University of Manchester

Industrial Rubber

O’Fallon Casting

Siemens 3D laser scanning monitors turbine blade production quality

NikoN Metrology NewsCase Studies and Product News VoluMe 05

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LC60Dx Digital line scanner

LC60Dx brings laser scanning on CMM in the accuracy range of tactile measurement.By acquiring a multitude of measurement points, LC60Dx reliably digitizes freeform shapes and supports highly accurate feature extraction.

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ContentInterview CEO Yoshikawa 4

Introducing Nikon Instruments 6

University of Manchester 8

Industrial Rubber 11

New digital scanners 12

Siemens 14

O’Fallon Casting 18

ITA 21

RWTH 22

DEK 24

XT V 130 25

Process Sciences Inc. 26

BTM Corporation 28

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From Metris to Nikon MetrologyNIkON MetROLOgy I VISION BEYOND PRECISION

With the acquisition of Metris last year by Nikon, the world of industrial metrology continues to consolidate. With the Control Show coming up, it is the right time to offer an open forum to kenji yoshikawa, the CeO of the newly formed company Nikon Metrology. He looks back at the past months and unfolds the plans for the future.

kenji yoshikawa already works for Nikon for 30 years. Over the years, he led Nikon Instruments in the eU and held leading positions with Nikon Instruments in the USA. From 2001 to 2009, he was general managing director of Nikon Instruments Industrial Systems. yoshikawa is therefore very familiar with metrology, and is happy to share his views on how metrology impacts the entire design-through-manufacturing process chain.

A new company, a new baselineThis is exactly what the new baseline of Nikon Metrology conveys. “Vision beyond Precision” expresses how innovative metrology and precision instruments help manufacturers deliver premium quality products in a shorter time with fewer resources.

why “Vision beyond Precision”?K.Y. : We carefully selected this baseline because we want to take the company one step further. In addition to being a leading metrology and precision solution supplier, we envision an in-depth understanding of what customers require to become more productive and efficient.

How did Nikon’s interest for Metris grow?K.Y. : Nikon always followed how successful optical metrology innovations fuelled the growth of Metris. Non-contact metrology is the common ground between Metris and Nikon, because Nikon is known as a leading manufacturer of 2.5D vision product and microscope systems. Acquiring Metris perfectly fitted in our long-term strategy to provide a full range of optical measuring solutions in small, medium and large-scale measurement.

what are the synergies in markets, technologies and organization?K.Y. : Nikon Instruments and Metris are complementary to a large extent. Nikon systems are used for contour and surface measurements, whereas non-contact Metris solutions digitize the full 3D geometry of specimens. The primary focus of Metris was on the medium and large-scale measurement segments in automotive, aerospace, shipbuilding, electronics and energy markets. This nicely complements with Nikon offering measuring solutions for small-scale applications in electronics, materials, gears and medical sectors. Also in terms of geography there is strong synergy. By merging the sales teams, we establish a very complementary sales and support organization with a worldwide coverage. Nikon Metrology – headquartered in Leuven, Belgium – takes responsibility for Europe, USA and Africa, while Nikon Instruments Japan will distribute the complete Nikon Metrology product portfolio in Asia.

How will branding change?K.Y. : Currently, we are introducing Nikon Metrology, a new sub-brand of Nikon. The

products in Nikon Metrology’s portfolio cover the former Metris products and the industrial metrology products of Nikon Instruments. The latter group of products covers automated vision measuring systems, industrial (measuring) microscopes, optical comparators, autocollimators and semiconductor inspection systems and more. All former Metris products will adopt new branding, incorporating the values of the Nikon Brand: innovative and trustworthy products that excel in precision and productivity to meet customer expectations.

How will customers benefit from the acquisition?K.Y. : The perfect match between the two entities in terms of technology and geography will certainly bring value for the customer. Customers will benefit from excellent support through Nikon Metrology’s worldwide client-focused organization. At the same time, we will expand the implementation of our typical Japanese process-based production methods to consistently realize highest product quality standards. Nikon’s strong company position and long-term commitment guarantees future-proof investments and a growth path for continued product development.

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How will Nikon Metrology capitalize on new market trends?K.Y. : Manufacturing companies implementing a digital development process are more successful in reducing time to market and cutting development costs. Digital inspection is key in this regard, as it is the backbone of today’s design-through-manufacturing process. Optical inspection solutions – including 3D laser scanning, point cloud processing, graphic part-to-CAD verification and virtual part assembly – detect potential flaws earlier and reduce time to market. Manufacturing economics can be further optimized by tightly integrating geometry inspection into manufacturing. Instead of running quality checks in dedicated inspection facilities, state-of-the-art production lines apply metrology for in-process measurement or even metrology-assisted production. Convincing examples include inline inspection performed at different stages in the car manufacturing process and metrology solutions supporting first-time-right assembly of aircrafts and cargo ships.

what is Nikon Metrology’s mission and strategy?K.Y. : In the short term, we want to consolidate the organization of the Nikon Metrology group and position its brand in the market. In the medium and long term, we intend to become the worldwide market leader in the non-contact 3D metrology market sector.

“ Incorporating the values of the Nikon Brand: innovative and trustworthy products that excel in precision and productivity.

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renowned for unrivalled optical excellence

Nikon Corporation is a leading Japanese industrial multinational with a strong global consumer brand and a pioneer in the field of optical technology. Nikon catering a broad public with premium cameras is commonly known, however this activity only started in 1945. Since its inception 18 years earlier, “Nippon Kogaku KK” started producing precision optical glass. In 1925 the brand expanded to produce the first microscope with a revolving nosepiece and interchangeable objectives - the Joico microscope.

The next few decades brought considerable growth to the microscopy division, ground-breaking polarising and stereo microscopes were introduced in addition to new products for the increasing measuring and inspection market. Today, the diverse product lines of Nikon Instruments cover precision optical and digital imaging systems for inspection and non-contact measurement. These industrial-strength tools provide unmatched optical precision and increased productivity through greater automation and the elimination of human error.

lightweight and compact iNeXiV measuring systems

The iNEXIV VMA platform consists of multi-sensor measuring systems that are lightweight and compact enough to be used on factory benchtops. They offer fast automatic and accurate features that make these systems suited for a broad range of industrial measuring, inspection and quality control applications. The iNEXIV VMA systems are specifically designed for measuring 3D workpieces and incorporate sophisticated vision and laser sensing capabilities. They also provide the option to add touch-probe technology into 3D specimen measurements.

Introducing

Nikon Instruments’ industrial metrology solutions

today Nikon is a world-renowned brand, firmly established as a market leader in optical instrumentation. It is the only microscope company to manufacture its own glass, ensuring the very finest quality assurance throughout production. With over 90 years expertise in the field, Nikon has always been at the forefront of optical and technological innovation, promoting creativity and trustworthiness as part of the company’s global mission statement. Prior to acquiring Metris, the Instruments division represented roughly 6% of Nikon group sales. Its industrial metrology products comprise of vision measuring systems, industrial (measuring) microscopes, optical comparators, autocollimators and semiconductor inspection systems and more.

Highly accurate measuring microscope MM-800 for demanding industrial environments

NeoScope combines the familiarity of a digital camera with the high resolution and depth of field of a powerful scanning electron microscope (SEM).

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Autocollimators and digital length measuring systems

Nikon’s autocollimators provide exceptional measuring accuracy and reliability in demanding measurements, such as flatness or height by simple geometry. Digimicro is the name of the company’s most advanced photoelectric digital length measuring systems. They offer flawless contact measurement of dimensions, thickness and depth.

Basic to sophisticated industrial microscopes

Nikon Metrology offers a complete portfolio of industrial microscopes for a wide range of applications, from basic models to sophisticated systems for high-end inspection. The Eclipse range featuring optical and digital microscope systems offers outstanding versatility, performance and productivity.

Advanced and versatile semiconductor inspection systems

Manufacturing equipment from steppers to the most sophisticated inspection systems has given Nikon invaluable experience in the field of microelectronics. They are designed specifically for the inspection of semiconductors and flat panel displays and the management of wafers.

