to the Faro technology was the result of a Faro trial program the manufacturer took part in. Called the FaroTechnology Test Drive, it enabled Express Manufacturing to evaluate the equipment on its own shop floor. With a minimal investment and no risk, Express was able to test the gage and prove out its return on investment (ROI) before purchase. “We did the trial and saw straight away the savings we could make in time and material,” Wenger notes. “The portability and accuracy are what we were looking for and what we needed.” Express also benefits by having a coordinate measuring machine (CMM) in its shop. The company has since reverse-engineered parts and has been able to verify the quality of parts it has made for years. In fact, it verified its measurements using the Faro Gage with a “very expensive” table CMM, and found no discrepancy at all. SAVING TIME AND MONEY The gage has improved Express’ process measuring time and the accuracy of parts before taking parts off the
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Inspecting parts directly on the machine producing them not only increases productivity, but also quality. Source: Faro Technologies Inc.
machine, which saves a significant amount of material cost. “The implementation was very easy, especially with the Test Drive program and training.” Wenger says. “We have better peace of mind now.”
Express Manufacturing’s goal to maintain high accuracy was hindered by the inherent difficulty of removing a part from a tooling machine while in-process. Source: Faro Technologies Inc.
According to Wenger, the gage turned a five-week job into a threeweek job. It saved approximately $15,000 in one year, a number Wenger says could double in easier economic times. “I project that Faro will save us
about $25,000 to $30,000 a year in a normal economy,” Wenger adds. Faro Technologies Inc. (800) 736-0234 www.faro.com
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Some vision dimensional metrology systems have streaming vision technology, which replaces conventional digital cameras and associated lighting with stroboscopic illumination, enabling a progressive scanning camera to capture images while the workpiece is in motion. Source: Mitutoyo America Corp.
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implemented. For example, there are CNC vision measuring systems capable of measuring radii, holes and other features with a total tolerance bandwidth of 0.5 micrometer. Interestingly, the pixel count of a vision metrology system’s digital camera is not a limiting factor because almost all the charged-coupled device (CCD) pixels are applied against the magnified image being scrutinized. This is in contrast to machine vision systems, which typically image fields of interest measured in square inches.
Measure with Vision Vision dimensional metrology can offer unique productivity enhancing opportunities. BY ALLEN J. CIUS
V
ision dimensional metrology should not be confused with machine vision. While both are based on image analysis, vision dimensional metrology systems generally are offline or near-line systems, collecting dimensional data points in 2-D or 3-D, analogous to those collected by coordinate measuring machines (CMMs). By contrast, machine vision systems generally are located in-line, snapping images of moving parts for real-time examination of features of interest.
TECHNOLOGY OVERVIEW Today, parts requiring dimensional measurement and inspection are becoming extremely small. Some, on the nanoscale, are built up from the molecular level. These parts are too small for measurement via conventional CMMs because contact probes typically cause enough displacement to prevent accurate results.
As applied, vision dimensional measurement systems image the features to be examined with a digital camera that is driven into position using computer numerical control (CNC) technology, operating much like a CMM. Applied in this way, the focal point of the objective lens is analogous to the center of the CMM’s stylus. A magnification level is determined, the workpiece is illuminated to optimize contrast and an appropriate lens train is selected. The feature of interest is programmed into the system using appropriate software tools such as edge detection or pattern detection. In some systems, auto-focus technologies that correlate depth of field to known Z-axis values can generate 3-D measurements. Because the workpiece view can be magnified to any power, there is virtually no lower limit to the size of features that can be measured, provided that the optics are properly
ILLUMINATION Workpiece illumination is crucial to the function of vision metrology tools. These tools rely on contrast to automatically find edges and light color to resolve color-based features. The three basic types of illumination include stage, through the lens (co-axial) and programmable ring. Stage lighting is simplest and performs much like lighting used in optical comparators. Coaxial lighting is directed to the workpiece through the optical train and is mainly used to illuminate a workpiece surface. Ring lighting is the most flexible. Some ring designs employ halogen/ fiber optic illumination; others use LEDs. For example, rings can make use of red, green and blue LEDs, mixing the colors to obtain white light. A choice of colors makes it easier to define edges and textures and to distinguish colored features. Color and intensity of light can be programmed by quadrant.
STREAMING VISION Streaming vision is a new technology that in certain applications can greatly impact the throughput of vision metrology. Streaming replaces conventional digital cameras and associated lighting with stroboscopic
Reprinted from Quality, Copyright October 2008
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2011
CASE STUDIES SPECIAL A DVERTISI N G SEC TI O N This Case Studies Special Advertising Section features manufacturing companies with real-world challenges using quality equipment, software and services to solve their problems and improve their processes. These problem-solving stories describe myriad manufacturing challenges and how the correct application of a supplier’s product or service made the difference, providing quantitative benefits to quality and manufacturing issues. The suppliers in this special section present these real-world problems and solutions to help Quality Magazine subscribers who may have similar experiences.
ADVERTISER CASE STUDY INDEX ADVERTISER
PAGE
CASE STUDY TITLE
Affri Testing Instruments
60
Automatic Hardness Tester for Determining Hardness of Stainless Steel Dye Plates
Bruker Nano Inc.
55
Precision Micro Metrology in Non-Contact Large Measurement Envelope
Creaform
51
Jig inspection made simple with the HandyPROBE Portable CMM
Cybermetrics Corp
52
For Terumo Medical, FaciliWorks 8i is just what the Doctor ordered
Gradient Lens Corporation
59
Borescope Assure the Quality of Mission Critical Aviation Parts
Hexagon Metrology Inc.
54
Measuring the Universe
Hommel- Etamic
57
Optical shaft inspection is H-O-G
Intelex
53
A Quality Management Success Story: Saving 23 Million
Mark 10 Corporation
57
180 Degree Peel Testing - Determining the seal strength in packaging
Micro-Vu
58
Multi-Sensor Machine Replaces CMM
Mitutoyo America Corp
56
Space Metal Fabricators and Mitutoyo America Collaborate on helicoper blade adjustment tool
Omnex Engineering & Mgmt
54
Bombardier Launches Risk management Program
Optical Gaging Prods
51
UK-Based High Tech Manufacturer Keeps Quality in Check with SmartScope
PQ Systems
53
Thermal Spray Technologies reduce inspection time with SQCpack
Qioptiq Linos Inc.
59
Increasing Metrology throughput without compromising quality
Starrett Company
56
Porsche Motorsport North America Improves Performance with Starrett Custom Ride Height Gage
50
TE-CO
55
TE-CO introduces its new CMM Fixturing Kits in Metric Sizes
Thermo Niton Analyzers Llc
60
Vegas Fastener Forges Quality Connection with XRF Analysis
Tinius Olsen Testing Mach Co
52
SAIT Students Learn How to Build Things by Breaking Them
Yxlon International
58
CT Solutions - Industrial Computed Tomography Systems
QUALITY | May 2011
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UK-Based High-Tech Manufacturer Keeps Quality in Check with SmartScope® Measurement System MTT Technologies Group (www.mtt-group.com)
bid (for a job), without the ZIP Lite our success
is a UK-based manufacturer of SLM machines.
was almost entirely down to luck.
SLM (Selective Laser Melting) is an additive
outset we knew we would only need one sale
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parts, using a laser to melt metal powders into
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MTT used manual methods or incurred addi-
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As a solution, MTT purchased a SmartScope®
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ZIP Lite 300 multisensor dimensional measure-
sales of MTT machines are growing, due in large
ment system from Optical Gaging Products
part to the addition of the SmartScope ZIP Lite.
(OGP®). According to Robin Weston, Group Marketing Manager, “Our new ZIP Lite measures points on a standard grid produced by an SLM to check for X-Y location variations. From
Sample fixture of SLM 3D metal parts on SmartScope® ZIP Lite 300 metrology system.
the results we see how much compensation to apply to each machine. This process ultimately achieves accuracy of 0.03 mm and better.” MTT sees its investment in the SmartScope ZIP Lite as money
Optical Gaging Products (OGP®) 850 Hudson Avenue | Rochester, NY 14621 585.544.0400 or 800.647.4243 | Fax 585.544.8092
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well spent. Adds Weston, “If we must make a very accurate part to
Jig inspection made simple with the HandyPROBE Portable CMM ronment (inspection had to take place at AGT’s plant). Creaform’s HandyPROBE arm-free optical CMM probing system stood out as the best choice among existing measuring technologies, mainly because it bypasses major limitations of conventional technologies: no leapfrog, no set-up realignment and no error accumulations. Toolmakers adjust a jig by hammering it so to insert or remove the stops. When using a traditional CMM system, such manipulations ruin the entire alignment and necessitate set-up realignment every single time. In this case, the HandyPROBE’s “Dynamic Referential” mode showed particularly useful, as it made it possible to move both the sensor and the part during the measuring process, without losing in precision or tracking. This feature was key to the project, as it allowed measurement of the jig even though it was under constant vibration, without any rigid set-up or interruptions in the measuring sessions. In the end, AGT succeeded in delivering manufacturing welding jigs that met the AGT, leader in the development and manufacturing of automated
expectations of their client.
industrial equipment, was to manufacture a welding jig for fabricated parts used in garbage trucks loading arms. Technically, the project aimed at measuring and adjusting the jig’s plan A, cylinder B and cylinder C and assessing the position of other parts on the jig. To carry out this project, AGT called upon Creaform’s metrology
Creaform
experts, who quickly agreed that the measuring system used would
www.creaform3d.com
basically need to do two things: continuously locate the part (as
[email protected] it could not be immobilized) and measure it in a vibrating envi-
T.: 1.302.444.6696
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May 2011 | QUALITY
51
2011 CASE STUDIES
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SAIT Students Learn How to Build Things by Breaking Them ing point. Such knowledge is critical in establishing and adhering to specifications when designing, engineering, and building structures. "Our students are really amazed how a destructive testing machine can make short work of a steel rod," notes Steve Paul, who heads the CVT laboratory at SAIT's School of Construction. "They watch as metal is stretched until it pulls apart with an audible pop. No such thing as indestructible." The new Super L is equipped with an extensometer and a computer control package so students can graph and analyze test results and determine strength of materials they are breaking. "This is a great machine to learn on," adds Wayne Hayward, Tinius Olsen's Marketing Manager. "Super Ls are high capacity testers and dramatically underscore that every material, when force is applied, has a breaking point." The program in Civil Engineering Technology (CVT) at SAIT Polytechnic (Calgary, Alberta, Canada) is rich with opportunities to learn about building materials. The school has invested in lab equipment so students can experiment with, and understand the property differences between the many materials used in construction, especially metals and concrete. Last fall, SAIT added a brand new 600 kN Super L materials tester from Tinius Olsen so students can perform strength and tensile testing of steel and cast iron samples. The new machine complements two other Tinius Olsen machines: a compression machine used for concrete testing and a horizontally-oriented torsion tester. SAIT’s goal is to help students see that every material and sample has its break-
Tinius Olsen 1065 Easton Road, Horsham, PA 19044 USA, (215) 675-7100 www.tiniusolsen.com or www.schooloftesting.com Wayne Hayward, Marketing Manager
[email protected] FOR TERUMO MEDICAL, FACILIWORKS 8i IS JUST WHAT THE DOCTOR ORDERED For more than 80 years, the
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ties at once. Paper records and electronic spreadsheets were time consuming and left far too much room for human error. Additionally, because of Terumo’s multiple locations, they needed a centralized software solution to control all assets, including but not limited to preventative maintenance and repairs.
52
QUALITY | May 2011
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Thermal Spray Technologies reduces inspection time with SQCpack Karen Hitchcock, Director of Quality Assurance at TST, has used SQCpack to analyze data related to incoming inspection and for specific quality related projects. The ease of charting from external sources has appealed to her, saving time and assuring accuracy in data transfer. Judy Crook, a quality assurance technician in Hitchcock’s department, uses SQCpack to collect visual and complex dimensional data on receiving inspections. “SQCpack enables us to track individual vendors’ performance and to more easily identify and quickly react to trends that could affect the high level of quality in coated parts that we provide to our customers,” she says. Crook estimates that as much as 50 percent of time spent inspecting product has been saved by using data cables to connect measuring equipment directly to the computer. She points out that “an inspection that used to take 45 minutes now takes only 22 minutes.” TST’s mission is, “Dedication of fully satisfying the needs of its customers by engineering, improving, and continuously providing high quality application-specific coatings and coated components.” When a company makes something that helps other organizations create high-quality products, it has a special understanding of the
Like TST, PQ Systems understands its role in helping other organizations demonstrate proof of their quality performance.
importance of quality in its operation. This is true of Thermal Spray Technologies (TST) (www.tst.coatings.com) of Sun Prairie, WI which develops its products for industries that range from food processing to electronics. TST uses SQCpack software from PQ Systems to track quality performance and reduce inspection time.
