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ZEISS And Senorics Establish Partnership In Sensor Technology

ZEISS and Senorics Establish Partnership In Sensor Technology

ZEISS’ investment in Senorics marks the start of a technology collaboration with the sensorics startup based in Dresden, Germany. The partnership aims to further the joint development of small and cost-effective sensors for industrial use in quality assurance and in process monitoring, e.g. on production lines for foodstuffs, agricultural products, plastics and medicine.

ZEISS can draw on its longstanding, extensive knowledge in the development, manufacturing and marketing of optical and photonics systems, as well as the digital solutions that go with them – particularly in quality measuring technology. At the same time, the company is actively shaping global markets in the field. Senorics now stands to benefit from this expertise.

And ZEISS will get the chance to use the Senorics technology to tap into new applications that it was previously harder to do with the technologies in its portfolio.

“We will begin by examining common application cases. Senorics’ innovative technology has the potential to create compact, cost-effective sensors for applications such as compositional analysis. The investment is a way of consistently implementing our strategy in the field of Advanced Sensor and Data Solutions,” says Dr. Philipp Strack, Head of ZEISS Ventures.

“The fact that ZEISS has approved the quality of our technology and would like to use it in the future considerably increases our customers’ trust,” says Dr. Ronny Timmreck, CEO of Senorics GmbH. “Moreover, the collaboration with ZEISS supports us with both the development and marketing for our technology. What’s more, the collaboration with ZEISS following the closing of our seed funding round in late 2018 was a further milestone in the long-term advancement of Senorics.”

 

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Achieving Perfect Gaps And Joints

Achieving Perfect Gaps And Joints

Here’s how BMW in Munich was able to increase process reliability for front and rear end assembly. Article by Carl Zeiss.

The ZEISS T-SCAN fulfils the highest demands with regard to ergonomy. For this reason, larger components can also be scanned without fatigue.

The front-end decisively characterises the silhouette of a vehicle. For this reason, perfect assembly and strict adherence to the joint plan are of great importance to car maker BMW. For a long time, gaps have been tested only with gap gauges. In this process, deviations of tolerances are effectively visualised, however, it does not contribute to determining the cause of an error. In the past, in order to track down this error, vehicles with a conspicuous joint and gap profile, therefore, had to be driven to the measuring room and measured there.

So, the department searched for a digi­tising system to optimise the assembly process. It should be used right after the final assembly and should provide as precise results as did the system in the measurement room.

Intuitive 3D Scanning

The hand-held ZEISS T-SCAN laser scan­ner enables fast, intuitive, and highly precise 3D scanning. Hand scanner, tracking camera and the touch probe are perfectly matched. The modular system can thus be used for numerous appli­cations. Here, the unique scanning speed and the precise measurement results are of great value. This is because the surface of the component is scanned contact-free and lightning-fast with the help of the laser line generated in the hand scanner. Around 210,000 points per second are recorded—more than with any other conventional method. As the tracking camera detects the position of the scanner, 3D surface data can be calculated with the help of triangulation.

With the touch probe, it is also pos­sible to take tactile measurements of additional single points, for example, in order to capture hole edges or not observable depressions. The data captured with the ZEISS T-SCAN thus describes the actual state precisely. This can then be easily compared with the target specifications, as defined in the CAD model. Deviations can be quickly detected in a user-friendly way with a false colour comparison of the entire surface.

As the ZEISS T-SCAN also fulfils the highest ergonomic demands, fatigue-free scanning even of larger components is possible. Thanks to the light and compact scanner housing, the ZEISS sys­tem can also easily capture data in areas that are difficult to access. The intuitive and easy handling extend the range of applications or user groups.

Single point 3D data acquisition at optically inaccessible areas with the touch¬probe ZEISS T-POINT.

