Coordinate Measuring Machine (CMM) http://en.wikipedia.org/wiki/Coordinate-measuring_machineNURUL AINI

Learning OutcomesAt the end of this lesson, students will be able to:Describe the principle of CMM.State the applications of CMM. Explain the operating methods of CMM.

IntroductionA 'coordinate measuring machine' (CMM) is a device for measuring the physical geometrical characteristics of an object.This machine may be manually controlled by an operator or it may be computer controlled.

Introduction (Contd)CMM

Introduction (Contd)CMM

Introduction (Contd)Measurements are defined by a probe attached to the third moving axis of this machine.This probe touches the part of interest and allows collecting discrete points on the object's surface.

Introduction (Contd)Probe

Introduction (Contd)Methods of probing

Introduction (Contd)The typical CMM is composed of three axes, an X, Y and Z. These axes are orthogonal to each other in a typical three dimensional coordinate system.Each axis has a very accurate scale system that indicates the location of that axis. All three axes are displayed on a digital readout.

Introduction (Contd)The probe is used to touch different spots on the part being measured. The machine then uses the X,Y,Z coordinates of each of these points to determine size and position. There are newer models that have probes that drag along the surface of the part taking points at specified intervals. This method of CMM inspection is more accurate than the conventional touch-probe method and most times faster as well.

Introduction (Contd)The next generation of scanning, known as laser scanning, is advancing very quickly.This method uses laser beams that are projected against the surface of the part.Many thousands of points can then be taken and used to not only check size and position, but to create a 3D image of the part as well.This "point-cloud data" can then be transferred to CAD software to create a working 3D model of the part.

Introduction (Contd)The laser scanner is often used to facilitate the "reverse engineering" process.This is the process of taking an existing part, measuring it to determine its size, and creating engineering drawings from these measurements.This is most often necessary in cases where engineering drawings may no longer exist or are unavailable for the particular part that needs replacement.

Introduction (Contd)Reverse Engineering Propeller model being probed so that a 3D CAD drawing of the surfaces could be obtained.

Introduction (Contd)Quality Control CMM used to verify dimensions of machined features

Introduction (Contd)A coordinate measuring machine (CMM) is also a device used in manufacturing and assembly processes to test a part or assembly against the design intent.By precisely recording the X, Y, and Z coordinates of the target, points are generated which can then be analyzed via regression algorithms for the construction of features.

Introduction (Contd)These points are collected by using a probe that is positioned manually by an operator or automatically via Direct Computer Control (DCC).

Parts Of CMM MachineCoordinate-measuring machines include three main components:The main structure which include three axes of motion Probing system Data collection and Reduction system - typically includes a machine controller, desktop computer and application software.

Parts (Contd)Fixed Bridge Coordinate Measuring MachineMoving Bridge Coordinate Measuring Machine

Parts (Contd)Fixed Table Cantilever Coordinate Measuring MachineColumn Coordinate Measuring Machine

Parts (Contd)Probing System

Uses/ApplicationsThey are often used for:Dimensional measurement Profile measurement Angularity or orientation measurement Depth mapping Digitizing or imaging Shaft measurement

FeaturesThey are offered with features like:Crash protection Offline programming Reverse engineering Shop floor suitability SPC software and temperature compensation. CAD Model import capability

FeaturesThe machines are available in a wide range of sizes and designs with a variety of different probe technologies.They can be controlled and operated manually, or by CNC or PC controls.They are offered in various configurations such as benchtop, free-standing, handheld and portable.

Machine bodyThe first CMM was developed by the Ferranti company of Scotland in the 1950s as the result of a direct need to measure precision components in their military products.One of the subsequent coordinate measuring devices was the UMS 500 (Zeiss/Germany).Leitz/Germany subsequently produced a fixed machine structure with moving table.

Machine body (Contd)In modern machines, the gantry type superstructure has two legs and is often called a bridge.This moves freely along the granite table with one leg (often referred to as the inside leg) following a guide rail attached to one side of the granite table.

