ATOS 3D-Coordinate Measurement Techniques in … 2 Optical 3D Coordinate Measuring Techniques in...
Transcript of ATOS 3D-Coordinate Measurement Techniques in … 2 Optical 3D Coordinate Measuring Techniques in...
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GOM ATOS 3D-Coordinate Measurement Techniques in Foundry Process Chains 21 November 2014
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GOM – 3D Measurement Technology in Casting Processes Presentation overview
Patterns, forms, tools & dies
Inspection of cast parts
About the company
Functioning of optical 3D metrology
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GOM – Gesellschaft für Optische Messtechnik Company structure
GOM is a global industry partner for optical 3D measurement systems since more than 20 years
· Development, manufacturing and sales
· Over 200 employees
· More than 4,000 installations
· 7 GOM branch offices in Europe
· 45 dedicated partner offices worldwide
· Leading firms from the automotive and aviation industries as well as makers of consumer goods rely on metrology solutions from GOM
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GOM – Industrial 3D Metrology Measurement systems
· With comprehensive know-how in 3D coordinate metrology, material and component testing, inspection and analysis, digital image processing
· Material testing
· 3D shape and dimension inspection
· Dynamic component testing
ATOS Full-field
3D Digitizing
TRITOPCMM Mobile
Optical CMM
PONTOS Dynamic
3D Analysis
TRITOPDef Displacement Vector Analysis
ARAMIS Full-field 3D Strain Measurement
ARGUS Deformation Analysis in Metal Forming
GOM is a global industry partner for optical 3D measurement systems since more than 20 years
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GOM – Single-Source Provider Measurement systems, software solutions, technical service and support
Gravity die casting
Sand casting Pressure die casting
Investment casting
ATOS 3D Digitizer
Pattern & mold making
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ATOS 3D Metrology Deployment throughout the casting process chain
Cast parts Molding shop Core making shop
Design CAD
Simulation comparison Component warp
Model & tool construction
CNC processing
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ATOS 3D Digitizer: Full-field 3D Coordinate Measurement Technology
· Full-field data capture · Mobile · Large & small components · Manual and automatic · GOM Touch Probe: tactile and optical metrology
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ATOS 3D Digitizer Precise 3D coordinates with high-quality data
Optical 3D scanner for full-field 3D component measurement and inspection Precise 3D coordinates and high-quality data Any object size, surface characteristics and component complexity
3D surface measurements
· Injection molding and plastics industries
·Sheet metal forming industries
·Casting industry
· Tool and pattern making
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ATOS - Optical 3D Coordinate Measuring Machine Stereo camera system – industrial 3D metrology
Stereo camera technology
Flexibility Mobility
Robust
Blue Light technology
Triple scan
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ATOS - Optical 3D Coordinate Measuring Machine Function principle and measurement process
Fringe projection supplies precise 3D coordinates for each pixel
The result: a complete 3D point cloud (STL polygon mesh)
Approx. 2 seconds for each measurement Up to 8 million points per measurement field
Automatic transformation of individual measurements to a common coordinate system
Individual measurements are polygonized to eliminate overlapping areas
ATOS - Optical 3D Coordinate Measuring Machine Function
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Stereo Camera Setup Process security during operation
Security for every
measurement
Control DURING the
scanning process
Online monitoring of sensor and object movement
Prevention of measurement errors
Online monitoring of sensor calibration
Verifiable scanning accuracy
Online tracking of 3D sensor position
Flexible positioning of component or sensor
Supports various alignment strategies
Automatic transformation of single measurements
Secure
Precise
Flexible
Fast
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ATOS - Optical 3D Coordinate Measuring Machine 3D measurement data for following processes
· Export formats for following processes
STL mesh ASCI point cloud
IGES sections
IGES curves/contrast lines
IGES primitives
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Large Mobile
Small Stationary
ATOS - Optical 3D Coordinate Measuring Machine Flexible sensor concept: from small to large – stationary and mobile
Pin Plane Office Production
Modular design Easy adjustable
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Modular and Flexible Sensor Concept Mobile – Stationary - Automated
Automated Scanning Cell Stationary System Mobile Metrology
System
One Sensor Head | Modular Design | Easy Setup
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ATOS - Optical 3D Coordinate Measuring Machine Optically hidden surfaces
GOM Touch Probe GOM reference point system
CT data inspection with GOM software
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· ATOS sensor serves as tracker for the reference point group on the probe
· GOM Touch Probe
·Measurement on hidden/partly hidden surfaces
·Measurement of primitives
·Comparing measurements with CAD data
·Quick measurement of individual points
·Online alignment
ATOS - Optical 3D Coordinate Measuring Machine Optically tracked GOM Touch Probe
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ATOS - Optical 3D Coordinate Measuring Machine Optical and tactile in a one system
· ATOS Touch Probe combines full-field and tactile measurement
· Fast process, since all measurements are made with one system
·All evaluations (full-field and tactile) directly in the ATOS software
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ATOS Triple Scan Precise 3D measuring data for following processes
ATOS 3D coordinate metrology:
· High-quality 3D mesh
· High resolution for finest details
· Measurement of small radii
Reducible database for following processes:
· Precision-based
· Curvature-dependent
Data for following processes
Quality Control
CNC Processing
Reverse Engineering
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Step 1 Measurement
Step 3 Inspection report
Step 2 Inspection
3D Form and Dimension Analysis ATOS: Measurement process in three simple steps
Step 2 Alignment
Step 3 Evaluation
All 3D measurement data and inspection results in compact format for exchange and further analysis
Free GOM Inspect software Colleagues and customers
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GOM Inspect Professional 3D Inspection Software: Shape and dimension analysis of cast parts
Component warp
Sink marks
Shrinkage analysis
Material accumulation
Allowance analysis
3D shape & dimension control with CAD
2D analysis against drawing
Measurement of undercuts
First article inspection
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Shape and Dimension Analysis of Cast Components CAD import, measurement plan import, FTA import
· CAD data import with surface tolerances and FTA features
· Measurement plan import
· CATIA V4, CATIA V5, PRO/E,
Unigraphics, IGES, STEP, JT-
Open, Parasolid.