Faster Evaluation

Since March 2016, three assembly wor­kers have been inspecting front and rear ends of an average of six completely finished vehicles per day. As a result, joint and gap widths of the two-part and rounded off radiator grille, the so-called BMW kidney, the headlight, and the bumper are measured. The briefly trained operators of the ZEISS T-SCAN capture 80 to 90 measurement points at the front end and 40 measurement points at the rear end of the various models. The measured actual values are then compared with the set values of the CAD model. Within two hours, it can be determined whether the front and rear ends show any defects. In this way, the quality engineers of assembly and body construction can counteract much faster.

For the quality and process engineers, the ZEISS system is therefore an impor­tant prerequisite to more effectively control in-house processes as well as those of the suppliers. Thanks to the portability of the ZEISS T-SCAN system, the apparatus for the assembly of the front and rear end can be measured directly in the production hall.

 

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Precision For Guaranteed Stability Using 3D Scanners

Precision For Guaranteed Stability Using 3D Scanners

Precision For Guaranteed Stability Using 3D Scanners PERI checks key components for formwork and scaffolding systems with ZEISS COMET and ZEISS T-SCAN. Article by Carl Zeiss.

“There is always something being built here,” said Daniel Steck as he enters the extensive premises of PERI, one of the world’s largest producers and suppliers of formwork and scaffolding systems. Together with a colleague, Steck is responsible for measuring technology at company headquarters in Weißenhorn, Germany. Prototypes, reference gages and initial samples all make their way to his measuring lab.

When Steck joined the Quality Assurance department three years ago after studying to become a mechanical engineer, the company was still performing manual measurements with a profile projector. This was not only time-consuming, but also meant the measuring results could not be reproduced. “Each person had their own approach to measuring which led to different results,” recalled Steck. This is a common problem with manual measurements.

As the functionality of in Weißenhorn inspected component has to be guaranteed so that they can later be used without any problems, the company had to find a solution everyone could count on. “Ultimately, it comes down to making sure people are safe when constructing framework and scaffolding.”

Precise Acquisition Of Component Geometry With Optical 3D Scanning Systems

“We use the parts we produce ourselves as much as possible,” explained the quality assurance expert. For example: a ledger UH – the horizontal bar on the scaffolding – comprises a pipe, wedges, and wedge heads welded to both ends. This ledger UH is later mounted between the scaffolding uprights. The shape of the individual components ensures a secure fit. The resulting tension is essential for the stability of the entire solution: “Without this, the ledgers might come loose.”

Thus, PERI employs this design for all its scaffolding worldwide. To ensure optimum quality, all components are first measured individually and then again following assembly – the exact tolerances are specified in the design drawings. A thorough inspection requires an extremely exact capture of the entire component geometry.

PERI first conducted a benchmarking analysis and opted to purchase an optical solution that would meet their special requirements. They quickly set their sights on ZEISS and immediately decided to purchase two measuring systems for inspecting the entire spectrum of PERI components: ZEISS COMET and ZEISS T-SCAN. Steck was pleased with this decision. “Learning to operate these user-friendly systems was no sweat. That helped me a lot when I was still learning the ropes,” said Steck, who started using the new systems as soon as he joined the department.

He measures the smaller, individual parts like ledger heads and wedges with the ZEISS COMET. The fringe projection system captures data at a rate of 1.25 megapixels per second with great precision, speed, and largely automatically.

The parts are positioned on the rotary table and fixtured as needed. After that, the measuring system runs automatically: “It is really great knowing you can trust the system, freeing you up to do other things during the measurement.”

Measurement Of Larger Components With The Hand-Held Laser Scanner ZEISS T-SCAN

With ZEISS T-SCAN, Steck measures larger components like formwork elements and the aforementioned ledgers UH. He takes the manual laser scanner and first measures the ledger pipe by itself and later the entire welded construction, including ledger heads.

“This is also quick and easy,” he reported. Steck demonstrates how ZEISS T-SCAN achieves the perfect measuring distance, using a green dot that intersects with the red laser stripe. He then moves the scanner over the upper and lower side of the component just once.

Generating precise, repeatable results is particularly important for initial inspection. “We have suppliers from all over the world. They receive standard test protocols with the measurement reports created with the ZEISS systems – this way, everyone is on the same page if any improvements are necessary.”