New advanced Neoscope seM imaging solutions

As an entirely new advanced imaging tool for industrial inspection fields, the benchtop NeoScope combines the familiarity of a digital camera with the high resolution and depth of field of a powerful scanning electron microscope (SEM). Born from the combined expertise of Nikon Instruments and JEOL, the NeoScope SEM’s advanced features are complemented by simplicity and affordability.

NeXiV VMr for fast and accurate 3D surface analysis

NEXIV VMR automated inspection systems range from small to wide measurement platforms and offer a variety of optical head options. Each system offers through-the-lens laser autofocus for high-accuracy 3D surface analysis, and intelligent search functions help with alignment to keep fixturing costs low. They also correct for deviations in expected edge and feature locations and do pattern matching measurements to ascertain the best coordinates for hard-to-determine shapes.

Measuring microscopes with full-digital control

The measuring microscopes product range focuses on industrial measuring and image analysis. These systems offer complete digital control for maximum measuring accuracy, and provide total integration of microscope peripherals managed by Nikon’s E-Max metrology software. Measuring microscopes are available with through-the-lens laser autofocus, automated edge detection and white LED illumination.

Crisp silhouette images of profile projectors

Profile projectors apply the principles of optics to the inspection of manufactured parts, by projecting the magnified silhouette of a part on a screen. To suit your specific application, each profile projector comes with multiple projection lenses, each featuring a different magnification, working distance and field of view size. Rugged optical comparators are built to handle an incredible range of specimens; delivering bright crisp images and excellent clarity, even in a sharply lit room.

Aluminum die casting part captured by the iNexiv VMA measuring system

Metalized patterns of FPC connectors for multimedia systems

iNexiv VMA-2520 CNC video measuring system

Aluminum die casting part captured by the iNexiv VMA

measuring system

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Located at the School of Materials at the University of Manchester, the Henry Moseley X Ray Imaging Facility houses a suite of six computed tomography (CT) systems. “Worldwide academic and industry researchers have access to top-class equipment that offers full resolution and length scale capabilities for samples ranging from heavy engineering items to micron-sized biological specimens,” says Professor Phil Withers, founder and Director of the X-ray imaging facility. “Evaluating stunning 3D models reconstructed from a series of X-ray images revolutionizes many research fields, including materials science, biology, mineralogy, paleontology, entomology, medicine and life science.”

About dinosaurs and other animal specimens

The Henry Moseley X-ray Imaging Facility is shedding light on a diverse range of natural samples. Recently, fossilised portions of ungual claws of

University of Manchester achieves breakthroughs in science and engineering with Computer tomography

Paleontologists rub shoulders with aircraft designers at the Henry Moseley X-ray Imaging Facility. Academic and industrial users gather instant scientific proof regarding otherwise hidden information using radiography and Computer tomography (Ct). Projects run on Nikon Metrology systems have shed new light on Velociraptor behavior, animal organ vascular networks, power plant metal corrosion and damage propagation in composite aerospace structures.

Xt H @ Manchester University (Uk)two X-ray and Computer tomography (Ct) systems allow academic and industrial researchers to literally look inside a diversity of specimens, at a detail level in the order of microns.

•Xt H gathers instant scientific proof regarding otherwise hidden information

•Powerful systems feature high accuracy, large field of view and fast image acquisition

•Walk-in radiation bay fits voluminous parts and instrumentation for dynamic investigations Taking a virtual tour inside specimens and taking accurate

measurements benefit many research fields

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failure mechanisms in composites is a tricky business, knowing that the damage often remains largely invisible externally until late in the testing process. X-ray and CT technology help gain a better understanding of the failure mechanisms and develop mathematical formulae describing the degrading performance characteristics.”

At various stages throughout the fatigue process, the composite samples are investigated in the walk-in radiation bay of the unique Nikon Metrology 320kV microfocus X-ray system. Such voluminous parts easily fit in the large cabinet bay, which is equipped with a fully programmable 5-axis manipulator designed for samples up to 100kg.

The X-ray source is a proprietary 225/320kV microfocus source with a spot size that is considerably smaller than competitors’ mini-focus sources, providing image resolution up to 3 microns.

a Velociraptor dinosaur were inspected to generate an accurate 3D finite element (FE) microstructurally faithful model. Analogue material from a similar dinosaur as well as the pedal digit and claw of an eagle owl, were analyzed to provide input data for the Velociraptor claw FE model. Strength and strain simulations confirmed that the claws were resistant to extreme forces in the longitudinal direction and therefore well adapted for climbing.

“Medicine is undoubtedly a growth area in high resolution X-ray micro tomography,” says Chris Martin, Senior Experimental Officer managing the operation of the Henry Moseley Imaging Facility. “A nice example is a research project for investigating the action of cancer treatments. It encompasses ex-vivo studies of the vascular system of blood vessels in animal brains, livers, kidneys and lungs.”

When evaluating these remarkable 3D images on powerful workstations, the software determines the volumetric fraction of the blood vessels. This project illustrates that ex-vivo CT inspection offers much higher resolution than in-vivo magnetic resonance imaging (MRI), which typically falls short on detailed visualization of the smaller vessels.

Ct is critical in studying composites failure mechanisms

According to Chris Martin, another growing research activity concerns new lightweight materials gaining popularity, particularly for aerospace applications. He mentions current research projects to develop and exploit in-situ rigs to enable multi-mode stressing of composite samples – a keen interest of the international aerospace companies the School of Materials collaborates with. “Identifying

The University of Manchester runs static and dynamic inspection using a large Computer Tomography (CT) bay

The large walk-in inspection cabinet is equipped with a custom manipulator designed for samples up to 100kg

CT slices of a Velociraptor manus claw served as input for FE modeling to predict claw capability

Ex-vivo studies of the vascular system in animal organs shed new light on cancer treatment research

“ Stunning 3D Computer Tomography models revolutionize many research fields, including materials science, biology, mineralogy, paleontology, entomology, medicine and life science.Professor Phil Withers, Founder and Director of the Henry Moseley X-ray Imaging Facility at the University of Manchester

Unlike metals, cracks in composites often remain largely invisible until very late in the testing process

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increasing productivity and pushing the limits of Ct technology

“To maximize CT infrastructure availability for fundamental research and commercial projects, we decided to operate the facility 24/7,” says Professor Phil Withers. “To free up CT equipment after data capture, the X-ray data is automatically transferred to a central cluster of computers, which handles the reconstruction of the 3D models from a series of X-ray images. This guarantees maximum productivity, while local reconstruction resources remain available in case of failure.”

“Equally important is that we try to push the limits of CT technology by focusing on the optimization of the reconstruction software. We benefit from strong programming expertise present at the University of Manchester, and have active academic links with Nikon Metrology and other CT specialists. Detailed insight into our own reconstruction software allows us to optimize data acquisition and precisely figure out how to interpret 3D Computer Tomography models.”

“Both our micro-CT systems from Nikon Metrology respond to a broad range of academic and industrial applications. The systems’ high accuracy, large field of view and fast image acquisition are well appreciated. Our experience with these systems is that parties applying CT for a specific purpose generally discover more purposes for this enabling technology. We are currently expanding the imaging facility to further explore the nano length scale, in order to provide an even wider range of possibilities.”

A premium 2000 x 2000 pixel Perkin Elmer flat panel detector accurately digitizes cracks and fractions formed in the composite material, within a 400x400mm field of view. “Superior X-ray technology is needed to get sufficient contrast, as composite parts are low-density by nature and absorb different energies in different directions,” Chris Martin concludes.