PQ Systems 800-777-3020
[email protected] www.pqsystems.com
A Quality Management Success Story: Saving 23 Million The Challenge When one of North America’s leading food manufacturers first approached Intelex, they were in search of a software solution that would improve their system for tracking and redistributing product placed on hold in their manufacturing and storage facilities. With a product line sensitive to expiration, any units not re-distributed efficiently must be discarded, resulting in lost production and revenue. Historically, standard email was used for communication, with Excel spreadsheets used to store and track data. The company required a more sophisticated tool to better connect all parties involved, streamline the process and decrease lost revenues. The Solution The web-based Intelex System provided the ideal solution to store all the organization’s data in one easily accessible location, track both internal and external product holds, and seamlessly foster a twoway avenue of communication between manufacturing and storage facilities. Intelex’s configurable iForm® tool was used to create an application that tracked the quantity, type, expiration and location of all product placed on hold and generate custom core reports and dashboards to easily manage the data.
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The Results With implementation and roll out to approximately 30 manufacturing facilities and 50 cold storage facilities taking place in a three-month period, a significant margin of savings was quickly realized as all product placed on hold was much more easily and efficiently tracked and re-distributed. With a first-year recorded savings of $13.1 million and a second-year savings of $9.8 million, in comparison to the email/ Excel method baseline, the Intelex solution cultivated an impressive $22.9 million in savings within two years of implementation.
For more information please contact JP Nadeau at
[email protected] or 416-599-6009 ext. 345.
May 2011 | QUALITY
53
2011 CASE STUDIES
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Measuring the Universe: When grinding mirrors for the largest ground-based telescope ever built, Cranfield University relies on Hexagon Metrology’s CMM brands ments, the optical tower measurement system uses a Leica Absolute Tracker AT901. The laser tracker system measures the positioning of the tower’s main optics, tracking any movement due to thermal effects. These movements can be several microns over such a large structure. Future developments will incorporate Leica Trackers with a robotic lapping system. The Cranfield team, assisted by Hexagon Metrology, is looking at a configuration using Fanuc 5-axis robots fitted with a smoothing spindle. One area of research is thermal stability and dimensional movement of robots over long periods of time. The investigation will also discover temperature shifts occurring on the robot during the lapping cycles. It’s an important investigation that adds significant value to the E-ELT mirror program. To build the European Extremely Large Telescope (E-ELT), 1,000 hexagonal mirrors 1.5m (4.92 feet) in length and 5cm (1.97 inches) thick are required. Each mirror needs to meet tolerances of 10 nanometers RMS for form accuracy and 1-2 nanometers RMS for surface roughness. Cranfield University, currently bidding to manufacture them, is tackling this challenge by utilizing the Leitz PMM-F 30.20.10. This Ultra High Accuracy (UHA) measuring system validates the initial grinding process. It also generates error surface maps to be used at an off-site facility where the mirrors are polished. Once polishing is complete, the mirrors are inspected using laser interferometry techniques. To insure accurate measure-
For more details, visit www.hexmet.us/qmcs511
Hexagon Metrology, Inc. North Kingstown, RI 800-274-9433
[email protected] www.HexagonMetrology.us
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TE-CO introduces its new CMM Fixturing Kits in Metric Sizes TE-CO recently introduced its new M8 thread sizes CMM fixturing kits and components. The comprehensive product line includes: fixture plates, locators, positioners, clamping components and accessories. This fixturing system allows users to quickly build fixturing for inspection applications using standard components saving time, money and storage space. Other products available from TE-CO include: tooling & inspection balls, tapped hole location gages & plastic clamp sets for inspection applications.
TE-CO 109 Quinter Farm Rd. Union, OH 45322 Phone: 800-543-4071 Fax: 937-832-1274 Website: www.te-co.com Email:
[email protected] Precision Micro Metrology in Non-Contact Large Measurement Envelope
Bruker NPFLEX™ 3D Surface Metrology System.
Bruker Vision64™ measuring glass substrate.
Have you ever wondered how quality measurements are attained on glass? Glafo, Glass Research Institute of Sweden (http://www. glafo.se), found that Bruker’s NPFLEX™ 3D Surface Metrology System provides the right combination of precision accuracy and size for their unique measurement needs. Though Glafo manufactures all sorts of glass substrates, their engineers have discovered that the NPFLEX provides the ideal solution when measuring surfaces that were not generally considered measureable, such as polished glass surfaces, which may also be large in size. Discussing the fl exible size and accuracy benefi ts of the NPFLEX,
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Glafo Research Engineer Christina Stålhandske said, “For us this is an important advantage as we can measure on full-size objects without destroying them. When analysing shaped glass surfaces, like decorative cuts, the long working range of the Linnik objectives is necessary.” Clearly, the NPFLEX provides the right fi t with its very unique interferometry-based optical profiling technology to measure challenging surfaces like highly polished glass surfaces very accurately. Along with the very demanding type of measurements outlined by Glafo, the NPFLEX’s interferometry-based optical profiling technology also provides unique measurement capability for lead angle measurements. The NPFLEX-LA model was developed to address some of the most challenging problems in measuring lead angles on components with quantifiable data. The NPFLEX-LA provides reliable and repeatable measurement of complex geometry and surface topography, both more rapidly and more repeatably than was possible with previous methods. Bruker Nano Surfaces Division 2650 E. Elvira Rd. Tucson, AZ 85756 520-741-1044 www.bruker-axs.com
[email protected] May 2011 | QUALITY
55
2011 CASE STUDIES
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Space Metal Fabricators and Mitutoyo America Collaborate on helicopter blade adjustment tool
FIGURE 1.
FIGURE 2.
Space Metal Fabricators of Columbia, South Carolina, and Mitutoyo America Corporation have jointly developed a tool to help helicopters fly smoother. While flying, helicopters generally experience a low frequency vibration in the main rotor blades. This is due, in part, to slight differences in each blade’s aerodynamics. These vibrations are not likely to cause structural damage but may adversely affect electronics; they also absorb power. To dampen vibration, some main rotors incorporate trim tabs located on the blades’ trailing edges which can be adjusted to keep blades rotating smoothly. Some systems incorporate electronic, inflight rotor track-and-balance systems that provide information used to adjust the pitch of the tabs. Specialized tools then are used to physically bend the tabs. Besides in-flight indication, tab adjustment may result from preventive maintenance routines. Due to the frequency of these adjustments, a helicopter operator asked Space Metals to develop a tool to improve productivity of the procedure. According to Keith Berry,
Senior Engineer, Space Metal Fabricators, “We developed a trim tab bender tool consisting of three components: a measuring device utilizing a custom-built Mitutoyo dial indicator, a tab bender and a gage plate. In operation, the device is mounted to the gage plate for calibration to zero. Next the zeroed-out tool is mounted to the rotor blade. (See Fig. 1) Then, the tab bender is used to set the correct trim as expressed by the dial indicator measuring displacement in degrees.” Commenting on the indicator design, Pat Harkness, Product Specialist, Mitutoyo America, said, “The indicator’s zerosetting needed to be the mid-point from which the tab would be displaced in either a positive or negative direction. So we designed a gear ratio to match expected displacement – in either direction – plus an indicator face marked in ± degrees. (See Fig. 2) Keith Berry, Senior Engineer Space Metal Fabricators, Inc. 8523 Wilson Boulevard Columbia, SC 29203 Phone: (803)786-0048
[email protected] www.spacemetals.com Mark T. Izumi, Advertising and Promotions Manager Mitutoyo America Corporation 965 Corporate Boulevard Aurora, IL 60502 Phone: (630) 820-9666 Fax: (630) 978-5394
[email protected] www.mitutoyo.com
Porsche Motorsport North America Improves Performance with Starrett Custom Ride Height Gage Controlling race car height is one of the strictest rules in racing.
Porsche also utilizes the Gage’s output
Cars must be as
capability to transmit gage readings to
low to the surface of the track as possible to
their computer systems with the Starrett
achieve the best performance – dialing in the
DataSure Wireless Data Collection System.
proper ride height can mean the difference
DataSure provides Porsche with real-time,
between winning and losing.
error-free data collection to quickly analyze
Setting the optimal ride height level within
ride height data and make adjustments.
the rules requires the right tool. Porsche
With Starrett’s innovative, custom-engi-
Motorsport North America Racing turned to
neered gage, Porsche Motorsports has bet-
L.S. Starrett to develop a custom-engineered Ride Height Gage that provides easier, more precise measurement
ter accuracy, repeatability and traceability. Seems winning races just got a little easier.
before and after the race. Porsche uses the Starrett gage under the race car to measure from the surface where the tire sets up to buttons built into the chassis of the car. It is unique in that it offers two measuring units easily swapped out by hand as needed – faster, simpler and more accurate than competitors’ gages. Compared to other gages, it has a stiffer measuring axis, hardened surfaces and easy adjustment to measure width at different inspection points. In the American Le Mans Series, the race cars go rain or shine. Porsches’ previous gages produced readout errors or total shutdown at inspection in wet conditions. The new Starrett gage operates flaw-
Mike Sawin Engineering Manager, Starrett Special Gage Division The L.S. Starrett Company 121 Crescent St. Athol, MA 01331 978-249-3551
[email protected] lessly in all weather conditions.
56
QUALITY | May 2011
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Optical shaft inspection is a H-O-G “We measure diameters to 4 microns with a gage R&R of 5%,” reports Clay. “You can’t touch that anywhere.” Hommel-Etamic’s Opticline noncontact CNC shaft gaging system measures form, dimensional, and positional tolerances of shaft-type parts in submicron detail with a maintenance-free two-camera system, recording results instantly. “With air gaging or hard gaging, there is a lot of setup and timeconsuming changeover, but with the Opticline,” Clay said, “I can change programs in about 15 seconds and be ready for the new part number. Flexible chucking helps also.” To create a program, Clay scans the part with the Opticline cameras, establishes a length of scan, and then starts a measurement cycle. “To accomplish the shaft measurements with air gages or ring gages, you would have multiple gages, which require setup, mastering, and maintenance. This adds up to greater cost over 3-4 shaft designs with a couple of sizes of each,” Clay said. The family of turbocharger shafts produced at Cummins Turbo Technologies, Palmetto, SC, have up to 11 diameters and various lengths—a complex part to inspect consistently and at rates that keep up with production. But Clayton Butler, metrology technician has a solution that has been working on the Cummins shop floor alongside the grinding machines for several years. He calls it his HOG -- the Hommel Optical Gage. Machine operators use the Opticline from Hommel-Etamic America to measure a shaft and turbine impeller wheel assembly for the turbochargers it produces-- diameter, runout, straightness, length. The staff also uses the gage on the shop floor alongside the grinders to measure an impeller mounted on an arbor. Each part is measured between centers in less than a minute.