Machine body (Contd)The opposite leg (often outside leg) simply rests on the granite table following the vertical surface contour.Air bearings are the chosen method for ensuring friction free travel.In these, compressed air is forced through a series of very small holes in a flat bearing surface to provide a smooth but controlled air cushion on which the CMM can move.

Machine body (Contd)The movement of the bridge or gantry along the granite table forms one axis of the XY plane.The bridge of the gantry contains a carriage which traverses between the inside and outside legs and forms the other X or Y horizontal axis.The third axis of movement (Z axis) is provided by the addition of a vertical quill or spindle which moves up and down through the centre of the carriage.

Machine body (Contd)

Machine body (Contd)The touch probe forms the sensing device on the end of the quill. The movement of the X, Y and Z axes fully describes the measuring envelope.Optional rotary tables can be used to enhance the approachability of the measuring probe to complicated workpieces.

Machine body (Contd)The rotary table as a forth drive axis does not enhance the measuring dimensions, which remain 3D, but it does provide a degree of flexibility.Some touch probes are themselves powered rotary devices with the probe tip able to swivel vertically through 90 degrees and through a full 360 degree rotation.

Machine body (Contd)As well as the traditional three axis machines (as pictured above), CMMs are now also available in a variety of other forms.These include CMM arms that use angular measurements taken at the joints of the arm to calculate the position of the stylus tip.

Machine body (Contd)Such arm CMMs are often used where their portablity is an advantage over traditional fixed bed CMMs.Because CMM arms imitate the flexibility of a human arm they are also often able to reach the insides of complex parts that could not be probed using a standard three axis machine.

Mechanical probeIn the early days of coordinate measurement mechanical probes were fitted into a special holder on the end of the quill. A very common probe was made by soldering a hard ball to the end of a shaft. This was ideal for measuring a whole range of flat, cylindrical or spherical surfaces.

Mechanical probe (Contd)Other probes were ground to specific shapes, for example a quadrant, to enable measurement of special features.These probes were physically held against the workpiece with the position in space being read from a 3-Axis digital readout (DRO) or, in more advanced systems, being logged into a computer by means of a footswitch or similar device.

Mechanical probe (Contd)Measurements taken by this contact method were often unreliable as machines were moved by hand and each machine operator applied different amounts of pressure on the probe or adopted differing techniques for the measurement.

Mechanical probe (Contd)A further development was the addition of motors for driving each axis. Operators no longer had to physically touch the machine but could drive each axis using a handbox with joysticks in much the same way as with modern remote controlled cars. Measurement accuracy and precision improved dramatically with the invention of the electronic touch trigger probe.

Mechanical probe (Contd)Joy stick

Mechanical probe (Contd)The pioneer of this new probe device was David McMurtry who subsequently formed what is now Renishaw, even today the driving force behind many developments in the CMM field.Although still a contact device, the probe had a spring loaded steel ball (later ruby ball) stylus.

Mechanical probe (Contd)As the probe touched the surface of the component the stylus deflected and simultaneously sent the X.Y,Z coordinate information to the computer. Measurement errors caused by individual operators became fewer and the stage was set for the introduction of CNC operations and the coming of age of CMMs.

Mechanical probe (Contd)

Mechanical probe (Contd)

Mechanical probe (Contd)Optical probes are lens-CCD-systems, which are moved like the mechanical ones, and are aimed at the point of interest, instead of touching the material. The captured image of the surface will be enclosed in the borders of a measuring window, until the residue is adequate to contrast between black and white zones.

Mechanical probe (Contd)The dividing curve can be calculated to a point, which is the wanted measuring point in space. The horizontal information on the CCD is 2D (XY) and the vertical position is the position of the complete probing system on the stand Z-drive (or other device component). This allows entire 3D-probing.

Physical PrinciplesOptical probes and/or laser probes can be used (if possible in combination), which change CMMs to measuring microscopes or multi sensor measuring machines. Fringe projection systems, theodolite triangulation systems or laser distant and triangulation systems are not called measuring machines, but the measuring result is the same: a space point.