A similar approach is applied to study metal corrosion mechanisms that occur in nuclear reactors or chemical plants. CT observations provided insight into the development of corrosion pits, stress corrosion cracks and their geometries, to improve system design and deduce mathematical formulae. When dealing with metal and other dense materials, the system can be equipped with a rotating target source. Such a source generates an X-ray flux that is up to 5 times higher without risking permanent source damage, providing faster data acquisition and/or higher image accuracy. Chris Martin says that the Nikon Metrology 225/320kV inspection system also supports dynamic investigations. Its walk-in radiation bay provides sufficient space to install instrumentation to study how specimens evolve over time, either naturally or under a range of loads, temperatures or other stimuli. A triaxial loading cell, for example, can be used to monitor the evolution of voids, inclusions, fractions and disturbances in large rock and soil samples. For the inspection of smaller parts, researchers at the imaging facility use a similar, yet more compact 225kV CT inspection system from Nikon Metrology.

Imaging equipment is supported by a suite of powerful workstations for off-line visualization of data

X-ray imaging is challenged by composites exhibiting low density and direction-specific energy absorption

Pitting corrosion in stainless steel usually initiates through local breakdown of the passive surface film

To free CT equipment after completing X-ray acquisition, the data is transferred for off-line CT reconstruction

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Industrial Rubber plc manufactures rubber moldings and built a solid worldwide reputation for technical ability, flexibility, customer service and quality. Manufactured components are destined for many downstream manufacturing sectors, including medical, electronic, electrical, automotive, rail, aerospace and other engineering industries. One of its best known products, the “Light Dome” road stud reflector, is approved by the Department of transport for use on all the Uk’s roads and motorways. Industrial Rubber recently invested in a new iNexiv VMA-2520 to assure its customers of consistent high-quality products no matter where in the world they are manufactured.

“The iNexiv VMA-2520 has given us a whole new level of accuracy and precision. We can now measure to four decimal places of accuracy and can check the pieces visually with minute detail. This is an excellent quality control tool for some of our precision pieces destined for life-critical medical devices. It allows us to monitor the quality and repeatability of manufacture with great precision.”

Carol Watch, Quality Assurance Technician and iNexiv VMA-2520 user says: “Once the initial setup has been completed, measuring becomes a lot faster and many more measurement tasks can be completed in any given time. Nikon provided training sessions for all the users both individually and in a group to ensure that the system was up and running in the shortest time possible.”

Industrial Rubber plc takes quality control to new levels with iNexiv VMA-2520

Monitoring manufacturing repeatability by checking pieces visually using the iNEXIV VMA-2520

Simon Elgar, Quality Manager explains: “In addition to comprehensive plant and machinery in the UK, Industrial Rubber also has sister companies in China, enabling dual manufacturing at home and abroad. This is a great advantage in meeting large batch orders and in ensuring continuity of supply even when customers have exceptional demand.” Quality-checking rubber components can be challenging as rubber is a dynamic material that can compress under its own weight, can be flexible and can deform on contact. Non-contact vision metrology systems are, therefore, the only realistic inspection option. All quality checks are carried out centrally at Industrial Rubber’s UK site and when Industrial Rubber decided recently to upgrade its QC facilities, it chose to invest in an iNexiv VMA-2520 vision metrology system.

“ The iNexiv VMA-2520 is an excellent quality control tool for some of our precision pieces destined for life-critical medical devices.Simon elgar, Quality Manager for Industrial Rubber plc

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realizing higher scanning accuracy and speed

Nikon Metrology introduces the all-digital LC60Dx scanner with powerful CMOS technology, an evolution from the LC60D CMM laser scanner. The major improvement for LC60Dx is increased accuracy, resulting in a typical MPEp value of 7 micron according to EN ISO 10360-5, the standard method to determine the accuracy of probe measurements. This brings the scanner in the accuracy range of tactile measurement, while offering the advantage of capturing 75,000 points a second. By acquiring a multitude of measurement points, LC60Dx reliably digitizes freeform shapes and supports highly accurate feature extraction.

Also new in the LC family is the LC50Cx laser scanner. This entirely digital scanner benefits from an upgraded scanning rate of 45 stripes per second and Enhanced Sensor Performance of the 3rd generation (ESP3). Through ESP3 technology, LC scanners digitize surfaces with varying color, high reflectivity or abrupt transitions under any lighting conditions by dynamically adapting laser beam intensity point per point. Altogether, the LC50Cx is an affordable, yet powerful CMM scanner offering adequate productivity for a broad range of inspection and reverse engineering applications. simplified CMM programming and faster feature scanning

Fast scanning along straightforward motion paths also reduces off-line CMM programming effort. This compares favorably with tactile inspection that requires elaborated programming to define numerous indexing head rotations and multiple CMM axes displacements.

The single-laser LC60Dx scanner is ideally suited for digitizing freeform surfaces. Therefore it is used a lot for the verification of die and mold components, such as a sheet metal panel, turbine blade or plastic parts. The scanner is equally capable of tackling dimensional

New digital scanners raise the bar in terms of inspection accuracy, ease and throughput

3D laser scanners relentlessly digitize prototype and serial produced parts at a growing number of worldwide manufacturers across markets. yet again, Nikon Metrology reconfirms its status of leading innovator by introducing new digital laser scanners setting new performance standards. the all-digital LC60Dx scanner brings laser scanning on CMM in the accuracy range of tactile measurement. For handheld scanning applications, Nikon Metrology releases the ModelMaker Dx series: digital technology that scans all sample materials and nearly all surface finishes in a single move. Nikon Metrology also presents new releases of Camio and Focus software that drive these digital scanners and manage data acquisition, processing and analysis.

New technology innovation brings the LC60Dx in the accuracy range of tactile measurement, while capturing 75,000 measurement points a second

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Handheld laser scanners offer great value for on-site inspection and reverse engineering applications. Large manufacturers scan vehicle body parts at different sites to ensure assembled body elements will fit perfectly. Reverse engineering the available space envelopes in vehicles for specific after-market developments is also popular. The scan data streamlines the development of customized items such as armored vehicle, structural tow bar connections and turbo chargers for tuned sports cars.

Faster and more versatile point cloud processing

The new subrelease of Camio 6.3 software subrelease speeds up data acquisition even further by introducing so-called Fly-by Scanning mode. Using this mode, the software automatically calculates optimum and continuous scanner motion path curves and avoids scanner stops, resulting in up to 25% faster scanning and simplified programming.

Furthermore, Focus Inspection 9.2 offers a complete set of functions for digital surface and feature inspection. It instantly delivers geometric feedback that is essential in tuning final part design and monitor product quality in the fabrication process. In addition to supporting infinite point cloud size on 64-bit computers, Focus introduces extended language support, CATIA V5 file import, enhanced feature extraction and new GD&T capabilities. GD&T in Focus is a complete implementation, which is compliant with the ASME Y14.5M standard.

Graphic visualization of processed data makes it faster for parties concerned to review the inspection report and understand the implications of dimensional data analysis. Systematically gaining more profound insight avoids trial and error, translating into fewer prototyping rounds and quality that is better maintained along the entire production line.

problems related to cast metal shrinkage and sheet metal spring back issues.

To achieve highest throughput when inspecting geometric features or measuring deep into pockets, Nikon Metrology offers the Cross Scanner. With lasers sweeping from 3 different angles and 3 cameras capturing all the action, the XC65D scans feature geometry all around in one go. The XC65D not just captures all 3D details of slots, notches and edges, but is also able to scan specialized geometric features, including connection pins, welded bolts, T-studs and christmas trees. By acquiring a multitude of measuring points, the position and orientation of geometric features can be extracted much more reliably. In addition, the XC65D supports single-scanner mode with one selected laser out of 3 operating at full 75 Hertz.

simply scan anything with digital handheld scanners

For handheld scanning applications, Nikon Metrology launches the ModelMaker Dx series (MMDx). This laser scanner family features digital camera technology and ESP3 to scan all sample materials and surface finishes in a single move. The MMDx also features an anti-reflection filter for optimum scanning of highly reflective materials. This advanced filter takes into account the correct laser beam projection and eliminates reflected projections. MMDx laser scanners come in 50, 100 and 200mm laser stripe widths, to suit every inspection need. The scanner is compatible with Nikon Metrology arms and all leading 3rd party articulated arms, including Faro and Romer/ CimCore.