Hommel-Etamic America 1505 West Hamlin Rd., Rochester Hills, MI 48309 Tel. 1-248-853-5888 www.hommel-etamic.com Email
[email protected] 180 Degree Peel Testing - Determining the seal strength in packaging The amount of force required to open a bag of
this test is consistent test speed, the ESM301’s
pretzels or candy isn’t typically first and foremost
programmable speed ensures that the rate of peel
in our minds. Opening a package of snack foods
is consistent.
is normally a mundane affair – unless the pack-
An adjustable upper grip is attached to the
age is too difficult or too easy to open. That’s
force gauge, pulling the material upwards, while
when it becomes more obvious that proper test-
the lower grip remains stationary. The force gauge
ing is critical to achieving customer satisfaction.
records the maximum breaking strength. Then the
The testing of sealed pouches for such items
test stand’s crosshead reaches a limit switch and
as snack foods, medical devices, and consumer
returns automatically to the home position. The
products is often done to conform to ASTM D903
force gauge transmits data to a PC for further analy-
and ASTM F88. These procedures call for a 1”
sis in MESURgauge software. Anomalies in peel
wide strip of material to be pulled apart at the
force consistency can be viewed on a graph. Upper
seal at an orientation of 180 degrees. A constant
and lower acceptable force limits are determined
rate of speed, typically 6” or 12” per minute, is
by the manufacturer, allowing for quick identifica-
required. The end result is a force measurement
tion of failures.
value, typically in Newtons or pounds. One manufacturer of snack foods has been
By Mark Fridman, Marketing Manager
performing such testing with their Mark-10 force
[email protected] testing system, consisting of a model ESM301
Toll Free: 888-MARK-TEN
motorized test stand with digital force gauge and
Tel: 631-842-9200
pair of film & paper grips to secure each end
Fax: 631-842-9201
of the material. Since an important element of
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May 2011 | QUALITY
57
2011 CASE STUDIES
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CT SOLUTIONS - INDUSTRIAL COMPUTED TOMOGRAPHY SYSTEMS
Non-destructive testing with Computed Tomography (CT) systems
solutions for the inspection of tires and wheels. Based on our experi-
offers new possibilities to meet increasing quality demands in many
ence we can also offer special solutions for your CT inspection task.
areas of industrial production. Using Computed Tomography systems flaws can be simultaneously detected and located in almost any
In our application labs you have the possibility to use our CT systems and our know-how for application services.
material – without destroying the object. The measurement of the internal and external geometry is likewise precisely done by indus-
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sal usage or for the inspection of standing items as well as special
Multi-Sensor Machine Replaces CMM To meet the needs of new medical customers and to stay ahead of competition, a precision plastic injection company in Santa Rosa, CA searched for a multi-sensor inspection system. They needed to measure smaller features, reduce programming time, reduce measurement time, and improve operator/programmer easeof-use compared to their CMM. The company selected the Micro-Vu Vertex 320 vision system with a 4-station touch probe kit and a 12"x12"x6" measurement capacity. The company retired its CMM within months. The company's metrologist began programming parts using Micro-Vu's InSpec Metrology Software during the first demonstration. Small holes, angles, gaps, and steps are programmed and measured in seconds. Previous "operators" become "programmers" with InSpec's point-and-click programming. Parts from multiple mold cavities are measured in a single inspection program and setup. While the Vertex measures multiple pieces, the operator completes other quality/inspection tasks. When the inspection program is complete, the operator can quickly review toleranced and exported features in a summary window. If needed, the operator can edit tools from the multi-capture cache of images.
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QUALITY | May 2011
Tools can be reviewed and edited even after parts have been removed from the stage. When the company expanded, it purchased a second Vertex. InSpec's lighting calibration ensures that programs from one machine can run on another. Also, the system price with the 2-port touch probe kit, didn't require a VP's signature. Micro-Vu Corporation was established in 1959 and is a leading manufacturer of optical comparators, video systems, and multi-sensor measurement systems. Micro-Vu machines are designed, manufactured, and assembled in the United States.
Micro-Vu Corporation http://www.microvu.com
[email protected] 707-838-6272
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Increasing Metrology throughput without compromising quality
Within the custom manufacturing industry each job presents new challenges and every application requires special attention to detail. There does seem to remain one constant however… “Deliver highest quality parts at lowest possible cost”. To achieve this goal, companies continue to develop their metrology capabilities looking to achieve faster inspections without sacrificing the quality assurances delivered to their customers. Vision-based measuring systems are a key component in achieving quality-control productivity as vision-based systems typically surpass contact metrology alternatives in speed and throughput, while maintaining precision and capturing comprehensive data. Additionally, vision metrology systems eliminate potential part damage from contact inspection. The new Fetura® Vision Metrology Systems from Qioptiq represent a vanguard approach to optical measurement, combining years of optomechanical expertise with cutting-edge software and robust mechanics to deliver unparalleled productivity, flexibility, and precision. At the heart of the system is the market’s fastest and most precise zoom imaging lens technology. Nearly 10-times faster than conventional zoom lenses across a 12.5X optical zoom range, Fetura images from low to high magnification in less than 1-second (approaching that of digital zoom speeds). This important feature affords users the ability to perform critical quality inspections in shorter cycle times with greater
operational savings… a value they can pass on to their customers. In one particular case, a customer required 100% parts inspection of a high-volume medical components process. Metrology speed and accuracy gains were a necessity in achieving maximum throughput and ultimately greater quality and net productivity. The Fetura System’s imaging agility and high-speed mechanics, combined with multi-part fixturing readily achieved the customer’s aggressive inspection throughput and productivity goals. In this case, each individual component required measurements to be taken at multiple magnifications. With the Fetura’s unmatched imaging speed, the customer reduced their inspection time for each lot by more than 8 minutes. This translated to 33% more parts inspected per shift and ultimately more than $31,000 projected savings in the first year of production in inspection costs alone. This increased speed at inspection also means savings across the complete manufacturing process. In addition to its unmatched speed, the unique design of the Fetura’s imaging lens enables it to maintain optomechanical precision over 1 million zoom cycles with virtually zero performance degradation. This means prolonged and consistent precision and accuracy over the extreme rigors of a high-volume inspection application like the medical components case cited above, without the need for recalibration and uncertain software compensations. The Fetura Vision Metrology System is a robust measurement workhorse that meets the needs of demanding global manufacturing markets. The Fetura Vision Metrology Systems offer an alternative in the metrology industry that is measurably different. Article and images by: Thomas Goundry Metrology Product Manager Qioptiq, Inc. www.qioptiq.com 585-223-2370
Borescopes Assure the Quality of Mission Critical Aviation Parts tion. Hartzell Propeller exclusively uses Hawkeye Precision Borescopes, manufactured by Gradient Lens Corporation of Rochester, NY. Hartzell uses Hawkeye borescopes exclusively because they are easily portable, dependable, accurate, and very cost-efficient. Because the company’s manufacturing and service operations are in multiple facilities, Hawkeye borescope systems can easily be moved from building to building as needed. Hartzell primarily use rigid borescopes, 7 to 22-inches in length, with a 0º direction-of-view (DOV). The Hawkeye’s can easily be changed to a 90º DOV by adding a mirror tube accessory. Hartzell also connects some borescopes to video systems for on-screen viewing and image capturing. When the entry Serving private, commercial, and military customers, Hartzell
path is not straight, Gradient Lens also carries a full line of flexible,
Propeller is one of America’s oldest aviation manufacturers. From
articulating borescopes, including fully portable video borescopes.
constant speed propellers, to governors, and deicing systems for propellers, Hartzell manufactures over 18,000 mission-critical parts and systems used on over 2,000 makes and models of aircraft. For products where contamination, dirt, or, surface finish defects
Gradient Lens Corporation www.gradientlens.com
[email protected] 800-536-0790
could be a concern, Hartzell primarily uses visual inspection to verify that the product is acceptable. In tight locations to inspect such as small bores and blind holes, they rely on borescopes to conduct visual inspec-
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May 2011 | QUALITY
59
2011 CASE STUDIES
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Vegas Fastener Forges Quality Connection with XRF Analysis With decades of experience in the special-
critical-use alloy materials won’t be sub-
ty fastener business, Las Vegas, Nevada-
ject to premature or catastrophic failure.
based Vegas Fastener Manufacturing
Using the handheld x-ray fluorescence
(VFM) specializes in the hot forging of
(XRF) analyzers, VFM could confidently
high-temperature and corrosion-resistant
verify alloy grades, fulfill customer require-
alloys for the manufacture of bolts, nuts,
ments for positive material identification
screws, sockets, and studs. They serve
(PMI) testing, and add a powerful, easy-to-
industries worldwide, including aerospace,
use tool to their quality program.
power generation, military, marine, con-
“Customers have a greater confidence
struction, transportation, mining, environ-
in our manufacturing process, which many
mental, bulk paper, food processing, and
have come in and audited. The Niton XL3t
petrochemical applications.
analyzer is a critical part of that,” con-
Vic Scheuplein, VFM quality manager,
cludes Scheuplein. “It’s very reliable, very
notes, “Our fasteners are used in critical,
user friendly, and it’s so day-to-day that we
often life-and-death applications, and we
don’t really even think about it as a special
need to ensure that the incoming raw
piece of equipment anymore…that’s how
material and the resulting outgoing product
good the device is.”
meet the expected composition analysis. It’s a double-check system.” Toward this end, VFM bought a Thermo Scientific Niton XLt 898 alloy analyzer, followed by two Niton® XL3t alloy analyzers. Alloy grade and quality control testing with Niton XL3t analyzers typically take 1 to 2 seconds, with lab-quality elemental analysis requiring only a few seconds longer for more precise results – helping ensure that
Thermo Scientific Niton Analyzers 900 Middlesex Turnpike • Building 8 • Billerica, MA 01821 +1 978-670-7460 • Fax: +1 978-670-7430 niton@thermofisher.com • www.thermoscientific.com/niton
Automatic Hardness Tester for Determining Hardness of Stainless Steel Dye Plates dye from above until it reaches the surface, then clamping the dye and penetrating through its surface. The material has the tendency to bend while being penetrated. Affri Inc. adopted a very technically advanced
system that provided
absolute and accurate measurements regardless of surface conditions, including the bending from the material. In addition, this solution can also be applied to composite materials. The measurement is always perfect even if the plate reflexes during the test. The gage R & R results are more than satisfactory at 8%, best results of any hardness tester. In addition, due to the fact the plate is not always balanced, Affri to The customer had a need to test metal printing dye plates 40” X 40” and a thickness of 0.1 to 3mm. The die plates are used to print money and stamps. This presented a major challenge, to test the dyes without destroying or comprising their integrity. Affri Inc. designed and installed a hardness tester for automatically measuring hardness HRB, HRN, HRT, to satisfy this need and at the same time making it simple to operate. Affri Inc. designed the system to initiate the analysis with just one remote control command. The measurement head approaches the
60
QUALITY | May 2011
design a support system made from polyethylene material, to protect it from the scratching the plate engravings. The preload and load is controlled by the latest generation of Affri closed loop load cell system. Only Affri Inc. can offer this type of technical superiority over other closed loop cell systems. The entire system is not affected by vibrations or adverse working environments. For more information; www.affri.com Email
[email protected] Affri Inc. 170 N Brandon Drive. Glendale Heights, IL 60139 Tel: 224-374-0931
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SHOWCASE This Quality Showcase section brings you information on new products and services available through print and online. To receive more information about the the products and services in this section, visit Quality Quick Clicks online at www.qualitymag.com.
MEYER GAGE ANNOUNCES FIXED LIMIT GAGE CALIBRATION SERVICES South Windsor, CT - 2011 Meyer Gage Company Inc., has just completed a new calibration and final inspection laboratory. The new laboratory will allow for more precise temperature and humidity control resulting in lower measurement uncertainty. The laboratory is 20' x 44' and includes Calibration Laboratory a custom designed HVAC system with microprocessor for precise automatic environmental control. Services provided include calibration of pin, plug, ring, trilock and taperlock gages.
For Complete Details Contact MEYER GAGE COMPANY INC. 230 Burnham Street, South Windsor, CT 06074 Phone (860) 528-6526 Fax (860) 528-1428
FULL SERVICE DIMENSIONAL MEASUREMENT LAB For Your Product’s Perfection
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Since 1987
Q-PLUS Labs • Irvine, CA www.qpluslabs.com Tel: (949) 380-7758 • Fax: (949) 380-7790
62
QUALITY | May 2011
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CALIBRATION SERVICES Hexagon Metrology’s Universal Calibration Services is your one-stop shop for on-site calibrations, no matter what you need to calibrate. Competitive rates, nationwide ISO 17025 certified for: • All brands of CMM • Machining Centers • Boring Mills • Turning Centers • Rotary Tables • Surface Plates
Hexagon Universal Calibration Services www.HexMet.us/qshucs 248-449-9508
CUSTOM GAGE APPLICATIONS • Fast and Accurate • Simplified Dimensional Control for in-process or post-process inspection of lengths, depths, diameters, position of slots or shoulders and angle of taper (male or female) • Mechanical or Electronic Indicators • Bench top or Hand Held • Quick Change and Interchangeable • Standard Gages or Customer Designs
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You can balloon drawings/models and simultaneously create the corresponding inspection sheets. Customizable for various customer/internal formats. DISCUS Software Company 829 Bethel Rd Columbus, OH 43214 (614) 360-2424 www.DISCUSsoftware.com
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Stop looking. We have what you need! Any bulb. Any purpose. Replacement lamps for all makes of optical comparators, microscopes, inspection equipment, fiber-optic light sources and other precision instruments. Fluorescent, incandescent, LEDs, mercury arc, metal halide, miniatures, quartz halogen, xenon, and miniatures. Sockets and lamp holders for all lamp types.
Dimensional Inspection Statistical Process Control First Piece/Multiple Lots
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QUALITY | May 2011
download to your computer or listen to directly from Quality Magazine’s Web site.