Physical PrinciplesLaser probes are used to detect the distance between the surface and the reference point on the end of the kinematic chain (i.e.: end of the Z-drive component). This can use an interferometrical, a light deflection or half beam shadowing principle.

On contact, the coordinate position are recorded by the CMM controller, adjusting for over travel and probe size.Positioning of the probe relative to the part can be accomplished either manually or under computer control.Methods of operating a CMM are classified as i) manual control, ii) manual computer-assisted, iii) motorized computer-assisted, and iv) direct computer control.Operation of CMM

In manual control, a human operator physically moves the probe along the axes to contact the part and record the measurement.The probe is free-floating for easy movement.Measurement are indicated by digital read-out, and the operator can record the measurement manually or automatically.Any trigonometric calculation must be made by operator.Method of Operating- Manual Control

The manual computer-assisted CMM is capable of computer data processing to perform trigonometric calculations.Types of computations include determining hole-centre locations.The probe is still free floating to permit the operator to bring it into contact with part surfaces.Method of Operating- Manual Computer-Assisted

Motorized computer-assisted CMMs power drive the probe along the machine axes under operator guidance.A joystick or similar device is used to control the motion.Low power stepping motors and friction clutches are used to reduced the effects of collisions between probe and part.Method of Operating- Motorized Computer-assisted

Direct computer-control CMM operation like a CNC machine tool.It is computerized inspection machine that operates under program control.The computer also records measurements made during inspection and performs various calculations associated with certain measurement (for example, computing the centre of a hole from three or more points on the hole surface). Method of Operating- Direct Computer Control

Step 1: Calibration of the stylus or probe tip with respect to the probe head reference point using a calibrated ball.Step 2: Metrological determination of the work piece position in the measuring machine-related coordinated system.Measurement with CMM

Measurement with CMMStep 3: Measurement of the surface points on the work piece in the measuring machine-related coordinate system.Step 4: Evaluation of the geometric parameters of the work pieceStep 5: Representation of the measurement results after coordinate transformation into the work piece related coordinate system.

Basic Geometric ElementsCircle: Requires 3 points for measurement: By measuring 4 (up to 50) or more points form deviation is determinedPlane: Planar measurements require 4 or more points for form. The intersection of Planes 2 and 3 generate Line 5; Point 6 is the intersection of Plane 4 and Line 5

Basic Geometric ElementsCylinder:To define a cylinder, 5 points are necessary. Calculations provide its axis and diameter. The intersection of the Cylinder 7 and Plane 4 is Line 8.Cone: The cone (or taper) requires at least 6 points for definition. Calculations determine the cones included angle and its axis in space.

Basic Geometric ElementsSphere: The location of a sphere is found by measuring 4 points is also calculated.

Calculated Solution-Distance

Calculated Solution-Distance

Calculated Solution-Angle

Calculated Solution-Plane

Calculated Solution-Circle

Calculated Solution-Cylinder

Calculated Solution-Sphere

Calculated Solution-Cone

The basic capability of a CMM is determination of coordinate values where its probe contacts the surface of a part.Computer control permits the CMM to accomplish more sophisticated measurements and inspections, such as:a) determining center location of hole or cylinderb) definition of a planec) measurement of flatness of a surface or parallelism between two surfaces, andd) measurement of a angle between two planes.CMM Measurements and Advantages

Advantages of using coordinates measuring machines over manual inspection methods include:1) Higher productivity-a CMM can perform complex inspection procedures in much less time than traditional manual methods.2) Greater inherent accuracy and precision than conventional methods.3) Reduced human error through automation of the inspection procedure and associated computations.A CMM is a general purpose machine that can be used to inspect a variety of part configuration. CMM Measurements and Advantages

A CMM is a general purpose machine that can be used to inspect a variety of part configuration.

CMM Measurements and Advantages

ConclusionWith the prices of desktop computer dropping drastically in the last few years, small manufacturing firms can afford to own a CMM with a computer interface.CMMs are slowly working their way into automation.With the major emphasis being on closed loop process control, CMMs provide the ability to make precise measurements, using the sophisticated hardware, and convert this information using integrated software, into data that is meaningful to the entire automated system.