Automatic optical measurement without any operator influence

Automation is more than the automatic measurement of surface roughness and form parameters. Automation means simple interaction between administrator and machine operator, intuitive order management, high measuring accuracy as well as simple communication and networking with existing production systems including the connection to an ERP and QM system. The following is an overview of the automation options available. The range includes "simple" automated measurement up to the realization of Smart Manufacturing.

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The AutomationManager software offers a variety of automation options:

#1 Automatic measurement of dimension, position, shape and roughness

Automation interfaces enable the automatic and user-independent measurement of micro-precision parts or smallest component features on large surfaces. Measurement of form (distances, roundness, flatness, shape deviation, positional relationships...) and roughness parameters as well as of cutting edge parameters (radius, contour, angle...) is based on the interaction between an administrator for the teach-in of measurement programs and an operator who starts the measurement using single-button solutions. The teach-in is designed for maximum user-friendliness and can be implemented in only a few steps without programming knowledge. The component to be measured is identified by means of a drop-down menu or barcode. The corresponding measuring program is started automatically, and the machine operator receives a measurement protocol including ok/not ok data.

Picture: Teach-in process, one button measurement, result

#2 Digital measurement planning

A CADCAM connection enables the definition of measuring points, measuring directions etc. already in the CAD file of the reference part. Tilting angles, travel ranges in XYZ as well as rotation angles are automatically calculated and synchronized. A simulation provides a preview of the measurement process to be carried out and thus supports reliable measurement planning. The time-consuming definition of measurement positions on the real component becomes obsolete. This is an attractive solution, especially if users have to define and teach in 100 or more measuring positions on components with complex geometries.

Picture: CADCAM Measure Suite Simulation

#3 Extended database management

The measuring programs stored for a single component or a whole batch are automatically recognized by a barcode scanner. Each measurement is thus assigned to a respective order. In addition, information such as end user/customer, operator, machine tool, etc. can be added via freely editable and configurable fields. This enables, among other things, user-specific reports to check, for example, whether production is of consistent quality. It also ensures that deviations can be detected and corrected at an early stage.

Picture: Example of real-time quality dashboards with external CAQ software

#4 Connection to a QM and/or ERP system

Our measuring systems provide the option to connect to the end users' ERP and QM system. This means that measuring systems can access the nominal values, tolerances and measuring strategies stored in the ERP via DMC or RFT. At the same time, measurement results are fed into the QM system, enabling production managers to access all production data from their global locations and react immediately to negative and positive trends. The networking of measurement data, ERP and QM also enables the autonomous, user-independent creation of measurement programs in the medium term.

Picture: Integration of the automation process

#5 Machine to machine communication

Modern production facilities based on connected, networking machines and measuring technology usually target adaptive production planning and self-optimized production. Measuring sensors detect faulty components, and this information is automatically fed into the production cycle, and production adapts or corrects itself automatically. This also includes workflows such as the automatic clamping and unclamping of components from a machine tool and the equipping of the measuring system with a robot ("Pick & Place”).

#6 Intelligent algorithms for automatic segmetation and classification

A number of expansion options for automatic segmentation and classification of surface features complete the automation options. Intelligent, self-learning algorithms are the basis of a smart method to characterize, segment, analyze and classify surfaces. Subsequently, relevant parameters for surface evaluation are automatically derived and evaluated. Bruker Alicona currently offers solutions for the analysis of grain size distribution on grinding tools and for the evaluation of sandblasted and laser machined surfaces.

Picture: Artificial intelligence used in grinding grain analysis

Automated optical measurement with the AutomationManager software

The AutomationManager software platform enables the automated and user-independent surface measurement and evaluation of micro-precision components or micro-structured surface details on large components.

The process is based on the interaction between an administrator, who defines the measurement program, and operators in the production area. The operator starts pre-programmed measurements at the touch of a button, the selection of the components to be measured is done using a drop-down menu or barcode scanner. The measurement and evaluation of surface roughness and/or form parameters proceeds automatically, the worker has no influence on the measurement result. At the end an O.K./not O.K. report is provided. Modular expansion options in the areas of defect detection and surface treatment by grinding, shot peening and laser complete the evaluation methods.