11/10/09 10:05:36 AM
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QUALITY
PRODUCTS THE LATEST PRODUCTS TO HELP YOU IMPROVE YOUR MANUFACTURING PROCESS
DIGITAL COATING THICKNESS GAGE The Elcometer 456 sets measure dry film thickness on ferrous and nonferrous metal substrates. It has a 2.4-inch color display; memory capacity up to 75,000 readings in alphanumeric batches; measurement capability to ±1% on smooth, rough, thin and curved surfaces; and measuring speed of more than 70 readings per minute. ELCOMETER (248) 650-0500 WWW.ELCOMETER456.COM
DIAGNOSTIC TOOL KIT
The I-360 2011 model is the newest iteration of both the wireless and the probe and scanning versions of the I-360, which is a 300 degree laser tracker for part measurement. It is easier to use and more comfortable to hold than previous models. It is made more identifiable by its bright red color. The updated I-360 2011 suite of product offerings has probe-only, scanner-only, probe/ scanner and wireless probe versions.
The HPX1 Diagnostic Tool Kit is a kit that allows operators to check parameters of their HPX 1 nondestructive testing system calibration against factory specifications within minutes. It can ensure optimum performance, give objective, automated analysis, store and review previous tests, give proof of system calibration and reduce risk and guesswork. The new HPX 1 Small and irregular Plate Carrier can run small and/or irregular plates on a HPX 1 system annd accepts any shape as long as they fit within the carrier area.
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The VP5200 in-line, 3-D solder paste inspection system uses the phase shift method to measure height. Program generation takes less than 10 minutes, and it has one-touch operation through touch panel control. It has accuracy and repeatability for height inspection within 1 μm and volume inspection within 3%. It has horizontal resolution of 15 μm or 25 μm. Omron
The Series 3 digital force gages are designed for tension and compression force testing in quality control, manufacturing and research and design areas. They are available from 0.12 pound to 500 pounds to address applications in medical device, pharmaceutical, packaging, consumer products, automotive and aerospace industries. Accuracy is better than +/-0.3% of full scale. The force gauges have a sampling rate of 2,000 hertz and backlit graphic display.
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GAGING SYSTEM The Equator gaging system is an alternative to traditional dedicated gaging. It is a high-speed comparative gaging for inspection of high-volume manufactured parts. It has been developed for the automotive, aerospace and medical sectors. It can be programmed for multiple parts and reprogrammed in minutes for design changes. It can switch between parts in seconds and allows high-speed scanning and rapid moves between features, while retaining stiffness. It has the Renishaw SP25 compact scanning probe to allow thousands of data points to be taken to define a feature for true form analysis. It can be used in wide temperature variations. RENISHAW INC. (847) 286-9953 WWW.RENISHAW.COM
DATA ACQUISITION SYSTEM The DynoLAB PT data acquisition and control system integrates external devices, including dynamometers, throttle actuators, spark and fuel controllers, combustion analysis systems, emission analyzers and other input/output devices into one test system. It was designed as part of a turnkey test cell control system for engine, powertrain and component testing. SAKOR TECHNOLOGIES INC. (517) 332-7256 WWW.SAKOR.COM
Snap Gages Customizable To Meet Your Application Needs Fast, precision OD measurement on the shop floor Readout options include dial / digital indicators and transducers for highest sensitivity Easy to adjust while still maintaining contact parallelism - ensures high performance Available for fast delivery
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PRODUCTS DIGITAL INDICATORS The most recent μMaxμm line of digital indicators has new features including two point difference measurement; multiplier factor for ratio measurements; indicator serial number identification; resolution to 10 μin; selectable continuous output; and longer battery life. Two point difference measurements allows comparison of different readings or calculation of measured values. The addition of multiple factors for ratio measurements allows chordal-type measurements for making inside diameter/outside diameter measurements using a V plate, or for gage fixtures using lever-type nondirect contacts. MAHR FEDERAL INC. • (401) 784-3275 • WWW.MAHRFEDERAL.COM
3-D INSPECTION SOFTWARE GOM Inspect allows operators to import scan data from various types of measuring systems with point cloud and inspection functionalities. It handles mesh processing such as polygonizeing points to meshes, smoothing, thinning, hole filling, data refinement and extracting curvature lines from meshes. It has inspection-CAD import, alignments, comparisons, CAD-based primitive generation, 2-D section analysis, geometric dimensioning and tolerance analysis, reporting and other inspection features. CAPTURE 3D • (714) 546-7278 • WWW.CAPTURE3D.COM
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DIFFERENTIAL MEASURING SYSTEMS The KD-5100 differential impedance position/displacement measuring systems detect the position of a conductive target relative to a pair of noncontacting sensors. Two sensors per channel give resolution to a nanometer, and measures without contacting the target. The inductive eddy current technology on which these sensors are built is unaffected by radiation and environmental contaminants. Output is differential and bipolar. KAMAN (800) 552-6267 WWW.KAMANSENSORS.COM
OPTICAL SENSOR SYSTEM The SHSLab BR-110-GE-STD gives characterization of optical components and lasers in research and quality assurance. It measures curved wavefronts in real-time and with high stability. Its sensor head SHSCam BR-110-GE also can be used for partially coherent light sources such as LEDs. The sensor head delivers a lateral resolution of 58 by 43 micro lenses and is based on a camera with 12-bit gray scale. QIOPTIQ (800) 429-0257 WWW.QIOPTIQ.COM
METROLOGY SOFTWARE Map DCM 3D software quantifies features of measured surfaces and characterizes surface texture. It is part of the Leica Application Suite for use with the company’s industrial microscopes. Surface topography can be viewed at any zoom level and any angle in real time. Color and intensity image overlays facilitate the location of surface features, including defects. One also can measure distances, angles and step heights. LEICA GEOSYSTEMS-METROLOGY (800) 955-5200 METROLOGY.LEICA-GEOSYSTEMS.COM
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May 2011 | QUALITY
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PRODUCTS PROCESS MONITOR The sigPOD 1200 series renders the monitor suitable for harsh manufacturing environments without the use of an enclosure. The sigPOD 1202 and 1204, for two- and four-channel applications, now has a 40 gigabyte
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ADVERTISING INDEX ADVERTISER
PAGE
A.G. Davis Gage & Engineering
28
www.agdavis.com
40, 41, 42
www.affri.com
Bal-Tec
23
www.precisionballs.com
Bruker Nano Inc.
17
www.bruker-axs.com
Carl Zeiss Industrial Metrology
39
www.zeiss.com/metrology
Affri Testing Instruments
155 N. Pfingsten Rd., Suite 205 Deerfield, IL 60015
GROUP PUBLISHER
Darrell Dal Pozzo (847) 405-4044
[email protected] REGIONAL MARKETING NEW ENGLAND AND MID-ATLANTIC
Barbara Grim 1288 Centerton Rd. Pittsgrove, NJ 08318 Phone: (856) 358-4800 FAX: (856) 358-0900
[email protected] CENTRAL AND SOUTHEAST
Bill DeYoe 109 Willow Springs Trail Mt. Holly, NC 28120 Phone: (704) 822-6434 FAX: (704) 822-6834
[email protected] WEB SITE
Creaform
70
www.creaform3d.com
Cybermetrics Corp.
BC
www.cybermetrics.com
DeFelsko Corp.
46
www.defelsko.com
Deltronic Corp.
12
www.deltronic.com
Dorsey Metrology International
21
www.dorseymetrology.com
Gagemaker Inc.
30
www.gagemaker.com/quality
Gradient Lens Corp.
27
www.gradientlens.com
Helmel Engineering Products Inc.
69
www.helmel.com
Hexagon Metrology Inc.
31
www.hexmet.us
5
www.hommel-etamic.com
14
www.imada.com
10
www.intelex.com/quality
Hommel-Etamic Imada Intelex Mahr Federal Inc. Mark 10 Corp.
1, 15, 30, 67
www.mahr.com
7
www.mark-10.com
Micro-Vu
47
www.microvu.com
Mitutoyo America Corp.
IFC
www.mitutoyo.com
Olympus NDT
35
www.olympus.ims.com
Omnex Engineering & Mgmt
70
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Optical Gaging Products
29
www.ogpnet.com
Origin Technologies Corp.
34
www.origintech.com
PQ Systems
69
www.sqcpack.com
Qioptiq Linos Inc.
66
www.qioptiq.com
Ram Optical Instrumentation
23
www.ramoptical.com
Renishaw
11
www.renishaw.com
Resec Systems Inc.
68
www.resecsystems.com
MIDWEST, SOUTHWEST,
S-T Industries Inc.
WEST AND NORTHWEST
Sino Age Development Technology
9
www.stindustries.com
14
www.sadt.com.cn
3, 19, 49
www.starrett.com www.srtorque.com
Buck Bicek
Starrett Co., The L.S.
5820 Middaugh Ave.
Sturtevant Richmont
68
TE-CO
67
www.te-co.com
Thermo Niton Analyzers LLC
37
www.thermoscientific.com
Tinius Olsen Testing Mach Co.
70
www.tiniusolsen.com
United Testing
67
www.unitedtesting.com
Webster Instrument Inc.
11
www.webstertesters.com
Western Gage Corp.
68
www.westerngage.com
Yxlon International
13
www.yxlon.com
Downers Grove, IL 60516 Phone: (630) 971-0904 FAX: (248) 502-1086
[email protected] INSIDE SALES INSIDE SALES MANAGER
This index is provided as a reader service. The publisher assumes no liability for errors or omissions.
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[email protected] 72
QUALITY | May 2011
QUALITY (ISSN 0360-9936) is published 13 times annually, monthly except semi monthly in November, by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $178.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $216.00 USD (includes GST & postage); all other countries: $228.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: QUALITY, P.O. Box 2145, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to QUALITY, P.O. Box 2145, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or
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VISION & SENSORS
TA B L E O F C O N T E N T S
May 2011 12VS
DEPARTMENTS 4VS Editor’s Note
Finding Your Own Custom Solution 6VS Industry News 8VS Integration Corner
Successful Machine Vision Integration 10VS Machine Vision 101
Edge Detection 23VS Case Study
Sensing in Space 24VS Advertising Index 25VS Products IN THE NEXT ISSUE COLOR ANALYSIS
Digital Cameras
12VS MACHINE VISION IN COLOR Color analysis tools offer the accuracy, robustness, flexibility and speed to tackle color applications with confidence.
3-D Imaging Sensor Components
GIGE
16VS THE FUTURE OF 10 GIGE
ABOUT THE COVER
Why 10 GigE should drive your next quality inspection system design. May 2011
www.visionsensorsmag.com
INTEGRATION
20VS INTEGRATION QUESTIONS ANSWERED Managing change as it happens is the most critical skill that an integrator can have.
To o l s f o r C o l o r A n a l y s i s p. 12 V S | T h e F u t u r e o f 1 0 G i g E p. 16 V S
S System integration aalmost always involves ppulling together dispparate products, technnologies, some offtthe-shelf and some hhome-grown. Source: AAptúra Machine VVision Solutions
VISIT VISION & SENSORS ONLINE AT
www.visionsensorsmag.com
10 Truths About Smart Cameras
2VS
VISION & SENSORS | May 2011
www.visionsensorsmag.com
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Teledyne DALSA delivers imaging technology solutions that simplify application development, facilitate system deployment and increase yield. Like the BOA smart camera; with color or monochrome models, on–board processing and application tools such as verification and identification, BOA ensures quality control and increased productivity.
Get more vision. Download our latest customer story: BOA delivers 100% quality inspection www.teledynedalsa.com/boa/may/vs2011
*DALSA is now Teledyne DALSA.