· CAD data import with tolerances & FTA · Measurement plan import · CAD interfaces included
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Shape and Dimension Analysis of Cast Components Flexible alignment of measurement data
· Flexible alignment of measurement data to CAD
· Different alignment options, RPS, 3-2-1, best fit,…
· Flexible alignment · Alignment independent from fixture · Optimization of contact/support points
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Shape and Dimension Analysis of Cast Components 3D shape and dimension control with CAD
· Full-field verification with CAD data
·Component warp
·Sink marks
·Shrinkage analysis
·Allowance check / machining allowances
· Clear and easy to understand · Problematic areas immediately locatable · Decisions can be taken fast
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Shape and Dimension Analysis of Cast Components 2D analysis: CAD - inspection sections
· 2D inspection sections
·2D section versus CAD data
·Overview of section positions
·Vector lines
·Deviation points
· Tolerance bands
· Detailed analysis · Overview of section positions · Deviation points
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Shape and Dimension Analysis of Cast Components 2D analysis: CAD - inspection sections
· 2D inspection sections
·2D section versus CAD data
·Overview of section positions
·Vector lines
·Deviation points
· Tolerance bands
· Deviations as vector lines · Visualization of tolerance bands · Tolerances from CAD or manual
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Shape and Dimension Analysis of Cast Components STL versus STL: component vs. component, component vs. simulation
· Comparison of components from different mold cavities in multiple cavity tools
· Comparison with boundary / reference samples
· Comparison after changes of casting parameters
· Simulation comparison
· Faster verification of casting parameters · Analysis of tool cavities · Component deformation vs.simulation
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Shape and Dimension Analysis of Cast Components Complete material thickness analysis
· Full-field material thickness analysis
·Sink marks
·Melt flow
·Material accumulation
· Verification of CAD data for demolding chamfers / draft angles
· Fast definition of critical areas · Check for demolding draft angles · Detection of material accumulation
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Shape and Dimension Analysis of Cast Components Geometric dimensioning and tolerancing (GD&T)
· Geometric dimensioning and tolerancing (GD&T)
·Quick and automatic data selection
· Transparent reference systems
·Clear visualization of tolerance zones
·Simple interpretation of results
· Full surface data base · Simple results interpretation · EN ISO 1101 and ASME Y 14.5
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Shape and Dimension Analysis of Cast Components Inspection against drawing / CMM inspection
· CMM inspection
· Positions
·Distance inspection
·Dimension inspection (scalar)
·Angle inspection
· CMM inspection possible at any points · Complete first article inspection report · Automatable
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Shape and Dimension Analysis of Cast Components Inspection against drawing / CMM inspection
· Primitives
·Best fit
·Cheby fit
·Manual input
· 2D dimensioning
· Positions
·Distances
·Angles
· Analysis is possible at any points · 3D or section-based · User-defined reports
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Shape and Dimension Analysis of Cast Components Inspection against drawing / CMM inspection
· Dimensions
·Virtual calipers
· Inside caliper gage
· Outside caliper gage
· Disc caliper gage
· Cutting caliper gage
· Analysis is possible at any points · 3D or section-based · User-defined point selection
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Shape and Dimension Analysis of Cast Components Optically inaccessible areas – optically tracked touch probe
· Analysis of hidden areas with touch probe
·Online point probing
·Comparison with CAD data
·Check of geometry elements
· Measurement of undercuts · Fast measurement of individual points · Fast check of primitives
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Shape and Dimension Analysis of Cast Components Inspection reports and reporting
· Exporting measurement data and inspection reports
· Tables
·Customizable inspection reports
· Free GOM Inspect software
· Table export · Customizable inspection reports · 3D results in GOM Inspect software
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Step 1 Measurement
Step 3 Inspection report
Step 2 Inspection
3D Shape and Dimension Analysis ATOS: Measurement process in three simple steps
Step 2 Alignment
Step 3 Evaluation
All 3D measurement data and inspection results in compact format for exchange and further analysis
Free GOM Inspect software Colleagues and customers
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· Advantages
· Fast, full-field measurement
·Complete data capture
·Mobile – moves toward the object
· Flexible – different object sizes
·No fixture for stable components needed
·Variable alignment
· Disadvantage
·Slow for small number of inspection features
3D Shape and Dimension Analysis Comparison: tactile – optical
· Advantages
·Established technique
·Quick, with small number of inspection features
· Disadvantages
·Slow on free-form surfaces
· Long running times, little data
·Component holders needed
·User-dependent alignment
Tactile methods Optical methods