For applications involving larger parts, MMDx technology is also available as part of the K-Scan Optical CMM system. This unique scanning system allows the operator to freely walk around and take scans as desired.

Digital camera technology and enhanced Sensor Performance of the 3rd generation allows the handheld MMDx scanner to digitize all sample materials and surface finishes in a single move

Using Fly-by Scanning mode, Camio automatically calculates optimum and continuous scanner motion path curves, resulting in up to 25% faster scanning

Focus introduces support of infinite point cloud size on 64-bit computers, extended language support, CATIA V5 file import, enhanced feature extraction and new GD&T capabilities

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Siemens verifies turbine blade geometry with 3D laser scanners

Siemens, a worldwide leader in power plant turbines, investigates laser scanning to monitor the production quality of casting blades. Powerful 3D scanning technology accurately captures the aerofoil surfaces of blades as well as their fine alignment notches. A single mouse click triggers the automatic geometry verification process that provides detailed insight on the basis of graphic part-to-CAD comparison. LC50 laser scanning and Focus point cloud processing are the cornerstones of a much faster and operator-independent digital inspection process.

Capturing the complex geometry of turbine blades

The quality of turbine blades in stationary gas turbine power plants is critical. As hot combustion gas expands through the turbine, it spins aerofoil blades to drive a generator that produces electricity. Air-cooled in its internal channel, turbine blades reach high rotational speeds and face temperatures up to around 1000°C. Turbine blades are designed for optimum aerodynamics and mass center location, and are made of advanced metal alloy castings to increase strength, resist extreme temperature, and avoid corrosion. Inaccuracies in blade geometry and positioning may cause energy conversion efficiency loss and untimely blade failure.

The complete amount of turbine blades that Siemens produces on a yearly basis are measured at different manufacturing stages. “Already 10% of this amount of blades are inspected through laser scanning,” says Jörg Ziege, Metrology Manager at Siemens Fossil Power Generation in Berlin, Germany. “Our metrology engineers use 2 Nikon Metrology LC50 laser scanners to verify the shape of the aerodynamic blade surface and the dimensions of milled planes and flanges, drilled holes and alignment notches. We opted for laser scanning to efficiently and confidently capture freeform surfaces and geometric features. Compared to traditional tactile inspection, laser scanners capture much more point data in a shorter time frame, and embed measurement and analysis in an automatic digital inspection process. At the same time, non-contact measurement requires little or no blade pre-alignment, and eliminates probe compensation when scanning freeform blade surfaces.”

Particularly important are the linear notches that correctly align a blade to the inner and outer rotor ring rails of a turbine wheel.

LC50 @ Siemens (ge)LC50 laser scanners verify blade geometry and alignment at Siemens to guarantee premium economy and long life in stationary gas turbines.

•Scanners accurately capture blades’ aerofoil surfaces and fine alignment notches

•Automatic geometry verification process executes graphic part-to-CAD comparison

•Non-contact measurement is faster and requires little or no blade pre-alignment

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Thanks to automated inspection in Focus software, one click is sufficient to launch the inspection routine.

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Ziege explains that these alignment notches are manufactured internally using electrical discharge machining (EDM). “Inaccurate notch locations cause blade misalignment, and increase the likelihood of blade failure problems in the future. To capture the fine alignment notches, the LC50 performs multiple scans under different angles. By capturing thousands of inspection points per second, Focus software is able to apply far more accurate line fitting to determine the positions of notch edges and verify the angles between notches.”

Automatic inspection providing deeper insight

To prepare a laser scanning inspection routine for a new blade type, Ziege’s team sets up an inspection macro in Focus Scan software. This is a one-time effort that roughly takes half a day, depending on blade type and size. At the CMM, or off-line on the basis of blade CAD information, they define the straightforward travel paths of the

Linear blade notches determine the position of the blade relative to inner and outer turbine ring rail structures.

On average, a blade is inspected in a few minutes, including repeated scanning of its linear notches under different angles.

scanner and corresponding scanner angles. According to Ziege, it is much easier to define scanner motion and orientation than to program the hundreds of individual touch sensor points for a tactile inspection job. In addition, laser scanning only requires standard holding fixtures, whereas traditional inspection methods demand costly dedicated positioning and fixation tooling.

Once the macro is defined, serial blade inspection is run on either one of the two CMMs in the metrology laboratory. “One click on the button is all it takes to launch the inspection routine,” explains Ziege. “The scanner automatically moves around the blade, while capturing surfaces and features using a multitude of measuring points. On average, a blade is inspected in a few minutes, including repeated scanning of its linear notches under different angles. Since we deployed laser scanning, we reduced the inspection execution time. A short calibration routine is executed weekly to guarantee high accuracy.”

Focus Scan manages the data that is acquired in real time, and Focus Inspection executes alignment, filtering and meshing entirely automatically. Also the predefined analysis work is executed automatically. Graphic displays of blade sections show geometric part-to-CAD deviation, and calculated dimensions indicate the exact width and orientation of alignment notches, for example. Ziege says that results and analyses are incorporated into digital reports that accompany the inspected blades when turned out to customers. “As laser scanning reports yield more profound insight, they are essential for us to ensure high production quality and minimize blade failure in the field. Reports indicate issues that we take up internally and with suppliers in our continuous effort to systematically improve the quality of Siemens turbine blades.

“ Requires little or no blade pre-alignment, and eliminates probe compensation when scanning freeform blade surfaces.Jörg Ziege, Metrology Manager for Siemens Fossil Power Generation

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The wireless SpaceProbe and graphic operator assistance speed up inspection

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Measuring right at the production line

Farmers and construction workers value compact Gehl skid loaders, telescopic handlers, track loaders, excavators, all-wheel-steer loaders, articulated loaders and asphalt pavers for their ingenuity, innovation and reliability. At the production site in Madison, South Dakota, engineers manufacture skid and track steer loaders and telescopic handlers that have been designed at the company headquarters in Wisconsin. To monitor the production quality of this compact outdoor equipment, Gehl staff run geometric measurement right at the production line. “Quality control involves the inspection of selected geometric features and surface points on steel parts after being stamped, drilled, and painted,” explains Joseph Palmiotto, Quality Assurance Manager for Gehl in Madison. “We not only monitor finished parts, but also verify mechanical fixtures used for part production and assembly of chassis and driver compartment, for example. To more efficiently execute metrology tasks on components of various sizes, we moved early last year from an articulated measuring arm with a limited reach to a Nikon Metrology K-Series system that covers a considerably larger measuring volume.”

gehl reduces skid/track steer loaders inspection time by 50% with k-Series

engineers at gehl’s South Dakota production plant in Madison found a faster way to verify large production fixtures and manufactured parts of construction and agricultural equipment. they simply position the portable Nikon Metrology k-Series Optical CMM on the production floor, and measure points of choice right away using the wireless tactile SpaceProbe. this ergonomic metrology system allows gehl to halve geometric verification time-spending on chassis and driver compartment, and yields deeper insight when troubleshooting equipment prototypes.

k-Series @ gehl (USA)gehl engineers use a k-Series Optical CMM and a tactile SpaceProbe to verify large production fixtures and manufactured parts of construction and agricultural equipment.

•Portable system and wireless probe provide zero setup time and superb ergonomics

•Inspection time of skid/track steer loaders is reduced by 50%

•Scalable measurement volume fits an entire loader vehicle

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50% faster inspection and instant data feedback

“Overall, we realize 50% inspection time gains,” says Yeager, attributing this to K-Series’ zero setup time and Optical CMM covering all inspection points from a single position. “The absence of mechanical constraints creates superior operator comfort, which allows the inspection of hundreds of points in and around a skid steer loader to be performed a lot faster. After taking measurements in one production line, we readily move the system to another line using the cabinet roller and Optical CMM trolley. Overall, the system is used 5-6 hours a day by different operators in our production facility.” K-Series consistently reaches accuracy level of 1.5/1000 of an inch, and outputs the data in any graphic or numerical format of choice. Instant data feedback is critical in production, but also beneficial when assessing prototype vehicles of new models. Yeager explains that K-Series is sometimes brought in to quickly trace the root cause of specific assembly issues. “In the case of a load arm bushing problem, Gehl metrology engineers traced the source of the problem with the SpaceProbe without having to disassemble the load arm. As K-Series saves time and supports engineering, our colleagues at Gehl engineering headquarters in Wisconsin now use the same metrology system.”