VISION & SENSORS
FROM THE EDITOR
Finding Your Own
Custom Solution In March, I had the opportunity to attend Automate 2011 at the McCormick Place in Chicago, which several of you may know as the former International Robots, Vision & Motion Control Show. I was curious to see how the turnout would be since it was the first time this was being done with a new name and venue. In addition, the show was bumped up from June to March, which are two completely different seasons in Chicago— winter and summer. With that said, I was not disappointed. Upon entrance to the trade show floor, I was met by a pavilion of more than 20 system integrators who were demonstrating solutions for a number of industries to help improve productivity, quality and profits. The reasoning behind this, according to Jeffrey A A. Burnstein, president of Automation Technologies Council (ATC, Ann Arbor, MI), was so that visitors could see the solutions first. After visitors had a chance to see how everything worked, they could go meet with exhibitors that were showcasing the latest in products and technologies and find solutions for their own custom applications. During the show, I ran into our editorial advisory board member, David Dechow, president of Aptura Machine Vision Solutions (Lansing, MI), who was there to teach a couple of tutorials on machine vision solutions. He also was impressed with the attendance numbers and May 2011
hoped that this indicated a sign of movement in the industry and economy in general. According to Burnstein, this was the largest turnout in a decade for AIA. “The show conference sessions were the best I have ever seen. The wide variety of course offerings was impressive, and from my unofficial estimation, attendance was the best since the mid-90s—at least for my tutorials,” says Dechow. Dechow adds that the demonstrations of the brand-new CameraLinkHS and CoaXpress camera interfaces were standouts for d f him. Component offerings in machine vision seemed to be somewhat dominated by camera and sensor offerings, though there were some interesting recently new smart/ hybrid camera products from a couple of vendors. I also noticed a significant offering of lighting solutions from several companies for image processing applications. These booths were definitely not hard to miss with the constant strobe of red, white, green and blue. Just in case you missed the
www.visionsensorsmag.com
To o l s f o r C o l o r A n a l y s i s p. 1 4 V S | T h e F u t u r e o f 1 0 G i g E p. 1 6 V S
keynote presentation from General Motors and NASA at Automate where they discussed the research involved in developing the first human-like robot for space, we are featuring a case study on this humanoid robot that was recently delivered to the International Space Station (ISS) in February. See page 23VS for the full story. This was the final mission for the Discovery space shuttle as a six-member crew safely completed the task of delivering Robonaut 2. Inline with the theme from Automate, our cover story is on integration where we catch up with Ned Lecky, president of Lecky Integration (Little Falls, NY) and also our in-house columnist and member of the Vision & Sensors editorial advisory board, who has been busy on the road these past few months. Lecky talks about the selection process when considering a system integrator, as well as the critical skills that are necessary if one is to be successful. Read excerpts from the interview on page 20VS and be sure to go to www.visionsensorsmag.com to read the interview in its entirety.
Kari O’Rourke, Managing Editor
Vision & Sensors Editorial Advisory Board David Dechow Aptura Machine Vision Solutions
4VS
VISION & SENSORS | May 2011
Ned Lecky Lecky Integration
Perry West Automated Vision Systems Inc.
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VISION & SENSORS
NEWS
Kistler Announces Construction of U.S. Technical Center FARMINGTON HILLS, MI—Kistler, a worldwide supplier of precision sensors, systems and instrumentation for engine, chassis and vehicle development, as well as vehicle component manufacturing systems, announced that construction is underway for a new North American Technical Center in Novi, MI, to complement the existing sales support and manufacturing activities of its Amherst, NY-based corporate headquarters. With an official groundbreaking last November, the Kistler North America Technical Center is planned to be a 20,000-square foot sales and support entity, designed to provide customers in the Detroit corridor with fully dedicated onsite product sales, service and applications engineering expertise, as well as calibration services that are A2LA accredited to the ISO 17025 standard. Construction is expected to be completed in September 2011. Notes Kistler North American Managing Director, Nick Wilks, “A growing demand for Kistler products within the North American automotive sector has led to the decision for our new Detroit-area technical support facility. The combination of our recently acquired new product technologies, combined with the long time strength of our brand and product portfolio, allow us to now offer a number of state-of-the-art measurement capabilities that are not available outside of Kistler group companies. In parallel to our plan to further invest in the success of our Detroit-area customers, Kistler also is further expanding our Buffalo, NY-area manufacturing facility. We look forward to providing continued updates on these developments in the months ahead.” In addition to supporting the measurement technologies of Kistler North America, the new Detroit-area facility will house both the recently acquired KT North America, a manufacturer of on-board, off-board and in-dummy data acquisition systems and software for legislative and safety testing applications, and Corrsys-Datron (CDS), a manufacturer of optical sensing technologies to measure vehicle dynamics parameters, such as longitudinal speed and distance, lateral speed, slip angle, dynamic camber angle and ride height. CDS also offers measurement steering wheels, fuel flow meters, custom accelerometers and gyro modules, as well as wheel positioning systems, pedal force measurements, data acquisition devices, GPS systems and microwave speed sensors.
MVTEC ANNOUNCES NEW DISTRIBUTOR IN THAILAND MUNCHEN, GERMANY—MVTec machine vision software products are now distributed by Solimac Automation Co. Ltd. (Bangkok) in Thailand. Besides distributing Halcon and ActivVisionTools, Solimac Automation also is providing highlevel technical support for MVTec’s software products. Solimac Automation is a leading engineering company in Thailand with a long-term experience in machine vision, robotics and automation. With its decision to distribute MVTec’s software products, Solimac Automation completes its product portfolio in order to
6VS
meet the requirements of a growing market for powerful machine vision standard software. According to Pravee Kruachottikul, manager of Solimac Automation, the evolving industrial market in Thailand shows a growing demand for fast and accurate machine vision solutions and Solimac Automation is looking forward to offering MVTec’s state-of-the-art software not only for the factory field, but also for customers in the educational and infrastructure field. “We will now be able to offer highly robust machine vision solutions based on MVTec’s well-proven software products Halcon and ActivVisionTools,” he adds.
VISION & SENSORS | May 2011
“Thailand is a fast evolving industrial market in Southeast Asia,” says Dr. Olaf Munkelt, MVTec’s managing director. “Thus, MVTec expands its sales activities also in this important country. We are sure that Solimac Automation will meet our requirements in an outstanding way.” The Solimac Automation distribution and support team will be trained by MVTec to become also a member of the MVTec Certified Training Partner Program. Thus, not only the qualified distribution and fi rst level support for all MVTec software products is guaranteed by Solimac Automation, but also the qualification to hold Halcon trainings for customers.
PHOTONIC SENSE GMBH WINS SUPPLIER OF THE YEAR AWARD EISENACH, GERMANY—Photonic Sense GmbH, a company of the Jenoptik Group, has won the Supplier of the Year Award 2010 from Flir Systems AB (Stockholm, Sweden). With this award, the Swedish company recognizes the performance of Photonic Sense as a supplier of germanium optical components. Every year, the Swedish company presents the best-performing supplier of the year with the Supplier of the Year Award. The criteria for the selection are delivery reliability, quality, price, technology and development, as well as communication. Photonic Sense GmbH won out over almost 100 other suppliers. A business relationship between the two companies has existed since 2004. Photonic Sense GmbH supplies Flir Systems with a range of germanium lenses for use in thermographic equipment. Flir Systems uses the germanium optics, which are suitable for the infrared wavelength range from 2 to 12 μmas front lenses in thermographic cameras for commercial applications. Flir Systems is an international market leader in the development, production and sale of thermographic equipment and surveillance systems.
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APTINA AND DXO LABS PARTNER HAUTS-DE-SEINE, FRANCE—DxO Labs has entered into a licensing agreement with Aptina Imaging Corp. (San Jose, CA) to integrate its DxO digital pixel processing (DxO DPP) technology into high-end complementary metal-oxide semiconductor (CMOS) imaging products for Aptina. “We are very excited to team up with CMOS image sensor leader Aptina,” says Jérôme Ménière, CEO of DxO Labs. “Our DxO DPP technology research scientists have developed a ground-breaking solution that can significantly improve the image quality of miniaturized cameras while reducing manufacturing costs.” Aptina seconded the sentiment. “We are very pleased to partner with DxO Labs, a very innovative and leading imaging company,” adds Farshid Sabet, vice president and general manager of Aptina’s mobile, PC and gaming business unit.
high achievers says speaks volumes about the chosen employee. Jason is the kind of person who does his job professionally, maintains good relationships with clients, suppliers and fellow employees, and knows how to achieve that difficult balance of safety, cost, quality and schedule. He has come through for Epic’s client base time and time again.” Baron is a project manager and engineer at Epic Systems. He has been with the company for five years and has duties ranging from project management to design engineering and programming.
MICROSCAN NAMES SCOTT SUMMERVILLE AS NEW PRESIDENT RENTON, WA—Microscan, a global technology leader in barcode, machine vision and lighting solutions, announces the appointment of Scott Summerville as president.
Summerville brings more than 20 years experience in the automation industry to Microscan, having spent most of his professional career to date at Rockwell Automation. He spent 10 years with Rockwell in Asia, initially overseeing the company’s marketing activities, eventually taking on responsibility for the Chinese market, and ultimately running the entire Asia Pacific region as president. Summerville most recently held the position of vice president and general manager, Public Safety Systems Division for Federal Signal Corp. “My primary goal as president of Microscan is growth,” says Summerville, who acknowledges many opportunities in the company’s core markets. “Manufacturers in the electronics, automotive and life sciences markets need more data to secure, trace and trace their products and optimize the supply chain.”
JASON BARON WINS 2010 EPIC WAY AWARD ST. LOUIS—Epic Systems Inc. has announced Jason Baron as the winner of the Epic Way Award for 2010. The Epic Way Award is an annual honor given in recognition of the individual who best exemplifies the spirit and values upon which Epic Systems was founded. As the recipient of the honor, Baron was presented a crystal engraved award at the annual company meeting. He and his family were also given a weeklong trip to Disney World. “I am honored to be recognized as this year’s Epic Way Award winner,” he says. “I know there are many others at Epic who are deserving of this award which makes this all the more special to me.” The winner of the Epic Way Award is selected by the president of the company, John Schott, and the four group managers. Schott and the managers take the selection of the winner very seriously and struggle to narrow it down to one winner every year. “Epic is a high expectation place to work,” Schott says. “For someone to win this award out of a group of such
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May 2011 | VISION & SENSORS
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I N T E G R AT I O N C O R N E R
Successful Machine Vision
Integration
lutely do have years of experience in machine vision, and it is that experience alone that fully indicates the ability to execute the successful integration of a machine vision application.
KNOWLEDGE AND EXPERIENCE ARE ESSENTIAL TO DELIVERING RESULTS. By David Dechow
Automate 2011 featured many new components, and in particular there were many new offerings in digital camera technology. There has been significant progress in the machine vision industry in the area of digital camera interconnect and data communication. A few years ago, the GigEVision camera interface standard and the GenICam standard for device description made direct digital interface of cameras to processors a realistic and viable for plant floor automation. CameraLink and now CameraLinkHS provide ultra-fast digital interfacing of cameras to a dedicated frame grabber and remain the gold standard in speed. A new interface standard, which is already commercially available, CoaXPress, may provide features that overcome some of the physical and speed limitations of previous interfaces. All of these advances are for cameras, which will interface with centralized processors, specifically PCs. This technology is widely used in OEM solutions and assembly-specific machine vision (ASMV) devices. Is there a subtle movement in the industry back toward PC-based machine vision for general-purpose applications? Certainly, smart camera architecture will not be displaced as the leading technology in general-purpose machine vision. However, with advances in interconnectivity, falling component price points and improving ease-of-use, the centralized PCbased solution may continue to grow as a real and attractive option for industrial machine vision integration.
One question frequently asked of integrators involved in machine vision is “How do you make the technology succeed?” Conference sessions are devoted to successful machine vision applications. It’s almost as if there is some hope that there are a couple of key secret tips that will always ensure that the project goes smoothly, performing inspections exactly to specification, all with minimal engineering and programming effort. Unfortunately, there is no simple secret; no Rosetta Stone that can be used to translate every desired inspection task into a smoothly running online machine vision application. When it comes to machine vision systems integration—the task of designing the correct lighting, optics, cameras, part placement, inspection algorithms, automation and then making it all work together to deliver the required results—the integrator must have 1) a thorough knowledge of the technology, and 2) plain old experience. In the case of the technology question, the Automated Imaging Association (AIA, Ann Arbor, MI) has taken a major step forward in offering advanced Certified Machine Vision Professional (CVP) coursework during the 2011 Automate conference sessions in mid-March. These sessions, and the accompanying test, were a follow-up to the basic CVP offering introduced in 2010, which also was available in 2011. This is the first time that a thirdparty association has undertaken certification of individuals who integrate machine vision technology—a process of certification that is quite com-
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mon in other professions. The course material is relevant and, in some cases, downright difficult. Overall, the tests appear to be a reasonable indicator of technical knowledge. It has been a major effort, and the AIA should be commended for this huge contribution to the industry. The program is not totally without some bugs, however. The principal goal of certification of a machine vision professional should be to provide an indication of that individual’s capability to utilize the technology in real-world integration and application. To that end, some of the CVP material might be too esoteric and textbook to be a realworld indicator, and those are the things that the AIA likely will be working out in months to come. Ultimately, though, one must return to the issue of plain old experience in machine vision integration. No test in the world can fully evaluate real-world experience. It’s like an aspiring pilot who has taken all of the coursework in ground school and successfully passed the written exams. Despite having proved extensive fundamental technical knowledge, no one would want that pilot behind the controls of a 757 until he had accumulated literally thousands of hours of actual experience. To be sure, many of the basic and advanced CVP individuals abso-
VISION & SENSORS | May 2011
WHAT’S NEXT IN MACHINE VISION?
