manufacturing metrology 2020 - fast, accurate, safe and
TRANSCRIPT
Trends in Manufacturing Metrology Fast, Accurate, Safe and Flexible
Jochen Weinisch
Carl Zeiss Industrial Metrology GmbH
Regional Sales Manager China/Taiwan
24/10/2014 2 Carl Zeiss IMT GmbH, Jochen Weinisch
“System of Interchangeable Parts” in Industrial Production
Unit System
for a unique definition of
product
characteristics
Machines
for production
according to the
definition
Metrology
for determination and
check of characteristics
100 years ago: 2/3 of produced parts had to be manually adjusted to fit to each other
Today: Separated production of parts, but all fit to each other during assembly
WHY?? …Because of global standards:
3
Industrial Products
What do these
products have in
common?
www.leibinger-medizintechnik.de www.sustainableenergyworld.eu
www.streetscooter.rwth-aachen.de
www.presseanzeiger.de
24/10/2014 Carl Zeiss IMT GmbH, Jochen Weinisch
4
They stand for global boosters
Globalization
Resource efficiency
Mobility
Energy
Electro-mobility
Connection of fare apart places
Global communication
and networking
Change in the energy market
Health and fitness
24/10/2014 Carl Zeiss IMT GmbH, Jochen Weinisch
5
Megatrends like are the key driver of production trends
Globalization
Resource efficiency
Mobility
Global megatrends
Increasing
Individualism
Insecure trouble spots
Demographic change
Climate change
Boundary conditions
Energy
Efe
cts
Resource efficiency
(energy, raw materials, capital)
Flexibility (compensate market
fluctuation, individualization)
Transparency
(predictability, directed quality
control)
New Processes
(control of new processes)
Trends in production
24/10/2014 Carl Zeiss IMT GmbH, Jochen Weinisch
6
Productions Trends and their Influence on Challenges and Trends in Manufacturing Metrology
Resource efficiency Flexibility Transparency New Processes
Trends of production
Fast increasing
integration
reducing measuring
time
automatic data
processing
Accurate reducing measuring errors / uncertainty
Challenges and Trends in Manufacturing Metrology
Safe verification of measuring uncertainty
Flexible increasing variety of
measuring techniques increasing information density
24/10/2014 Carl Zeiss IMT GmbH, Jochen Weinisch
Fast
Lightning-fast systems
make lightning-fast mistakes.
Stanislaw Lem
7 24/10/2014 Carl Zeiss IMT GmbH, Jochen Weinisch
8
Inetegration of metrology in production lines allows fast results
Function
Direct installation of CMM in production
Integration into the automatic material and information flow
Performance
Fast adjustment to part variants by changing CNC programs without mechanical changes
Comparable results to measuring room within temperature range: 18-40°C
24/10/2014 Carl Zeiss IMT GmbH, Jochen Weinisch
9
Fast trough intelligent Software in metrology
Fly-scan with Performance pack
16 Scanning elements
Complex programming
Measurement time: 75 sec
1 Scanning element
Simple and quick programming
Saving: 69% of time / 52 seconds
Conventional
24/10/2014 Carl Zeiss IMT GmbH, Jochen Weinisch
Accurate
Anyone who doesn't take truth seriously in small
matters cannot be trusted in large ones either.
Albert Einstein
10 24/10/2014 Carl Zeiss IMT GmbH, Jochen Weinisch
11
Examples for the large Range of Metrology
Horizontalarm-
CMM
Multisensor-
CMM
Coordinate Measuring Machines
0,001
0,01
0,1
1
10
100
0,0000001 0,000001 0,00001 0,0001 0,001 0,01 0,1 1
„Length“
[m]
„Accuracy“
[mm]
atomic
diameter 1 m
human hair
90 m 1 m
0,00001
0,0001 Transmissions-
Electron
Microscope
Profilometer Confocal
Microscope
Surface Measuring
Electron Microscopy
Bridge-CMM
24/10/2014 Carl Zeiss IMT GmbH, Jochen Weinisch
Transmissions-
Electron
Microscope
Electron Microscopy
Confocal
Microscope
Surface Measuring
12
Examples for the large Range of Metrology
0,001
0,01
0,1
1
10
100
0,0000001 0,000001 0,00001 0,0001 0,001 0,01 0,1 1
„Length“
[m]
„Accuracy“
[mm]
atomic
diameter 1 m
human hair
90 m 1 m
0,00001
0,0001
Profilometer
Coordinate Measuring Machines
Horizontalarm-
CMM
Multisensor-
CMM
Bridge-CMM
Coordinate Measuring Machines
Horizontalarm-
CMM
Multisensor-
CMM
Bridge-CMM
Coordinate Measuring Machines
Horizontalarm-
CMM
Multisensor-
CMM
Bridge-CMM
24/10/2014 Carl Zeiss IMT GmbH, Jochen Weinisch
Safe
There is no safety in numbers,
or in anything else.