Making metrology an integral part of manufacturing

Inspecting telescopic handlers or larger assemblies measuring 10 feet or more seems quite challenging. Joseph Palmiotto says that he considers purchasing additional Optical CMMs, which would enable him to double or triple the measurement volume. As an alternative, his team uses magnetic reference spheres to leap frog measurements taken from multiple camera standpoints.

Palmiotto is impressed with K-Series because he sees that measurement time is cut in half, and that production staff is eager to tune the process based on the inspection results. “Where they initially backed down our internal metrology services, they are now begging for it. Portable ergonomic metrology systems such as K-Series increase the acceptance of metrology and make it an integral part of our manufacturing operations.”

Zero setup time and unmatched ergonomics

“The K-Series system impacts productivity big time,” says Dale Yeager, Gehl Quality Technician. “The Optical CMM immediately activates a measurement volume that fits an entire loader vehicle, even with its lifter moved in most upward position. Using the wireless tactile SpaceProbe, we can walk around and measure predefined points sequentially, as visually shown on the PC screen.”

When touching a point, the metrology software provides instant confirmation regarding measurement validity. Yeager says that quality technicians define inspection procedures by clicking the desired points on the graphic user interface and enter the points in a macro to record the process flow.

The wireless inspection probe creates a superior comfort level that increases inspection productivity

The operator touches predefined points sequentially, as visually indicated on the PC screen

“ We moved from an articulated measuring arm to a K-Series system that activates a measurement volume that fits an entire loader vehicle.Joseph Palmiotto, Quality Assurance Manager for gehl

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rapid prototyping of cast parts is good business

O’Fallon Casting of St. Louis, Missouri, is a premier nonferrous investment casting company that has built its reputation on making high-quality, competitively priced castings to meet demanding end-user applications. In its 50,000 square-foot facility, the company is specialized in casting a range of aluminum, metal and composite alloys, and serves a broad range of markets.

One area of growth for the company has been in its rapid prototyping operation. It uses expendable patterns generated from a 3D model from a CAD file to quickly and cost effectively produce a part and verify its design prior to building production tooling. “In recent years, there have been many improvements in the quality of pattern surface finishes, pattern accuracy, and pattern material alternatives, and today’s patterns are more user friendly to the near net shapes offered by the investment casting process,” said Ben Galmiche, O’Fallon Casting quality engineer. Because of these improvements, rapid prototyping of cast parts is good value for customers who want to reduce overall tooling costs and introduce products into the marketplace quickly. Quality inspection is a crucial aspect of the casting business.

O’Fallon Casting Inc. increases prototyping speed and quality using Cross Scanner and PolyWorks software

O’Fallon Casting in St. Louis, Missouri USA took a new approach by installing a Cross Scanner from Nikon Metrology and PolyWorks software from InnovMetric Inc. A prototyping project illustrating the innovation of 3D scanning and point cloud based inspection involved the housing for an integrated wing tip light of the Boeing 787 Dreamliner. O’Fallon engineers inspected both the housing’s foam pattern and inherent aluminum part, and managed to cut the entire process throughput time by 50%. the countless measurement points acquired and the CAD comparison analysis graphics enabled them to better supervise the process, eliminate prototype rounds and deliver top quality.

Prototyping the housing for an integrated wing tip light of the Boeing 787 DreamlinerCross Scanner

@ O’Fallon Casting (USA)the Cross Scanner digitized a housing prototype of an integrated Boeing 787 Dreamliner wing tip part. the point cloud data of the housing’s foam pattern and inherent aluminum part were fed into PolyWorks for further processing.

•Process cuts throughput time by 50%, reducing turnaround time for customer

•Detailed scans and graphic analysis improve quality and eliminate prototype rounds

•Reduced tooling cost through fast and accurate prototype verification

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Here is how O’Fallon successfully integrated the point cloud based analysis in all phases of its rapid-prototyping process:

•A pattern of the wing tip light housing was created from the customer’s 3D CAD model of the part using stereolithography (SLA) and selective laser sintering (SLS).

•The pattern was then visually and manually inspected to determine if it conformed to the reference CAD model of the part and if it was properly proportioned to account for shrinkage.

•Once the pattern was verified and approved through Nikon Metrology 3D scanning and PolyWorks inspection, O’Fallon Casting built a ceramic shell around the rapid prototype pattern.

•The ceramic shell with the pattern went through a burn out process, where the pattern was vaporized to leave only the ceramic mold. The part was cast from A356 aluminum artificially aged to the T6 condition.

•The part was then measured using the Global CMM and the laser scanner. The point cloud data gathered during this routine was transferred to the PolyWorks software electronically via the company’s internal network.

In the overall process, O’Fallon Casting used 3D digitizing and PolyWorks to inspect both the foam pattern and its inherent aluminum part. In the scan process, excess data is collected to capture freeform surfaces and accurately characterize 3D features. As the Nikon Metrology scanner sweeps lasers in 3 directions, the entire geometry of features is captured consistently, regardless of the scanning direction. This allows PolyWorks software to extract features through hundreds of points, rather that relying on a handful of tactile inspection points. Simplified scanner motion paths also means more straightforward off-line CMM programming. “The Cross Scanner and Focus Inspection software from Nikon Metrology is a powerful package,” marked Galmiche. “In less than one week we were up and running to use 3D scanning in real customer projects. The non-contact scanning solution offers the tremendous advantage of gathering complete data sets, better than what we have ever been able to accomplish through tactile inspection. Likewise, we now perform a laser scanning job in less than a day whereas it previously took us nearly one week. We have reached the point where laser scanning is used in virtually all our rapid prototyping projects, paying off big time both for inspection and troubleshooting purposes.”

Charged with increasingly complex freeform part surfaces

“In the past, we did not have an effective and efficient way of inspecting solid models. We had an old cantilever-type coordinate measuring machine (CMMs) and used a touch trigger probe to collect dimensional data. This process was slow and we were looking for a new alternative.” For decades, the use of traditional touch probes on CMMs has been the gold standard. However, the time-consuming process becomes an even bigger drain on a quality department’s valuable resources. Metrology engineers are charged with increasingly complex freeform part surfaces that take an exceptionally longer time to thoroughly inspect.

To help enhance the turnaround time of its rapid prototype inspection process, O’Fallon Casting turned to 3D scanning and point-cloud-based inspection. O’Fallon Casting replaced the older CMM and equipped it with a Nikon Metrology Cross Scanner, a high-speed, multi-stripe 3D laser scanner designed for inspecting part features that provides optimal point distribution in all directions. This new 3D measurement system was delivered with the PolyWorks software suite from InnovMetric Software Inc.

turbo charging a CMM with 3D laser scanning

This investment proved to be the right move, one that paid off quickly. Particularly when O’Fallon Casting received a request to inspect the housing for an integrated wing tip light of the Boeing 787 Dreamliner.

Part inspection with Ben Galmiche (left) and Ted Schnarre (right) from O’Fallon Casting Inc.

Example of an integrated wing tip light Boeing 787 Dreamliner © Boeing

“ The Cross Scanner offers the tremendous advantage of gathering complete data sets, better than what we have ever been able to accomplish through tactile inspection.Ben galmiche, Quality engineer for O’Fallon Casting

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Powerful point cloud processing and graphic geometry analysis

PolyWorks software’s IMAlign™ module was used to align partial scans, verify surface coverage and remove scan overlap data in creating a single set of data points. Next, the aligned scans were merged using the IMMerge™ module to create a highly accurate finely detailed polygonal mesh model of the digitized parts.