David Dechow is president and founder of Aptúra Machine Vision Solutions (Lansing, MI). For more information, call (517) 272-7820, e-mail
[email protected] or visit www.aptura.com.
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VISION & SENSORS
M A C H I N E V I S I O N 10 1
How to Use Machine Vision to Measure
Edge Positions
other instances of the object. Edgebased search can be faster and more robust than search based on pixel intensities.
RELIABLY LOCATE AND MEASURE OBJECTS WITHOUT UNIFORM LIGHTING BY DETECTING EDGES. By Ben Dawson
Modern machine vision systems hide most details of the edge detection process in easy-to-use tools, such as search or outside calipers. An understanding of how edges detection works and its limitations can improve use of these tools. Digital images are discrete in space and intensity, so use digital difference operations rather than continuous differentiation to detect edges. For example, take the difference between successive intensity values along a caliper line. Difference operators can be represented as a vector or kernel values that multiply (weight) and sum pixel intensity values. In linear algebra terms, this is a dot or inner product between a kernel vector and a vector of pixel values. For example, taking the difference between successive pixels is represent-
Human and machine vision use an object’s edges to locate, identify and gage the object. This tutorial will give a better understanding of how edge detection— or finding and measuring edge positions—works in machine vision, where it can fail and what level of precision to expect. In a digital image, object edges produce intensity changes over a few pixels of distance. When differentiating image intensity as a function of pixel distance, the rapid rate of change in intensity at edges generates large output values. One can then detect object edges by finding these large output values.
Image intensity along a caliper line (green line in image) is plotted in black and the differentiated image intensity is in red. Small intensity changes are removed by applying thresholds (green lines in plot) to the differentiated image intensity. Source: Teledyne Dalsa Inc.
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Intensity changes due to lighting variations are usually smaller and occur over longer distances in the image than edge intensity changes. Differentiating these changes gives smaller output values that can be filtered out by applying a threshold. By detecting edges, one can reliably locate and measure objects without having perfectly uniform lighting. An object’s edges can be used as a model or template to search for
The top-most caliper line detects false edges (red + marks) due to texture. The bottom caliper line has been set to stop on the first edge found that is above threshold, thus ignoring texture inside the part. The plot shows the edge intensity in black, the digital difference curve in red, thresholds as green, horizontal lines, and found edge positions as blue, vertical lines. Source: Teledyne Dalsa Inc.
VISION & SENSORS | May 2011
COMPUTING EDGES
A dark-to-light edge (top) gives intensity samples (blue dots). A curve (green) is fit to the digital differences (red), and interpolated to find the peak (green) dot, which is the subpixel edge position. Source: Teledyne Dalsa Inc.
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ed by a kernel of [-1, 1]. This means: take two successive pixels, multiply the left pixel by -1 and the right pixel by 1, and sum the results, so: output = (right pixel + (– left pixel)). The kernel is moved along a caliper line and this weight-andsum operation is performed at each pixel. This process is called convolution (it is actually correlation). One way to think of convolution is that the kernel is an intensity pattern that looks like an edge and slides along a line in the image. Where this pattern matches an edge, the output will be large values. Here are three problems with detecting edges using convolution: • First, convolution runs out of pixels at each end of the caliper line. It cannot detect edges that are closer to the end of the caliper line than half the number of kernel elements. So make both ends of the caliper lines a bit longer than the maximum expected edge positions. • Secondly, the object should have a width as large as or larger than the size of the kernel used. This restriction is needed for subpixel resolution, discussed below. Avoid measures on thin lines. • Thirdly, digital differences amplify any changes in intensity, including changes due to noise and texture on the part. Edge detectors smooth pixel intensity values before digital differencing to reduce the effects of noise and texture. Because convolution is linear, smoothing and digital differencing can be combined in one kernel. For example, combining a [1, 1] smoothing kernel and a [-1, 1] digital difference kernel gives a kernel of [-1, 0, 1]. Even after smoothing, noise or texture can produce false edges. Noise gives small convolution values so a threshold—the same one used to suppress lighting variation—can remove it. Texture can give outputs too large to remove by a threshold.
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Texture edges can sometimes be suppressed by setting the edge detection to avoid the textured area, for example, by stopping detection at the first above-threshold edge found or by picking the edge with the maximum value.
HOW PRECISE? Suppose an outside caliper tool is used. The tool returns edge-to-edge distance measures with, apparently, 4 or 5 decimal places of resolution, say 87.17095. This apparently great resolution is mostly noise—the precision of the measurement is much less, perhaps 1⁄10 of a pixel distance. If one thinks about it, any fractional or subpixel precision seems impossible. With pixel values at discrete locations, how can one measure between these locations? If the edge intensity changes in less than one pixel then subpixel position cannot be measured. As the position of that step edge moves inside the pixel, different values show up but there is no reliable way to relate those values to edge position within the pixel. Real object edges transition in intensity over some distance and the camera’s optics further smoothes or blurs edge intensity values over some distance. Both distribute information about the edge’s position over a number of pixels. To recover the subpixel edge position, model the distributed edge position samples and interpolate. For this to work, the smoothing or blurring must occur before the image is digitized. The model assumes that edges are at the point of maximum intensity change, so it peaks in the intensity derivative. Typically there will not be an intensity sample right at the peak of the digital difference values. Therefore, fit a parabola to the digital difference values that are closest to the peak, and interpolate along that curve to find the peak. To get subpixel position resolution, object edges that are smoothed by nature and the camera’s optics
are needed. Assume that, on these smoothed edges, the point of maximum intensity change—a peak in the derivative—is the edge position. In the digitized image recover that peak position by fitting a curve to the digital difference values (samples) and interpolating. The choice of lens and camera also effects precision and accuracy. Standard machine vision lenses—particularly short focal length lenses—significantly distort image distances. The vision system’s calibration can remove most of this distortion, but for high precision and accuracy use a lens designed for measurement, such as a telecentric lens. In theory, a lens that is too sharp will not smooth edge information over a number of pixels and so could decrease subpixel precision. Use a camera designed for machine vision. Among other things, these cameras have no defective pixels, which can give false edges. More camera pixels can give better precision on object measurements. Subpixel precision is not a function of the number of pixels. With a good lens, reasonable lighting and sharp object edges (but not too sharp), one can expect resolutions of ¼ to 1⁄25 of a pixel depending on how well the resulting edge intensity values match the subpixel model assumptions. Some vendors claim 1⁄100 of a pixel resolution or more, this maybe be with ideal conditions that are not likely on a manufacturing line. As with arms control, one should trust but verify these claims. Ben Dawson is director of strategic development at Teledyne Dalsa Inc. (Billerica, MA). For more information, call (978) 670-2050, e-mail ben.
[email protected] or visit www.dalsa.com.
May 2011 | VISION & SENSORS
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C O L O R A N A LY S I S
Machine Vision
color’s appearance. These subtleties come about from the fact that light emanates with its own color spectrum. Each object in a scene absorbs and reflects (filters) this spectrum differently and the camera system responds to (accepts and rejects) the reflected spectrum in its own way. The challenge for color machine vision is to deliver consisCOLOR ANALYSIS TOOLS OFFER THE ACCURACY, ROBUSTNESS, tent analysis throughout a system’s FLEXIBILITY AND SPEED TO TACKLE COLOR APPLICATIONS WITH operation—and between systems CONFIDENCE. By Pierantonio Boriero performing the same task—while also imitating a human’s ability to discern and interpret colors. The majority of today’s machine vision systems successfully restrict themselves to grayscale image analysis. In certain instances, however, it is unreliable or even impossible to just depend on intensity and/or geometric (shape) information. In these cases, the flexibility of color machine vision software is needed to: • Optimally convert an image from color to monochrome for proper analysis using grayscale machine vision software tools. • Calculate the color difference to identify anomalies. • Compare the color withShown here is a common in a region in an image Bayer color filter array against color samples to (CFA) or mosaic pattern. Source: Matrox Imaging assess if an acceptable match exists or to determine the best match. Color is the manifestation of light from the visible • Segment an image based on color to separate object or feapart of the electromagnetic spectrum. It is perceived tures from one another and from by an observer and is therefore subjective—two people the background.
In Color
may discern a different color from the same object in the same scene. This difference in interpretation also extends to camera systems with their lenses and image sensors. A camera system’s response to color varies not only between dif-
tech tips A color matching tool determines the best matching color from a collection of samples for each region of interest within an image.
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ferent makes and models for its components but also between components of the same make and model. Scene illumination adds further uncertainty by altering a
The color distance can be a simple and effective way of detecting defects best characterized by their color.
VISION & SENSORS | May 2011
Color images contain a greater amount of data to process— typically three times more—than grayscale images and require more intricate handling. Efficient and optimized algorithms are needed to analyze these images in a reasonable amount of time.
Color analysis tools must not only be accurate and robust to be effective, but they must also be optimized for speed.
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The most common color spaces for machine vision are RGB (left), HSL (middle) and CIELAB (right). Source: Matrox Imaging
COLOR ANALYSIS TOOLS Currently there are software tools available to help identify parts, products and items using color, assess quality from color and isolate features using color. A colormatching tool determines the best matching color from a collection of samples for each region of interest within an image. A color sample can be specified either interactively from an image—with the ability to mask out undesired colors—or using numerical values. A color sample can be a single color or a distribution of colors (histogram). The color matching method and the interpretation of color differences can be manually adjusted to suit particular application requirements. The color matching tool also can match each image pixel to color samples to segment the image into appropriate elements for further analysis using other tools. The color distance tool reveals the extent of color differences within and between images, while the projection tool enhances color to grayscale image conversion for analysis—again using other tools.
The majority of color cameras feature a single sensor that employs a color filter array (CFA) or mosaic. This mosaic typically consists of red (R), green (G) and blue (B) optical filters overlaid in a specific pattern over the pixels. A demosaicing operation— performed either by the camera or software—is needed to convert the raw sensor data into a proper color image, for example, with an RGB value for each pixel position. Several demosaicing techniques exist, each with a trade-off between speed and quality, such as an introduction of color artifacts. This demosaicing operation can and must be adjusted to normalize the (RGB) response of the setup, for example, camera system and illumination, and thus produce consistent color images. The normalization factors are determined—most often automatically—by performing a white balance calibration: the machine vision system is presented a sample deemed white and the normalization factors to produce a white image are computed accordingly. Controlled scene illumination also is critical for effective color machine
vision—the light source, usually white and diffused, must provide a sufficiently consistent output and the scene must be adequately shrouded from the effects of varying ambient light.
THE RIGHT COLOR SPACE Typically, color is represented mathematically by three components and is thus visualized as a point or region in three-dimensional (3-D) space. The most common color spaces for machine vision are RGB, hue, saturation and lightness (HSL) and Commission Internationale de l’Eclairage Lab (CIELAB). RGB is the most common color space since it is used natively by most cameras and by all computer monitors. In HSL, a given color is represented by its hue, saturation or purity, and luminance or brightness. The CIELAB color space was created to mimic human perception; the numerical difference between colors is proportional to typical human interpretation. With HSL and CIELAB, it is easier to factor out the effect on luminance from nonuniform lighting, which adversely affects analysis.
The difference between colors marked A and B from X are essentially the same in RGB (left) but are substantially different in CIELAB (right), which better reflects typical human perception. Source: Matrox Imaging
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May 2011 | VISION & SENSORS
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C O L O R A N A LY S I S
Extracting just the luminance information from a color image (left) produces an image where the objects are indistinguishable from one another (center) while principal component projection produces an image that still differentiates the objects (left). Source: Matrox Imaging
CIELAB is useful when the automated inspection needs to replicate human inspection criteria. Extracting just the intensity or luminance information from a color image can result in objects or features, which differ only in color, becoming indistinguishable from
tion. Color identification compares the color in a given region to a set of predefined color samples to determine the best match if one exists. The region whose color needs to be identified is either known beforehand or located using another tool-like geometric pat-
Color analysis tools offer the accuracy, robustness, flexibility and speed to tackle color applications with confidence. one another. Principal component projection is a tool provided in certain software packages that uses the color distribution trend to optimize the conversion from color to grayscale and minimizes the loss of critical image information.
COLOR DISTANCE Color distance is how the difference between colors is measured. In its simplest form, the distance is computed between every pixel in an image and the corresponding pixel in a reference image or a specific color. The distance can be computed using various methods, for example, Euclidean, Manhattan and Mahalanobis/Delta-E. The color distance can be a simple and effective way of detecting defects best characterized by their color.