If the component meets PERI’s specifications, then random sampling is performed at regular intervals. The same process applies to new potential suppliers. During the approval process, inspection gages are created for individual components so that the team in the Incoming Goods area can perform quick, reliable measurements to check the products’ dimensions and functionality.

The quality of the inspection gages is also checked with the ZEISS measuring systems prior to use, and these are then recalibrated regularly.

Reconstruction of CAD Data With Reverse Engineering

In addition to these standard requirements, reverse engineering is also part and parcel of the engineer’s work. “Until now, reverse engineering has simply not been an option when dealing with old tools and their replacement parts. Often there are not any design drawings available.” That is why Steck scans these older components with the ZEISS COMET to create drawings based on these precise 3D models, including the exact tolerances. “For us, this is more than just reverse engineering – this is how we keep knowledge in the company.”

 

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Additive Manufacturing Metrology Seminar Held By Zeiss Singapore

Additive Manufacturing Metrology Seminar Held By Zeiss Singapore

Singapore: Industrial metrology providers Zeiss Singapore recently held a seminar at the Advanced Remanufacturing and Technology Centre in Singapore, focussing on measurements in additive manufacturing.

Participants found out more about imaging and measurement technologies in the following areas of the 3D printing workflow:

  • Materials characterisation.
  • Non-destructive evaluation.
  • Reverse engineering.
  • High accuracy metrology.
  • Data management and analysis.

3D printing processes, also known as additive manufacturing, are increasingly becoming part of industrial production chains. This is especially true in safety-critical areas such as aerospace, medical technology and automotive industries where demanding standards apply. The biggest challenge is to prove the reliability of 3D printed parts.

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Carl Zeiss: Sub-Micrometre Accuracy Measurement For Steering Wheel Components

Carl Zeiss: Sub-Micrometre Accuracy Measurement For Steering Wheel Components

Accuracy in the manufacturing of components in the steering wheel system is essential in enabling optimal steering performance. Contributed by Carl Zeiss 

Automotive supplier TRW Automotive manufactures braking, steering and suspension systems, as well as occupant protection systems and vehicle electronics. The company supplies parts for around 250 different vehicle models and more than 40 car makers. Around 1,000 of the company’s 65,000 employees produce steering systems in the Polish cities of Bielsko-Biała and Czechowice-Dziedzice.

Production Quality

Jarosław Muchajer, a quality manager at the company, is responsible at the company’s Bielsko-Biała site in Poland for the one of the most complex and expensive component of a vehicle after the engine: the steering system.

If the measurement results exceed the tolerances of just 0.1 micrometre, production has to stop. This safety measure can quickly result in exorbitant costs. This led the company to look for precise measuring equipment and 24-hour support from the manufacturer.

Looking For A Solution

When the Bielsko-Biała factory opened in 2012, plant managers drew on their own experience when the time came to select the coordinate and surface measuring systems.

They selected a surface measuring instrument from Zeiss, called the Surfcom 5000. Using five lasers on its interferometer, the unit was able to measure with accuracy levels of around 0.31 nanometres on average. The unit also has a ratio of the measuring range to resolution of approximately 42 million to one.

Steering Systems Market

According to a market report by research firm MarketsAndMarkets, the steering market is projected to grow at a CAGR of 6.47 percent from 2016 to 2021, to reach US$42.77 billion by 2021.

The Asia-Oceania region is estimated to lead in the market in terms of growth rate during the forecast period. The increasing demand for automotive comfort and safety is a key driver of the steering market.

The majority of new cars sold today feature Electric Power Steering (EPS).

Asia-Oceania comprises some of the fastest growing economies in the world, including China, India, and Indonesia. The region has the highest vehicle production in the world, due to its sizeable population and increasing disposable income. The growing population, increase in per capita income, and improving standard of living have contributed to the growth of the automotive industry in Asia Pacific.

The key automotive market in this region is China, which produces the highest number of passenger cars in the world. Given that the steering market is directly dependent on vehicle production, Asia-Oceania has emerged as the fastest growing market for steering systems, in terms of value as well as volume.

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