The polygonal mesh model was then exported to PolyWorks IMInspect™ module for the actual dimensional inspection process. For this specific project, a global comparison was performed by calculating the deviation between each digitized point and its corresponding CAD reference. A color map was displayed according to the tolerances set by O’Fallon Casting. O’Fallon Casting engineers measured the clearance of the part by comparing 3D distances between two planes to ensure that the ray of light is projected without interference. gaining deeper insight through graphic geometry analysis

“In addition to the data, we include snapshots of the model comparison so that customers can quickly see where the part is out of tolerance,” Galmiche said. “We can also illustrate where the part is just a small amount out of tolerance or greatly so by using different colors to indicate different tolerance ranges. Finally, thanks to the PolyWorks IMView free viewer software, our customers can visualize their inspection projects in 3D from their own workstations.”

Nikon Metrology’s Cross Scanner acquired the entire geometry of the wing tip light housing.

A color map showing the global comparison between the digitized points and their CAD reference.

Wall thickness, clearance, 3D angle and flatness analyses are performed using PolyWorks IMInspect

Example of an integrated wing tip light

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Over the last few years, the aeronautical industry is using – at an increasing pace – automation solutions for aircraft structure assembly. this scenario has motivated two Brazilian institutions –– the Aeronautics Institute of technology (ItA) and embraer –– to develop a joint project. this encompasses designing and commissioning a low cost, flexible automation system for aircraft structure assembly suitable for the Brazilian aeronautical requirements. A number of industrial partners have joined the ItA – embraer project, among them Nikon Metrology, for supplying the equipment for setting up the large volume measurement cell.

A flexible low-cost automation system for aircraft structure assembly

Last June, the laboratory of Aircraft Structure Assembly Automation opened its doors after eleven months of work. 300 square meter (3,230 square foot) and 10 meter high (33 feet), the laboratory houses equipment, devices and systems that are considered innovative within their respective technical areas, namely:

•Robotic cell equipped with two industrial anthropomorphic robots that yield high load capability and large work space volume

• Large-volume measurement cell that consists of iGPS, photo-grammetric station and a Laser Radar (in process of purchase)

•Automatic alignment and levering process for aircraft fuselage using anthropomorphic robots assisted by external measurement systems, such as iGPS, Laser Radar, laser tracker, optical systems and theodolites.

• In this process, one anthropomorphic robot positions a fuselage ring relative to the other fuselage rings in order to assemble the complete aircraft structure. An alternative solution for the alignment and levering process is being derived based on a dedicatedly designed, non-conventional robot, to meet the requirements.

•Multitask end effector for drilling, inserting and inspecting rivets into the aircraft fuselage.

Joint project developed by Brazilian institutions itA and embraer

Besides the technology involved, the project aims at capacitating human resources in the technical area of the laboratory. The project is named Aircraft Structure Assembly Automation, and it is financially supported by Brazilian research agency FINEP and Embraer.

A number of industrial partners have joined the ITA – Embraer project described herein, among them Nikon Metrology, for supplying the equipment for setting up the large volume measurement cell.

The automated process of accurately positioning a fuselage ring relative to another fuselage ring. “ Over the last few years, the

aeronautical industry is using – at an increasing pace – automation solutions for aircraft structure assembly.igPS & Laser Radar @ ItA (BR)

In the automation system commissioned by ItA and embraer, igPS and Laser Radar assist the cell robots with automatic fuselage assembly alignment and levering.

•Nikon Metrology equipment is selected to set up a large-volume measurement cell

•Automatic alignment and levering process for optimum assembly of fuselage rings

•igPS and Laser Radar increase the positional accuracy of anthropomorphic cell robots

iGPS and Laser Radar used to set up large-volume

measurement cell commissioned by ITA and Embraer

Versatile production concepts driven by metrology

Innovation is shaped by market stimuli and market dynamics, but is also driven by research findings from RWTH in Aachen. WZL, RWTH’s Laboratory for Machine Tools and Production Engineering, develops new and optimizes existing solutions through a practice-oriented research and development process for production industries’ clients, and helps manufacturers improve their competitiveness. WZL’s department of production metrology and quality management relies on optical metrology to guide tomorrow’s shop floor production processes.

The versatility of a production system is an essential aspect that mainly focuses on the ability to understand organization and technology at low investment costs, while offering premium flexibility. Optical metrology in combination with industrial robots is a key enabler to achieve this level of flexibility. Robots are flexible production entities for handling, mounting, welding or other production processes that can be effectively deployed in production systems that manufacture small series first-time-right and easily switch from one product type to another. Still, their potential is left largely unexploited because too much time is needed to set up robot processes, program robot movement, rig it or align process fixtures. B. Damm, team leader of the imaging processes and coordinate metrology groups, marks that: “metrology is not a necessary evil. In particular, optical metrology technologies will be the ears and eyes of versatile and self-optimizing production systems of the future!”

In search of versatile production system concepts for german manufacturing industries, RWtH Aachen invested in Nikon Metrology igPS metrology. the renowned institution’s “Werkzeugmaschinenlabor WZL” uses a cell populated with two industrial robots to study how manufacturing quality can be maximized using igPS. Scientists at WZL confirm that the affordable combination of off-the-shelf robot and metrology technology yields better economics than expensive specialty equipment or manual work. Invisible igPS laser beams continuously track the locations of the robot’s tool center point, and feed back the filtered data in closed loop to improve absolute robot precision. WZL masters this unique concept to improve the manufacturing quality of numerous dynamic industrial applications, including handling, assembly, burnishing, deburring, welding and pleating.

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“Werkzeugmaschinenlabor WZL” relies on metrology to guide tomorrow’s shop floor production processes”

RWtH Aachen researches huge dynamic manufacturing potential of igPS enabled industrial robots

igPS @ RWtH (ge)igPS tracks robot tool center point positions in real time, and feed back the data in closed loop. igPS metrology is mastered to improve the manufacturing quality of dynamic industrial applications.

•igPS-turns an entire manufacturing cell into a single metrology enabled environment

•igPS enabled robots yield better economics than expensive specialty equipment or manual work

•Ideal for flexible robotized production cells manufacturing small series first-time-right

23News I Volume 5

Better dynamic robot precision through kalman filtering

Originally used to allow the spaceship of the Apollo program to land on the moon, Kalman filtering will guide dynamic robot movement with higher precision. “Robots need continuous adjustment when manufacturing tasks are actually taking place,” says A. Schönberg, responsible research assistant for the robot cell and member of the imaging processes group. From a mathematical point of view, Kalman is the optimum filter type for vector-based Gauss-Markov-Processes, as no other linear method exists that reaches smaller errors between the actual and predicted state of a system.

R. Schmitt, Professor of the Chair of Production Metrology and Quality Management, concludes: “Top-notch iGPS metrology combined with WZL specialist know-how will lead to flexible and affordable robot technology that may fit numerous manufacturing applications. This very interesting and promising topic will be targeted on a highly scientific level in an upcoming EU-project.” – Candidate partners are welcome to contact WZL.

“ Optical metrology technologies will be the ears and eyes of versatile and self-optimizing production systems of the future.B. Damm, team leader of the imaging processes and coordinate metrology groups for WZL of RWtH

unique laser-based igPs robot tracking

“The winning combination of industrial robot workhorses with innovative large-scale metrology offers distinct advantages compared to equipment specifically designed for a particular manufacturing task,” says J. Jans, Nikon Metrology Executive V. P. Marketing. “Today too many manufacturing tasks are performed by hand, or when automated the task is performed by expensive dedicatedly designed precision equipment.” For companies to remain competitive in the global setting, WZL scientists research enabling industrial application technologies, such as iGPS, to increase manufacturing precision, flexibility and throughput.

iGPS stirs up manufacturing communities by turning an entire manufacturing cell into a single metrology enabled environment. iGPS robot sensors capture their individual elevation and azimuth angles with respect to multiple iGPS transmitters that are within line of sight, based on the timing of the arriving invisible coded laser pulses. This is iGPS’ unique approach to continuously tracking robot tool center point positions, and possibly also the part that is clamped by the robot(s). By returning the acquired metrology data to the robots using a closed feedback loop, robot positioning improves drastically. iGPS plays an important role in this innovative metrology-adjusted process, which nearly eliminates the influence of robot warm-up, drift and backlash. Following this approach, Nikon Metrology transforms industrial robots into highly accurate and efficient in-line manufacturing stations.