COLOR MATCHING A color matching tool performs one of two basic tasks: color identification or supervised color segmenta-
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tern recognition. Supervised color segmentation consists of associating (and replacing) each pixel in an image or region with one of the predefined color samples and therefore separating objects or features by their color. Supervised color segmentation also is used to obtain color statistics on an image; how much of one color sample vs. another. A color sample is defined either from a reference image or a specific color. If based on an image, the sample’s color is derived from statistical analysis (mean or distribution). A target area in an image is matched either by comparing its statistics (mean or distribution) with those of each sample or each pixel voting for the closest sample. The mean-based method is quick but requires a carefully-defined target area. The vote-based method is slower, but the target area can be more loosely defined and it is more robust to outlying colors. The latter
VISION & SENSORS | May 2011
method also provides more detailed results and is used for supervised color segmentation. The histogrambased method is ideal for multicolored samples. A score is computed to indicate how close the target color is to each sample color. Controls are provided to tailor the color matching for a particular application. A match is reported if the score is above thresholds for the best color sample (acceptance level) and the next best color sample (relevance level). A situation can arise where the score is deemed acceptable for two or more color samples but too close between color samples for there to be a definite match. A color distance tolerance adjusts how close the target color needs to be to a sample color to be considered a match.
OPTIMIZED FOR SPEED Working in color means that there is more data to process and the data requires more elaborate manipulation. Color analysis tools must not only be accurate and robust to be effective, but they must also be optimized for speed. Color analysis tools take full advantage of the vector (SIMD) instruction units in contemporary CPUs, as well as their multicore designs. Color analysis tools offer the accuracy, robustness, flexibility and speed to tackle color applications with confidence. These color tools are complemented with a comprehensive set of field-proven grayscale analysis tools. V&S Pierantonio Boriero is product line manager at Matrox Imaging (Quebec, Canada). For more information, call (514) 685-7230 ext. 2757, e-mail
[email protected] or visit www.matroximaging.com.
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VISION & SENSORS
GIGE
The Future of 10 GigE WHY 10 GIGE SHOULD DRIVE YOUR NEXT QUALITY INSPECTION SYSTEM DESIGN. By John Phillips
For quality inspection systems, higher bandwidth interfaces are always an attractive prospect because they allow high resolution without sacrificing frame rate in the performance of precise inspection. Further, with an increased frame rate, a system becomes more costeffective because inspection throughput is faster. It is not surprising then to note that some of the highest data throughput cameras on the market today are those used in quality inspection systems. Predominately based on the Camera Link protocol, these cameras provide maximum throughput rates between 4.08 Gigabits per second (Gbps) and 6.12 Gbps, depending on whether Camera Link medium or full configurations are used. With higher bit rates becoming the norm for inspection systems, 10 Gigabit Ethernet (10 GigE) is increasingly being considered as a means to keep pace of sensor technology. However, what are the implications of using 10 GigE?
COST: CRUNCHING THE NUMBERS When considering which video interface to select for new systems, cost is a key concern for any system designer. While the bandwidth of 10 GigE is appealing, is it a reasonable contender to other video interfacing technologies? To answer this question, component pricing has been gathered to create a better understanding of a system’s overall costs. For illustration purposes, Figure 1 presents two design scenarios for a system that requires two Camera Link medium cameras and a PC that is 20 meters away from the system. In the left-hand column, the system has the two cameras connected to the PC using Camera Link; while in
Figure1: Shown here is a cost comparison between two systems, one with 10 GigE technology and one without. Source: Pleora Technologies
the right-hand column, the system employs 10 GigE technology. The cabling and extenders required in a Camera Link system represent a substantial proportion of overall interface costs. However, these same costs can be averted by taking advantage of the greater bandwidth afforded by 10 GigE and the flexibility of the actual Ethernet cabling. Further, the additional labor required for the cabling and extenders with Camera Link would add to costs. Therefore, although it might be a natural leap of logic to assume that 10 GigE represents a significant cost increase, crunching the numbers tells a different story: 10 GigE stands as a reasonably priced option. Further, the exponential market growth for 10 GigE technology indicates that it will only become more and more cost-effective as time goes on. The price per port continues to drop over time from its original introductory price. In 2006, the price per port of 10 GigE technology began to drop rapidly and every indication suggests that this trend will continue, as witnessed with 1 GigE and 100 megabits per second (Mbps).
Figure 2: 10 GigE technology continues to drop in cost due to cross-industry adoption. Source: Pleora Technologies
tech tips Any routing distance between cameras and processor that must exceed 10 meters requires Camera Link repeaters or extenders.
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Fiber is extremely flexible and easy to route and can be literally run for kilometers.
VISION & SENSORS | May 2011
By distributing video over a 10 GigE network, designers can create distributed inspection systems.
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This is a plasma screen inspection system designed with networked video. Source: Pleora Technologies
In fact, it is forecast that 10 GigE technology will likely be cost comparable with 1 GigE by the middle of this decade. Naturally, as cross-industry adoption of 10 GigE grows, costs will continue to decline, demand will accelerate and innovators will invest in further refining 10 GigE technology.
CABLING: A LOOK AT PRACTICALITIES Cabling distance can either limit or broaden a system’s design options. As noted earlier, the high bit rate applications required in quality inspection systems lend themselves to medium or full Camera Link configurations. This means that each camera requires two Camera Link cables to carry data, and these cables are limited to 10 meters in length. Any routing distance between cameras and processor that must exceed 10 meters requires Camera Link repeaters or extenders. These repeaters and extenders represent an extra cost in both materials and labor, but perhaps more importantly, they increase the cabling complexity and reduce reliability. At the processing end of the system, the required Camera Link-specific frame grabbers and the length limitations of
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Camera Link cables often require processing hardware to be located near the inspection machine. A more desirable design would enable the computers to be housed in a separate cabinet or room, away from dangerous or harsh manufacturing environments— yet this is not generally feasible given the cabling limitations described. The capacity to combine the video streams, as is possible with 10 GigE, eliminates these types of nagging challenges related to cabling distance. For instance, Camera Link cables can be shortened to the distance between camera and converter, while a single copper or fiber connection carries the video data of up to four cables—two Camera Link medium/full, or 4 Camera Link base cameras—to processors
located in a protective cabinet or other room. Fiber is extremely flexible and easy to route and can be literally run for kilometers, opening up exciting new design possibilities. But further, 10 GigE technology can be used to dramatically transform how the design of these systems is approached because rather than trying to design a PC into the system, a compact 10 GigE IP engine device can be used. Once 10 GigE cameras become widely available, the converter device can be removed from the system design.
NEXT GENERATION INNOVATIONS Of the market’s available video interfaces, 10 GigE is the only one to enable high value, next generation innovations, such as distributed inspection systems, made possible through networked video. This capacity lengthens the life span of a system, and therefore increases the operator’s return on investment—a key value proposition. System cost and complexity can be reduced via networking video since it reduces the hardware required per camera. It also broadens design and
Figure 3: With 10 GigE technologies, system designers no longer need to embed a PC into their system. Source: Pleora Technologies
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More Precision Non-Contact Dimensional Testing Confocal sensors optoNCDT 2400 Miniature sensor design Extreme resolution Tiny, constant measuring spot 7 μm Target independent even against mirror & glass
implementation options: designers can take advantage of different topologies, including traditional point-to-point, and topologies such as point-to-multipoint and multipoint-to-multipoint video connectivity options over 10 GigE to allow more efficient image processing. By distributing video over a 10 GigE network, designers can create distributed inspection systems. A distributed system allows each camera to send images to a bank of PCs, with each PC searching for a specific defect. This dramatically increases inspection speed and provides exceptional new value to manufacturers seeking to increase competitive advantage. Additionally, the introduction of new inspection algorithms is greatly simplified. In this scenario, a second bank of PCs could be trained by providing real-time image data from the
GIGE
cameras, all while not interrupting the in-service system (bank of PCs).
MAKING THE 10 GIGE CHOICE For quality inspection applications, a system designed using GigE Vision over 10 GigE provides unique advantages that are simply unavailable with other video interfacing technologies. Impossible to ignore is that this technology platform supports advanced new architectures with flexible video networking, while providing for significant cost savings over designs that employ only Camera Link cabling. As a high-bandwidth platform, 10 GigE best supports the high throughput requirements of today— and tomorrow. John Phillips is senior product manager at Pleora Technologies (Ontario, Canada). For more information, e-mail
[email protected] or visit www.pleora.com.
Standard sensors ø 27 mm, also for one-sided thickness measurement Miniature sensors ø 4 mm, also for cavities and bores
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I N T E G R AT I O N
Integration Questions Answered
endeavor is challenging—no management, no project. The third criterion for success is engineering bandwidth. Integrators are notorious for having one MANAGING CHANGE AS IT HAPPENS IS THE MOST CRITICAL SKILL of two things: too little work or THAT AN INTEGRATOR CAN HAVE. By Ned Lecky too much work. The former have a nasty habit of going out of business, and the latter have an equally nasty habit of delivering too little or too late. The vagaries of the business cycle, possibly exacerbated by inadequate management, contribute to a vacillation between both extremes at many integrators. This leads to the System integration almost fourth, and perhaps most always involves pulling important criterion— together disparate products, technologies, some off-thegeneral business ethic. shelf and some home-grown. Doing business with an Source: Lecky Integration unethical company is always unsatisfactory. Similarly, unhappy experiences come from dealing with poorly managed companies, disorganized companies and difficult or unsavory people. In Owner of Lecky Integration (Little Falls, NY) and many ways, this last criterion is the regular columnist and member of the Vision & Sensors’ first one to look at. If the company is going to be hard to deal with, the editorial advisory board, Ned Lecky addresses several long-term satisfaction with a project questions on how to achieve successful integration with and relationship is bound to be low. While laid out in the standard machine vision applications. He also discusses best order, companies thinking about using a systems integrator should evaluate the criteria last-to-first. The development and communications, practices and the criteria involved technical issues are much easier to and the integrator has no experience when determining if an outside address and augment than any of in robotics, being successful is much integrator is right for a company’s the other issues. more difficult and the complete application. project carries much more risk. The second criterion for sucVision & Sensors: Is there a parV&S: Discuss the development lifecess is project management. An ticular type of criteria that affects cycle for a project. integrator with excellent technical an integrator’s overall success? NL: Listed below is a spiral process experience and capability with no for product development: Ned Lecky: Generally, there are four project management discipline is 1) First, a need is recognized. Usumain criteria that influence the sucunlikely to succeed. System integraally, the customer recognizes this cess of a system integrator. The first tion almost always involves pullneed, but an astute integrator is clearly technical expertise. If the ing together disparate products, working with a customer can job at hand requires knowledge and technologies, some off-the-shelf often spot a need that the cuscapability in three different techniand some home-grown. Planning, tomer has not even thought of yet. cal areas, say robotics, software scheduling and executing such an An efficiency enhancement, new
tech tips
An integrator with excellent technical experience and capability with no project management discipline is unlikely to succeed.
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Do not give the most valuable parts of the company to an outside integrator unless a very clear and wellconstructed agreement is in place.
