Metrotomography University Uppsala OPT [Kompatibilitetsläge]

Metrotomography

A tool for optimization of business processesp

10.11.201010.11.2010

R lf B iRalf BenningerProduct Manager

Agenda

1 Who is Carl Zeiss1

2

3

What means Metrotomography

Accuracy

Who is Carl Zeiss

3

4

5

Accuracy

Industrial application

Summary

13.12.2010 2Carl Zeiss IMT GmbH, Ralf Benninger, IP-L

Agenda


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3


Accuracy

Who is Carl Zeiss

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Accuracy


Summary


Carl Zeiss Group

Carl Zeiss AG

s G

roup

s

Medical Systems Microscopy Semiconductor Technology

Industrial Metrology

Consumer Optics/Optronics Carl Zeiss Vision

Carl Zeiss AG

Busi

ness

Mar

kets Medical and Research

SolutionsLifestyle ProductsIndustrial Solutions Vision

Care

Employees worldwide approx. 24,000


Carl Zeiss Industrial Metrology

Coordinate Measurement Machines, Sensors, Software


Agenda


2

3


Accuracy

Who is Carl Zeiss

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Accuracy


Summary


The METROTOM® - Family

METROTOM® 800 METROTOM® 1500


Technology


Typical applications

3D-Volume

data

Reverse Engineering

CAD-Comparison

Defectanalysis

Dimensional Metrology

3D CAD3D CAD


Agenda


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3


Accuracy

Who is Carl Zeiss

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Accuracy


Summary


Customer‘s Question

„How accurate are o r res lts?“

Focus Spot Size your results?“?

Voxel Size

Detector Resolution

Level of Details

Resolution of Scales Sub-

voxelling


Measurement Uncertainty

Tolerance

N i lNominal Value

Measurement Uncertainty


y

Measurement Performance


Accuracy is depending mainly on right calibration of the projection geometry!

Geometrical distortion

Axis calibration

Geometric calibration

Detector calibration

Wire phantom Geometry phantom


Edge localizationEdge localization

Step cylinder with one h t i lhomogeny material

Beam HardeningDifferent lengths cause different grey valuesdifferent grey values.

ISO 50 thresholdISO 50 threshold

Global threshold cause high deviations in surface extraction

(40 µm error)(40 µm error)

D namic thresholdDynamic threshold

High accuracy demands an efficient method for local surface detection.


high subvoxel accuracy!

(5 µm error)

Specification of Accuracy according to VDI/VDE 2630

There are VDI/VDE Standards now, the draft has already been published (July 2009)

Gages for acceptance of CMMs with CT-Sensor according to VDI/VDE 2630:

MetrotomCheck Step Cylinder

13.12.2010 16Carl Zeiss IMT GmbH, Ralf Benninger, IP-L16

High Number of Acceptance Tests


METROTOM Customers

RWTH Aachen,

d !

Uni Kosice (SK),

Teknologisk Institut (DK)


… and many more!

Agenda


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3


Accuracy

Who is Carl Zeiss

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4

5

Accuracy


Summary


Metrology of Carl Zeiss supports the injection molding industryg y

Mold First part A bl ProductionVerificationMold development process

First part inspection report

Assembly control

Production process control

Verification of process parameter


Example: very complex case of a plug connector

More than 500 inspection characteristic!


Previous method

Because of the high accuracy requirements it is important to measure several hundreds of features.

To reach all features the plug connector has to be sliced into pieces For a first partTo reach all features the plug connector has to be sliced into pieces. For a first partinspection report of a 4 cavity casting mold the user has to calculate with 4 weeks work.

With the help of Metrotomographyit is possible to save more than3 weeks time.

Furthermore the parts have notFurthermore the parts have notto be destroyed.


Non-destructive measuring

Example:Example:

Complete inspection of a plastic plug connector consisting of threeconsisting of three different materials.


What can be measured?

All kind of features and elements, tolerances (shape tolerances (shape and location), ….

PTB-certified

Software!

13.12.2010 24Carl Zeiss IMT GmbH, Ralf Benninger, IP-L 24

Inspection reports

Metrological evaluation Metrological evaluation with CalypsoThe technology is new, theevaluation environment is thesame as before. As with tactilesame as before. As with tactilemeasurements, the evaluation ismade in Calypso.

From data import of the CADmodel up to the CNC run youcan work with your familiarevaluation tools.

VDA First part inspection report Presentation protocol

13.12.2010 25Carl Zeiss IMT GmbH, Ralf Benninger, IP-L 25

VDA First part inspection report Presentation protocol

Graphic inspection reports

Metrological evaluation Metrological evaluation with CalypsoThe technology is new, theevaluation environment is thesame as before. As with tactilesame as before. As with tactilemeasurements, the evaluation ismade in Calypso.

From data import of the CADmodel up to the CNC run youcan work with your familiarevaluation tools.

Flatness plot Graphic protocol


Flatness plot Graphic protocol

Mold correction -Process requirementsq

The dimensions of a part needs to be in predefined tolerancesThe part should be complete filled with medium.

In practice for complex plastic parts mostly there are multiple iteration cycle needed to getIn practice for complex plastic parts mostly there are multiple iteration cycle needed to get the final mold.Correction data's has to be determined and integrated into the Mold CAD-design

Form Correction datadata

BauteilPart


An injection mold development process

CAD 3D NominalNominal

Injection process

CAD mold 3D nominal Mold making Molded part Deviation of

size, shape and position First part

Mold manufacturing

position pinspection reportMold

measurement

Measurement report

M ld CAD mold actual


Mold correction

CAD mold actual + correction

Multiple Iteration cycle!

Optimized injection mold development processp

CAD 3D NominalNominal

Injection process

CAD mold 3D nominal Mold

makingMolded part Deviation of

size, shape and position First part

Mold manufacturing

position pinspection reportMold

measurement

C ti l

M ld CAD 3D mold Calypso mold

Required correction points

Correction values


Mold correction

CAD 3D mold actual +

correction

ypcorrection

30-70% saving of time

Defect Analysis

NDT technology Defect analysis is often usedfor the first check of the

tcomponent.


Quantitative und Qualitative Porosity Analysis

axial frontal

The Porosity Analysis helps to find defects and to optimize process parameter


The Porosity Analysis helps to find defects and to optimize process parameter

If the product process is solid there is always the same shrinking hole picture

Assembly Control

Assembly Control takes place at different stations in the value chain.It can be measured non-destructively.

DevelopmentDevelopmentDo all party fit together, clearances, …?Are the breeches consolidated, do the O-Ring sit right?

ProductionAre all components installed?Do all components sit like required?

Quality assuranceEnvironmental checks, temperature cycle, vibrations checks, drop tests,…Geometry modification before and after use

Complaint managementNon-destructive analysis of the components


Assembly control of a insulin pen


Agenda


2

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Accuracy

Who is Carl Zeiss

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5

Accuracy


Summary


Summary

Metrotomography is the fusion of metrology and tomography.

Accuracy is depending mainly on right calibration of the projection geometryAccuracy is depending mainly on right calibration of the projection geometry

The Metrotomography supports important processes in the injection molding industry

First part inspection reports in shorter time

Decrease the number of iteration cycle in the mold development process

Non-destructive assembly control


Metrotomography University Uppsala OPT [Kompatibilitetsläge]

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