Powerful solution for dynamic manufacturing

Nikon Metrology has already an impressive track record in metrology-assisted production. In a project that aimed at stretching the accuracy limits of industrial robots, Airbus applied iGPS to improve the precision of robotic drilling and riveting at CAD specified wing locations. As a result, the aerospace giant’s wing drilling and riveting cell is capable of reaching an accuracy level that is 10 times better than before.

Dynamic applications are much more challenging. When two robot-clamped parts are being welded, for example, the positioning of the parts ideally requires real-time adjustment, not just at the start and end point of a seam weld. WZL is heavily involved in optimizing this critical real-time adjustment process that determines the precision of dynamic manufacturing procedures.

An industrial robot cell allows RWTH WZL to study how to manufacturing quality can be maximized using iGPS

As part of calibration, a double ball bar is used to measure the accuracy of robot motion cooperation

Measuring key tolerances in up to nine directions

Purchased as part of its on-going quality improvement programme, DEK is now using the Nexiv VMR-6555 on a daily basis to measure key tolerances in up to nine directions on screens comprising over 500 micro-circuits located on just 300mm2. These are destined for use in the screen printing of sensor strips associated with handheld blood glucose testing meters.

According to Roger Holding, Product Development Manager – Screens at DEK, “We chose the Nexiv because its unique 8-segment LED ring illumination system allowed us to clearly locate the edge of our emulsions, even though they are coated on to a mesh. This has proved a problem with other video measuring systems, but the Nexiv merely ignored the mesh and allowed us to focus clearly and consistently on the emulsion that has been deposited.Furthermore, using the Nexiv’s AutoMeasure software, it was a simple process for us to automate the entire measuring sequence.”

Being able to measure the dimensions of the micro circuits with such a high degree of accuracy has allowed DEK to review its screen making processes and improve the quality of the end product. “Prior to the arrival of the Nikon system we could not measure the tolerances accurately enough to allow us to review how minor modifications to the screen process altered its performance” added Roger.“Now, armed with the data from the Nexiv, we have been able to optimize the process and materials in order to meet the increasingly tight demands placed upon us by our customers.”

In addition to the glucose sensors, the Nexiv has also been programmed to measure emulsion screens destined for use within electronic components for automotive braking systems and aircraft instrument display systems. However, with an exceptionally high level of accuracy, the Nexiv should be more than a match for anything DEK chooses to measure on it.

NeXIV gives Dek the edge in emulsion screen dimensional deposition measurement

By investing in a Nikon Nexiv CNC video measuring system, Dek Screens has significantly improved the accuracy and precision of its emulsion screen processes, leading to enhanced quality and reduced wastage.

“ Previously, we could not measure the tolerances accurately enough to allow us to review how minor modifications to the screen process altered its performance.Roger Holding, Product Development Manager – Screens at DEK

Nexiv VMR-6555 @ Dek Screens (Uk)Dek Screens invested in a Nexiv VMR-6555 video CNC inspection system to obtain higher-precision sensor strip micro structures of handheld blood glucose meters.

•Fast automated inspection of 500 micro circuits located on just 300mm2

•Coated emulsions edges are precisely located using a unique 8-segment LeD ring illumination

•Increased measurement accuracy resulted in a higher quality end product

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the compact yet versatile Xt V 130 X-ray inspection system efficiently traces failures inside complex electronic devices and multilayer circuit boards. to maintain highest quality standards in an environment of continuous miniaturization, electronics manufacturers prefer deploying intuitive, reliable and efficient X-ray imaging capability in-house. today, any OeM and subsystem supplier of consumer, automotive, aerospace, medical and electronics can take advantage of X-ray inspection technology to get the job done!

XT V 130 - Geared up for automated QA on serial-produced electronic samples

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operators intuitively navigate through the layers of a PCB or inside electronic devices, as joystick control changes position, angle and zoom as desired. Renowned for its powerful automation capabilities, the XT V 130 runs first-article inspection in minutes, instead of hours or days. Furthermore, the system puts safety first, offers low cost of ownership and small footprint, and does not require high-voltage power or special floor conditions.

QA workhorse for electronics X-ray

Hidden electronic defects that arise during production or assembly generally result in system failure, fabrication delay and additional cost. Defects can be traced efficiently by literally looking inside electronic specimens, at detail levels in the order of microns. The XT V 130 system is ideally suited to quickly spot material inconsistencies, connectivity issues, incomplete through-layer vias and other failures.

Designed for serial electronics X-ray inspection, the XT V 130 is a real QA workhorse that provides instant pass/fail status. Automated inspection functions and automatic board identification are available to ensure high inspection throughput rates. Inspection reports compliant with MRP systems facilitate tight integration into customers’ manufacturing processes.

Qualitative, robust and fast X-ray imaging

The system comes with a 30-130kV open micro-focus X-ray source, a 4-axis programmable manipulator and a 16-bit imaging system based on a 4” image intensifier. A focal spot size down to 3 micron, 320x geometric magnification and tilt angle up to 60° offer excellent image quality and operator flexibility. A rotate stage and CT capability are available as option. A hinged door provides easy access to the inspection area, which fits samples up to 40x35cm (16x14”).

The intuitive operation of the compact XT V 130 system is controlled by Inspect-X, the powerful proprietary software used on all Nikon Metrology XT systems. Using qualitative real-time X-ray capabilities,

5.3x 16.7x

320x image magnification enables users to zoom in on any specific item of interest

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X-ray irons out electronic flaws at

Process Sciences Inc.literally looking into electronic boards and devices

Hidden electronic defects that remain undetected at first are often the topic of heated discussions between electronic designers and production engineers. As a consequence, additional prototype rounds are needed to sort out uncertainty about electronic system behavior and robustness. To avoid process delay and extra fabrication cost, electronics assembly suppliers and OEMs rely on PSI to verify their PCB prototype and production samples. PSI has the know-how to inspect, troubleshoot and repair PCBs at a cost that is only a small fraction of the fabrication investment for a new full-functional PCB prototype. “Through electronics inspection at 3M, I learned about the extensive capabilities of Nikon Metrology XT V inspection systems,” says Stephen Schoppe, President of PSI in Leander, Texas. “For us, as an engineering and services company in the electronics industry, it is crucial to have the capability in-house to check PCB boards inside out. By visualizing connectivity failures in electronic devices and circuit boards, or between both, we are able to define the best way to readily provide a reliable fix. Insight into what really causes the problem is essential in optimizing customers’ electronics design and manufacturing practices.”

PSI’s 5,500 square foot engineering laboratory is equipped with electronics X-ray, rework equipment, microscopes, material validation systems, reballing stations, and other systems. Schoppe says that they organized X-ray inspection such that one system is dedicated to customers and the other to investigations performed by PSI. He marks that most customer projects are related to electronic connectivity issues including wire bonds, solder joints and through-layer vias.

Process Sciences Inc. (PSI) runs Nikon Metrology X-ray inspection to trace connectivity issues in electronic circuitry that otherwise remain hidden for the eye. Using intuitive real-time X-ray imaging, PSI collaborates with OeMs and contract assemblers nationwide to reveal and resolve weak points in their PCB manufacturing processes.

Xt V @ Process Sciences Inc. (USA)By tracing connectivity issues in electronic circuitry, real-time X-ray allows PSI to assists customers in optimizing their electronics manufacturing processes.