James Thurber
13 24/10/2014 Carl Zeiss IMT GmbH, Jochen Weinisch
14
Safe: Conformity Evaluation, Tolerance and Measuring Uncertainty
OT/UT = upper/lower tolerance, U = measuring uncertainty
The tolerance is
reduced by the
measurement
uncertainty.
The tolerance is not reduced if the
uncertainty does not exceed 10 .. 20%
of the tolerance. OK
Not OK Not OK
U U U U
Tolerance
(Specification)
"Golden Rule" "Decision Rule" (ISO 14253)
(Small) exceeding of tolerance by the
measurement uncertainty is allowed.
Exceeding of the tolerance by the
measurement uncertainty is not allowed.
T
U U
OT UT
UT-U
U U
OT+U T
U U
OT UT
UT-U
U U
OT+U
24/10/2014 Carl Zeiss IMT GmbH, Jochen Weinisch
15
Safe: The Cost of Measuring Uncertainty 安全:测量不确定度的成本
quality level
cost
total cost
error cost
quality cost
T
U U
OT UT
UT-U U U
OT+U
Golden Rule, Measuremente System Analysis
T
U U
OT UT
UT-U U U
OT+U
Decision Rules
Quelle: http://de.wikipedia.org/wiki/Airbus_A380
Quelle: http://www.n-tv.de/auto
24/10/2014 Carl Zeiss IMT GmbH, Jochen Weinisch
Measuring MachineMachine geometry
SensorsMeasuring standard
Accuracy (MPE)
Measuring range
Measuring software
Error correction (CAA)
Qualification normalIlluminationTelecentricitySensor limitsHysteresis, dynamics
...
Inspection TaskApplication orientation
Tolerance orientation
Process and cycle time orientationTask-oriented reports
Volume orientation...
OperatorEducation/trainingUse of toolsClamping check
Alignment checkStylus qualificationMeasurement planning
Avoiding of collisions
Stylus assemblyShaft probing
Machine monitoringCare and cleanliness
Motivation...
Measuring StrategyInspection planning
Sensor
Measuring methodFilter setting
Outlier eliminationAnalysis strategyClamping/fixturing strategyAlignment strategyIllumination strategyZoomNumber of measuring points
Distribution of measuring points
Probing force
Scanning speed
Usage of rotary table
...
EnvironmentTemperatureTemperature gradientTemperature driftThermal radiationContamination, dust
VibrationsHumidityAir draftLight reflections
...
WorkpieceForm error
DimensionWeight
MaterialLinear expansion
SurfaceBrightness/reflectionPart temperaturePart contaminationElasticity/plasticity
Drawing/CAD...
measuring
resu
lts
Safe results are hard work Influences on the measuring results
24/10/2014 Carl Zeiss IMT GmbH, Jochen Weinisch
Flexible
Stay committed to your decisions,
but stay flexible in your approach.
Tom Robbins
17 24/10/2014 Carl Zeiss IMT GmbH, Jochen Weinisch
18
The Application determines the equipment
24/10/2014 Carl Zeiss IMT GmbH, Jochen Weinisch
19
Carl Zeiss Industrial Metrology We offer a wide and flexible portfolio of products
Bridge-type CMMs Production CMMs
Horizontal Arm CMMs Computer Tomography Form and Surface Inspection Systems
Multisensor CMMs Gantry CMMs
24/10/2014 Carl Zeiss IMT GmbH, Jochen Weinisch
20
Summary: Trends in Manufacturing Metrology 2020
Fast
Accurate
Safe
Flexible
24/10/2014 Carl Zeiss IMT GmbH, Jochen Weinisch
2011 21 Carl Zeiss im Fokus