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· Measurement of inspection features acc. to drawing
· Evaluation of the 3D point cloud
3D Shape and Dimension Analysis Conventional first article inspection vs transparent 3D analysis
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· Traditional component drawing with inspection features for tactile measurement
· Only functional dimensions are defined via geometric dimensioning & tolerancing
· For all other surfaces
·CAD dataset as master
· Profile tolerance
3D Shape and Dimension Analysis Simplifying drawings
Component dimensioning for tactile measurement technology
Component dimensioning for optical metrology
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Optical 3D Coordinate Measurement Technology Targeted tool corrections
First article inspection
High data density
Multiple alignment
Good visualization
Fast feedback
Minimum intervention in the tool
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Patterns, Electrodes, Dies and Tools
· Inspection of milling results
· Wear analysis
· Reverse engineering
· Tool optimization
· Tool modification
· Maintenance and archiving
· CNC milling on ATOS data
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Patterns, Electrodes, Dies and Tools Inspection of milling results, wear analysis
· Complete inspection of milling results
· Wear analysis
· Complete analysis for fast, effective tool optimization
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Models, Electrodes, Patterns and Tools Reverse engineering
· Data backup of functioning and optimized pattern plates and tools
· For maintenance and archiving
· Integration of current tool modifications in the CAD base
Reverse engineering
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· Components are measured in one common coordinate system
· Automatic transformation of all individual parts in assembly on the basis of reference points
· Analysis options prior to casting:
Max. allowance check prior to casting
Determination of core clearance
Max. material thickness analysis, 2D and 3D
Compensation for shrinkage through scaling (global or various in X,Y,Z direction)
Patterns, Electrodes, Dies and Tools Virtual assembly
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Patterns, Electrodes, Dies and Tools Virtual assembly
· Analysis options prior to casting:
· Virtual assembly of a casting mold with sand cores
Determination of core clearance and core positions prior to casting
Determination of max. material thickness in 2D and 3D prior to casting
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Patterns, Electrodes, Dies and Tools Fit of die/mold halves / virtual material thickness
· GOM reference point system
· Fit of die/mold halves and calipers
·Virtual material thickness
· Indirect material thickness analysis
· Testing die-spotting surfaces
· Fit of die/mold halves and sliders
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CNC-machining of casted blanks
· Measuring of the real shape
· Allowance control
· Alignment on CNC machine
· Verification of milling results
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Rapid Milling on ATOS data direct duplication of patterns and tool blanks
· Duplication of patterns and tools
· Direct milling on ATOS data without reverse engineering
· Hybrid data
·Mesh data can be integrated directly into surface models
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CNC-machining of casted blanks alignment – tool path calculation - control
· Time-saving digitising of the real shape of the blank due to large measuring volume
· Alignment of measured data to CAD data
· Allowance control of blank geometry to CAD
· Positioning of the measured blank on the CNC-machine and milling of the calculated tool paths
· Utitlisation of the scanned blank data for
·Optimising of milling strategies / Rough machining based on the real blank shape
· Identification of obstacles on the blank
· Prevention of tool collisions
· Reduction of machining times
· Verification of the milling result
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Rapid Milling – CNC-Fräsen auf ATOS Daten Ausrichtung – Aufmaßkontrolle - Fräsbahngenerierung
· CNC-machining of casted blanks
·Capturing the real shape
·Allowance Control
Good alignemnt on CNC machnine
· Tool path calculation on ATOS-data
No „Airmilling“
Reduction of machining times
· Real shape of casted blank through ATOS data
Realizing obstacle contours
Avoiding tool collision
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Summary
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ATOS Triple Scan Precise 3D measuring data for following processes
ATOS 3D coordinate metrology:
· High-quality 3D mesh
· High resolution for finest details
· Measurement of small radii
Reducible database for following processes:
· Precision-based
· Curvature-dependent
Data for following processes
Quality Control
CNC Processing
Reverse Engineering
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ATOS 3D Metrology Deployment throughout the casting process chain
Cast parts Molding shop Core making shop
Design CAD
Simulation comparison Component warp
Model & tool construction
CNC processing
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Integration in Industrial Processes –ATOS Solution Advantages
· Increasing integration in industrial development and production processes with major potential for:
Improving process reliability
Optimizing production processes
Reducing development times
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Thank you for your attention
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