•X-ray visualizes internal electronic flaws that otherwise remain hidden for the eye

•Intuitive real-time navigation through automatic position, angle and zoom adaptation

•Radiography insight drives efficient troubleshooting and cost-effective PCB repair

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lower prototyping expenditure and manufacturing fail rate

Cisco, Flextronics, Schlumberger and St. Jude Medical are among nationwide customers that benefit from PSI’s X-ray related electronics services. Key in PSI’s services offering is supreme X-ray quality, which outperforms the imaging capability of previously installed systems on every single performance characteristic.

“The impact of top X-ray technology is huge,” Schoppe concludes. “Real-time displays showing angled views in highest resolution prove technical faults and support early defect discovery, reducing prototyping expenditure and manufacturing fail rate. Our technical expertise sharpened in advanced customer X-ray projects attracts new and repeat business for both services and consultancy.”

efficiently tracing and resolving connectivity issues

The XT V system enables us to literally look inside specimens, so that we can trace tricky defects that would otherwise remain buried under chip packages and PCB layers. Using angled imaging with high magnification, we reveal mysterious shorts in the form of minuscule solder dendrites and voids scattered around ball grid array (BGA) connections. In this case, we desolder, reball and reflow the device to reestablish correct and robust electronic connections.

Also incomplete vias are typically hard to trace without X-ray. “We use the system’s qualitative imaging and real-time X-ray capabilities to intuitively navigate through the layers of a PCB, by changing position, angle and zoom as desired. When detecting an open caused by an incomplete via, we investigate the surrounding internal structure to create an alternative route for the failing connection.” Schoppe explains that image resolution up to 1 micron provides great insight into internal defects, such as inclusions found in solid metallic material. “In solid-state switches, for example, X-ray helped us identify irregularities inside the welded parts of the components. Similarly, we traced internal cracks in ceramic chip capacitors that were caused by electric stress.”

A growing quality threat in the worldwide electronics business are counterfeit chip dies produced cheaply in Far-East countries. PSI identifies an increasing number of counterfeit silicon that yields electronic performance risks. This is another reason why electronics OEMs have their boards verified by PSI before they pay their assembly suppliers.

Insight into electronic connectivity issues greatly reduces prototyping effort and manufacturing cost

“ Angled views in highest resolution prove technical faults and support early defect discovery, reducing prototyping expenditure and manufacturing fail rate.Stephen Schoppe, President of Process Sciences Inc.

X-ray traces incomplete vias and helps create alternative routes for these open connections

PSI engineers trace minuscule solder dendrites and voids scattered around the solder balls of BGA devices

On magnified x-ray images, voids and other defects in metallic surfaces immediately attract the attention

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A single software driving multiple CMM brands

“We have our hands full with quality control of diverse clamps, grippers, presses and locators for Chrysler, Ford, GM, Magna, Whirlpool and many other manufacturers worldwide,” says George Croll, Quality Manager for BTM Corporation in Marysville, Michigan. “We used the proprietary software of our Mitutoyo and Brown & Sharpe CMMs for some years, but we needed to increase our inspection efficiency by utilizing a single straightforward software tool that supports both CMM brands.”

Mr. Croll explains that he researched different CMM software packages, and identified CMM-Manager as the solution of choice. “Although the majority of CMM software packages offer all the trimmings you need, most software packages lack an intuitive feel. This is why CMM Manager made the difference.”

CMM-Manager simplifies and automates tool inspection at

BtM Corporation

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Michigan-based tool maker BtM Corporation opted for Nikon Metrology’s user-centric CMM-Manager software to automate serial inspection on different CMM brands. BtM quality technicians also rely on CMM-Manager’s walk-in measurement capability to quickly take points on prototype and first-part articles. Parts designed and produced by BtM serve process automation at automotive and other manufacturers.

CMM-Manager makes life easier for serial inspection as well as for one-off inspection on a prototype article.

CMM-Manager @ BtM Corporation (USA)to increase tactile inspection efficiency, tool maker BtM Corporation uses intuitive CMM-Manager software in replacement of CMM-proprietary software.

•Ideal to quickly take points on prototype and first-part articles

•50% time reduction in automating serial inspection on different CMM brands

•Digital graphic reports provide instant feedback that streamlines customer interaction

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Performing instant walk-in measurement

In many instances, BTM quality technicians simply want to take a few measurements on prototype or first-part articles to feedback data to engineering or production. The intuitive CMM-Manager interface enables them to quickly align the part and measure planes and geometric features, such as hole patterns. They take snap point measurements on the screen, which almost totally eliminate manually probing the work pieces, to create dimensional charts that indicate size, geometry, and position information on the spot.

The software offers the opportunity to define color-coded marks that highlight point deviation before wrapping up the graphic report which can be passed on to the customer. “The software is very easy to use,” remarks Croll. “I would recommend CMM-Manager to any metrology system user who cares about measurement productivity. Even before attending any training sessions, we already figured out how to use most of the features the software offers.”

“ I would recommend CMM-Manager to any metrology system user who cares about measurement productivity.george Croll, Quality Manager for BtM Corporation

Before attending any training sessions, BTM operators already figured out how to use most software features.

save time through CAD-based serial inspection

When producing small or larger series of rotary actuator or clamp piston pieces, for example, we follow a different inspection strategy,” explains Croll. “First, we load the SolidWorks CAD file of the part into the CMM-Manager software and subsequently pick the positions and features that we want to have measured. We simply click a point or feature on a 3D view of the part, and drag-and-drop the icon in the part program representation. A smart software capability of CMM-Manager is the automatic conversion of the part program into a collision-free touch probe motion path including optimum probing angles to measure deep pockets or through holes, for example.”

Croll confirms that this interactive Pick-Confirm-and-Measure method is much more straightforward, time-efficient and error-proof than coding probe paths and angles manually. “As a result, BTM inspectors only spend half the time preparing new measurement routines and spend much less time on serial inspection. Instead, they focus on metrology work that really matters, such as defining and evaluating inspection reports. Overall, CMM-Manager is more user-friendly than any other package that we have used so far. And through graphic part-to-CAD comparison, CMM-Manager is a better communication tool for us in timely resolving technical issues with our customers.”

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Laser Radar MV224/260Laser Radar offers automated, true non-contact geometric verification of large scale objects up to 60 meters with metrology accuracy. Therefore Laser Radar is ideally suited to measure and inspect supersize parts used in aerospace, energy, shipbuilding, and other industries.

31Nikon Metrology News I Volume 5

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NikoN Metrology NVGeldenaaksebaan 329B-3001 Leuven, Belgiumphone: +32 16 74 01 00 fax: +32 16 74 01 03info@nikonmetrology.com

More offices and resellers at www.nikonmetrology.com

NikoN CorPorAtioNShin-Yurakucho Bldg., 12-1, Yurakucho 1-chomeChiyoda-ku, Tokyo 100-8331 Japanphone: +81 3 3773 9026 fax: +81 3 3773 9062www.nikon-instruments.jp/eng/

NikoN Metrology euroPe NVtel. +32 16 74 01 01sales_europe@nikonmetrology.com

NikoN Metrology gMBHtel. +49 6023 91733-0sales_germany@nikonmetrology.com

NikoN Metrology sArltel. +33 1 60 86 09 76sales_france@nikonmetrology.com

NikoN Metrology iNC.tel. +1 810 2204360sales_us@nikonmetrology.comus.nikonmetrology.comwww.nikoninstruments.com

NikoN Metrology uk ltD.tel. +44 1332 811349sales_uk@nikonmetrology.com

NikoN iNstruMeNts (sHANgHAi) Co. ltD.tel. +86 21 5836 0050tel. +86 10 5869 2255 (Beijing office)tel. +86 20 3882 0550 (guangzhou office)

NikoN siNgAPore Pte. ltD.tel. +65 6559 3618

NikoN MAlAysiA sDN. BHD.tel. +60 3 7809 3609

NikoN iNstruMeNts koreA Co. ltD.tel. +82 2 2186 8400

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