VISION & SENSORS | May 2011
Working with an integrator requires the in-house engineers to have some experience working with an outside team.
www.visionsensorsmag.com
The integrator is going to perform a variety of services for the customer. Each of these services needs to be considered and evaluated. They also are going to cost money to work with, and require management, oversight and monitoring time. Companies need to be sure that the rewards outweigh the risks. Source: Lecky Integration
product or product accessory can be equally well conceptualized by the customer or the integrator. 2) Next, a potential business deal has to be conceptualized. What will this cost to develop? What will the parts cost to buy? What will the assembly and testing costs add up to? How much should be charged for it? Many ideas will die at this stage. 3) Then the spiral begins. Go back to concept and design, and start to fill in details. After a few details are added, one needs to re-evaluate the business opportunity. Does this all make sense? There can be several iterations of steps 1 and 2. 4) If the concept is fleshed out and the business case still looks good, one still needs to decide to fund the project. Is there enough commitment to attempt to make this product a reality? This discussion involves the business decision makers and finance people. A compelling case for cost, value and ability to complete the design and development must be constructed. 5) If funded, prototyping starts up. Get in some of the components and test them. Write some demonstration software. Identify some of the key risk areas and determine whether the hurdles are small or large. At this stage, the product may seem like a rogue project within the company. If so, that is a very good sign. 6) Eventually, there must be a transition from rogue to mainstream. It is time to bring in professional management practice. The prod-
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uct idea is solid, the business case is good, major risks are retired and most of the team is on-board. Now it is time to lay out a formal plan, divide the work into components, schedule those components and assign each to a team member. From here on out, it is a much more predictable process. 7) Establish division of labor, milestones and deliverables. 8) Manage to plan and update plan if and as necessary. V&S: What are some questions an end user should ask to determine whether a systems integrator is needed? NL: The integrator is going to perform a variety of services for the customer. Each of these services needs to be considered and evaluated. They also are going to cost money to work with, and require management, oversight and monitoring time. Companies need to be sure that the rewards outweigh the risks. Here are some good questions to help reveal the need: Do they have the technical expertise internally to do this themselves? If there is no capability in this area, a consultant, vendor or integrator is needed. If expertise is world class, no integrator may be good enough to do what they do. Most of the time, the reality is somewhere between these two extremes. One must decide where. Do they have the resources to execute a technical plan to make this happen? Even if they are bestin-class at doing something, if their
resources are all committed, it may be acceptable to take a less-thanperfect solution from an integrator, particularly if they are working on non-mainstream additions or enhancements to an existing product line. If they do not have the resources, they need either to hire or subcontract, or start postponing some other project. Can they describe what they need well enough that in integrator can figure out what is needed? Sometimes the development idea is so obscure that it is hard to imagine how to even communicate it to an integrator. Other times, the need is so simple and easily carved out that an integrator approach is completely compelling. Again, real situations usually live somewhere between these extremes, and an estimate needs to be made as to where. Do the engineers involved in the project have experience working with integrators? Working with an integrator requires the in-house engineers to have some experience working with an outside team. If the integrator contacts are incapable or managing and directing the integrator relationship, the integrator is doomed. So having the right internal resources to work with the integrator is crucial. Is there some benefit or upside in the project that will keep the integrator interested and enthusiastic about the work? Most projects are late, rushed and thinly manned at the end. While this is never planned
May 2011 | VISION & SENSORS
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for, it often winds up there. If an integrator feels that he has underbid a job and been talked into delivering way more than originally intended, there can be a foot-off-the-pedal response just at the moment when the hammer should be going down. Keeping an integrator involved in the business upside, either with royalties or simply with the promise of the next project, can keep everyone enthusiastic when those dark and exhausted final days arrive. Save something for the final lap. Is there a liability or indemnification issue with this project that will be helped by using an outside integrator? There are hot potatoes in just about every project. Are they inspecting drugs? Ammunition? Trying to detect illegal substances or weapons? In situations like these, there can be considerable liability in the even that their product fails. In cases like these, it may be wise to involve another company to help improve the quality of the design and share some of the risk. Conversely, in projects involving trade secrets, military secrets or proprietary formulas or processes, bringing in an outside integrator can increase risk by spreading sensitive information outside the company. These considerations can often drive the determination of whether an integrator is appropriate. Are they developing a key internal technology that they want
I N T E G R AT I O N
to own, control and protect as part of their fundamental intellectual property (IP)? Getting ready to sell the company? Or perhaps write a few patent applications? Anything critical to IP or the due diligence process should be held onto. Do not give the most valuable parts of the company to an outside integrator unless a very clear and well-constructed agreement is in place. Keep crucial development in-house if possible. Is there an integrator available who has already done what they want to do? Do not reinvent the wheel. Many development efforts are incredibly similar, even if used for entirely different industries. There are many way to reuse the technology developed for one area, and if an integrator has expertise in that area, there may be a fast track to redeploying existing ideas for one’s own use. Many times, getting to market fast is more important than building a fully custom solution. This becomes a business call. V&S: How should end users go about choosing an outside systems integrator? NL: I think any integrator selection process has to involve a consideration of the original four criteria for success. Where are they technically? How good is their project management capability? How big—and available—is their
team? How are they going to be to work with? The customer’s engineering team can help with the technical evaluation, but all of the business issues really require discussions with other customers who have done business with the integrator. A well-run integrator will have numerous customers who are willing to talk enthusiastically about them. No company is perfect—always ask what was the best aspect of working with a particular integrator, and follow the question with what was worst. If the best things are impressive, and the worst things are worth overlooking, or commonly overlook in other vendor relationships, then one has a winner. The question “Would you give this integrator another project?” reveals huge amounts of information. V&S Ned Lecky, Ph.D., is the owner of Lecky Integration (Little Falls, NY).For more information, call (518) 258-5874, e-mail ned@lecky. com or visit www.lecky.com or his blog at www.visionsensorsmag.com.
Visit www.visionsensorsmag.com for more information from Ned Lecky on best practices and quality programs for integrators.
Coming Soon: Integration Certification Program Last year, the Automated Imaging Association (AIA, Ann Arbor, MI) launched a basic certification program for machine vision professionals. Bridging off that was the introduction at the advanced level during Automate 2011 held at the McCormick Place in Chicago. In response to member integrators wanting certification to verify their experience and capabilities, the AIA has stated that they are looking to certify system integrator companies toward the latter part of the year and has invited member integrators and end users to help share their expertise in developing the program. Company certification will include verification that integrators possess the employees, experience and resources to provide a successful system.
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VISION & SENSORS | May 2011
“Certification for machine vision system integrators could be an extremely valuable baseline consideration for end-users seeking integration support; if the certification is done by a qualified entity and in a way that truly represents the integrator capability,” says David Dechow, president of Aptúra Machine Vision Solutions LLC (Lansing, MI). Dechow urges individuals in the machine vision profession to complete the AIA certification. However, he adds that individual certification is a long way from what is needed to competently certify a company in a way that is meaningful and useful to the end user.
www.visionsensorsmag.com
VISION & SENSORS
CASE STUDY
Sensing in Space A HUMANOID ROBONAUT “SEES” WITH TWO SENSOR CAMERAS.
elastic joint technology, extended fi nger and thumb travel, miniaturized six-axis load cells, redundant force sensing, ultra high-speed joint controllers and extreme neck travel. Capable of 42 degrees of freedom, including 24 in its hands and fi ngers alone, R2’s dexterity allows it to use the same tools as astronauts, removing the need for robot specific tools.
REAL-TIME VISION RECOGNITION R2’s vision equipment is housed inside its helmet. The system uses color, pixel intensity and texturebased segmentation, as well as advanced pattern recogniIf successful, R2 could move tion techniques to extract on to stage two of the mission the necessary information. and become mobile to perform To simplify the procestation maintenance tasks, such as vacuuming or cleaning dure, the system focuses filters. Source: Allied Vision on certain areas of the Technologies Inc. image using region of interests (ROI). ROI is a function that allows a certain portion of the available pixels to be Built B il iin partnership hi with ih G Generall Motors M (GM) (GM) and d read out from the camera resulting a faster frame rate and less data the Oceaneering Space Systems of Houston, NASA’s in to be processed. Robonaut (R2) is the second generation of highly dexIn addition, the TOF sensor terous humanoid robots designed to work alongside data allows the background to be humans and execute simple, repetitive or dangerous removed in order to focus on the object of interest. Built-in classification techniques within the software are used to perform threeAllied Vision Technologies (AVT, tasks on Earth or on board the dimensional (3-D) and patternBurnaby, Canada) and an infrared International Space Station (ISS). recognition functions in real-time time-of-flight (TOF) camera. Developed in 1997, the fi rst to allow R2 to compute feasible Capable of speeds more than four generation of Robonaut (R1) was trajectories and decide where to times faster than R1, R2 features a human-like robotic assistant place its hands to execute a set a total of 350 sensors for tactile, capable of performing simple mainof pre-determined tasks, such as force, position, range-fi nding and tenance tasks. Its successor, R2, is opening boxes autonomously. vision sensing and 38 power PC a fully modular, highly dexterous The software used by the system processors enabling it to perform 300-pound robot that consists of a is MVtec’s Halcon 9.0. MVtec is an functions, such as object recognition head and a torso with two arms and AVT software partner. and manipulation. R2 also is able to two hands. react to its surroundings and operR2’s technological improveate semi-autonomously. ments include an improved range R2’S MISSION Other technological improvements of sensors that features two ProR2 underwent a series of rigorous include optimized overlapping dual silica GC2450 color cameras from tests prior to its launch on space arm dexterous workspace, series shuttle Discovery in February
benefits
R2’s dexterity allows it to use the same tools as astronauts removing the need for robot specific tools.
www.visionsensorsmag.com
Built-in classification techniques within the software are used to perform 3-D and patternrecognition functions in real-time.
R2 is capable of 42 degrees of freedom.
May 2011 | VISION & SENSORS
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CASE STUDY
2011. During stage one, R2 was hard-mounted and stationed in the Destiny laboratory on board the ISS where it was monitored while executing tasks and operations similar to those performed on Earth. If successful, R2 could move on to stage two of the mission and become mobile to perform station maintenance tasks such as vacuuming or cleaning fi lters. The ultimate goal is to send R2 outside the ISS to perform dangerous extravehicular activity (EVA) tasks during stage three. There are no plans to return R2 to Earth. Allied Vision Technologies Inc. (978) 225-2030 www.alliedvisiontech.com
Built-in classification techniques within the software are used to perform 3-D and pattern-recognition functions in real-time to allow R2 to compute feasible trajectories and decide where to place its hands to execute a set of predetermined tasks. Source: Allied Vision Technologies Inc.
VISION & SENSORS | AD INDEX ADVERTISER
PAGE
PHONE
WEB ADDRESS
AVT/Prosillica
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(877) USA-1394
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Cincinnati Automation Ltd.
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Dalsa
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JAI Pulnix
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Kowa Optimed Inc.
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Micro-Epsilon
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Pepperl+Fuchs
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Point Grey Research
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This index is provided as a reader service. The publisher assumes no liability for errors or omissions.
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VISION & SENSORS | May 2011
www.visionsensorsmag.com
VISION & SENSORS
PRODUCTS
INSPECTION CAMERA The uEye UI1495LE-C is a 10-megapixel USB color camera designed for applications ranging from parts inspection to microscopy. It has an Aptina ½-inch complementary metal–oxide semiconductor (CMOS) progressive scan sensor in 10-megapixel resolution. The camera delivers frame rates up to 14.94 frames per second. It can be interfaced into any USB 2.0 equipped component. Its ABS housing measures 44 millimeters by 44 millimeters by 25.4 millimeters.
SCAN CAMERAS The next ace area scan camera models are 29 millimeters by 29 millimeters by 42 millimeters. They have a 5-megapixel complementary metal-oxide semiconductor (CMOS) sensor. The cameras deliver up to 14 frames per second at full resolution. They consume 2.5 watts. Basler Vision Technologies (610) 280-0171 www.baslerweb.com
IDS GmbH (781) 787-0048 www.ids-imaging.com
INTERFACE GATEWAYS ENX Series AS-Interface Gateways support Modbus/TCP and Ethernet/IP protocols for communication with standard and safety networks in a single gateway. The entire AS-Interface network is controlled by one AS-Interface gateway. Inputs and outputs are handled asynchronous to the Ethernet traffic. These gateways scan every AS-i node in 150 μs, which enables up to 62 safety e-stops, magnetic switches and safe outputs.
LINEAR POSITION SENSORS
Pepperl+Fuchs (330) 425-3555 www.pepperl-fuchs.com
The device controller software development kit (SDK) for both Matlab and National Instruments LabView is a Photron Fastcam Viewer (PFV) software package. The functionality integrates control of Photron’s cameras with the customer’s existing Matlab and LabView functionality for image acquisition and download. The operator interface provides access to integrate functionality with the cameras ability to capture, replay and produce high-speed image sequences in industry-standard file formats.
The Macro Sensors CD 375 series of miniature linear variable differential transformers (LVDTs) provides displacement feedback in different robotic applications. The sensors detect position change when an actuator moves the robotic arm, providing an analog voltage signal, proportional to the amount of motion, to a controller that makes appropriate adjustments based on programmable set points. With the data provided by the sensor, the controller can determine when the robotic arm should stop or slow down. They are ⅜ inch in diameter and are designed for applications such automatic inspection equipment.
Photron (800) 585-2129 www.photron.com
Macro Sensors (856) 662-8000 www.macrosensors.com
DEVICE CONTROLLER SOFTWARE
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May 2011 | VISION & SENSORS
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Play to win
When you have only one chance to play, Guppy PRO is the one to grab. Based on the successful AVT Guppy, Guppy PRO has been retooled to be the prized camera for low-cost, plug-and-play applications. Featuring an even smaller package, six models now offer the faster FireWire 1394b interface while delivering up to 120 fps and offering VGA through 5 megapixel resolution. Each camera comes with AVT’s industry-leading smart features and superior robust housing. If you’re going to play, go for the biggest prize and visit www.AlliedVisionTec.com/PlayToWin.
S E E I N G
I S
B E L I E V I N G
