Step-by-step networking for in-house manufacturing, involving suppliers and customers and efficiently using data together – the digital services provided by c-Com, a member of MAPAL Group, make it all possible. However, the start-up isn’t just developing its own applications. It’s also generating added value for customers by working closely with cooperation partners.
Cooperation with MARPOSS: reduced setup times and maximum tool service life
The optimal and longest-possible use of tools represents a vital cost factor for machining companies. But compromises are often necessary – particularly in series production and as part of automated processes. Tools with a defined tool life are replaced as soon as the specified tool life has come to an end. In many cases, though, the tool has not truly reached the end of its tool life and replacement is not yet necessary. However, companies play it safe to avoid quality issues and the risk of producing items that later need to be rejected.
This is one of the elements addressed by the ARTIS GENIOR MODULAR module by MARPOSS. The fully automatic tool- and process-monitoring system has been an established feature of the market for many years. It works by recording various measurements and assessing them on the basis of several criteria.
MARPOSS recently launched a collaboration with c-Com GmbH and its c-Com open cloud platform to provide module users with additional value: the ARTIS GENIOR MODULAR module and c-Com are set to exchange data. Once the defined tool limits have been reached, the staff member responsible receives a notification on their mobile terminal – which is made possible by the cooperation with c-Com. As a result, operators can react more quickly and boost the efficiency of their manufacturing processes.
Cooperation with Oerlikon Balzers: transparency and sustainability thanks to digital processing for coating
Many tools are re-sharpened and re-coated to make production as cost-efficient as possible and to use raw materials sustainably. This procedure is very complex for everyone involved – from the machine operators to the staff members carrying out the re-sharpening and coating. If a staff member responsible for re-sharpening sends a tool for coating, this staff member is often not aware of corresponding order status. This results in frequent queries. In some cases, the number of re-sharpening processes is simply marked on the tool shank. Overall, the total benefit is reduced by the very high investment of time and effort required.
In cooperation with Oerlikon Balzers, c-Com has developed an application that enables significantly more effective and transparent order processing. The prototype was showcased at EMO Hannover. The only prerequisite to benefitting from the advantages of digital processing for coating is identifying all tools with a unique ID.
The c-Com application exchanges data with the myBalzers customer portal run by Oerlikon Balzers. This way, the entire order process is digitalised, and all receipts are available online. It is easy to share documents such as delivery slips, invoices or order confirmations, and the status of each coating order can be viewed in real time. There is no longer a need to ask for order updates – a quick glance at the application provides the user with all the information they need. On top of this, machine operators have access to all the important information about their tool at all times. Thanks to the collaborative approach by c-Com, they can access all data via the cloud.
The c-Com wear detection app: a technical advisor in your pocket
c-Com has developed a wear detection application to provide answers to these questions. The prototype for the application was presented at EMO Hannover. The application is very simple to use: first, the worn blade is documented using a smartphone and a conventional auxiliary lens for zooming in. The app then identifies the type of wear and suggests corresponding recommended actions. This allows users to prevent this type of wear in future.
The application is based on machine learning, a sub-category of artificial intelligence. This means that the application uses datasets to learn. Together with tool specialists at MAPAL, c-Com has compiled and categorized hundreds of images. Effectively, the algorithm was trained by being shown what different types of wear look like, allowing it to assess whether or not a blade is in good order.
Market outlook 2020: The year 2019 has been quite a challenging year for the manufacturing industry, with geopolitical tensions impacting investment decisions and shifts in manufacturing centres, and trends such as e-mobility, Industry 4.0, and additive manufacturing creating industrial transformation. In this Outlook 2020 special, six industry leaders share their thoughts on what to expect in 2020, how the industry will develop, new opportunities and market drivers, and how to navigate through the challenges and issues from these dynamics.
HEXAGON MANUFACTURING INTELLIGENCE
Lim Boon Choon, President, Asia Pacific, Hexagon Manufacturing Intelligence
The year 2019 was a time of economic uncertainty in global manufacturing. But the Asia Pacific region is well placed to capitalise on new opportunities in 2020, as increasing adoption of disruptive technologies shows organisations are facing market challenges by pursuing innovation-driven competitiveness. The growing recognition of the efficiency and operational excellence to be gained from digitised metrology offers long-term, sustainable investment and expansion in the Asia Pacific market.
The Growth of the Smart Factory
Increasingly connected enterprises will be a continuing trend throughout 2020 and beyond. The digital transformation of quality is a central part of this smart factory vision. Approaches to metrology data are maturing, and companies are focused on gaining actionable insights from real-time data. Growing demand for data analysis software is expected, and the adoption of platforms offering advanced big data and Industrial Internet of Things (IIoT) capabilities will enable far more predictive and proactive manufacturing.
Across the region, new business models will emerge with the prevalence of cloud computing, connecting quality systems to machines throughout end-to-end processes and across factories. Streamlining the analysis and communication of metrology data is essential to breakdown operational silos and drive growth by enhancing product customisation capabilities and throughput.
The trend of automating metrology operations will continue to grow with the increasing adoption of robotics, measuring cells, and automated part loading, enabling manufacturers to scale up their autonomous capabilities. And as manufacturers look to increase their application flexibility, demand for non-contact 3D scanning technology will increase.
Driving Additive Manufacturing Capabilities
Additive manufacturing, also known as industrial 3D printing, is still emerging in sectors such as medical, transportation and logistics, construction, aviation, automotive, and shipping. But according to research from Thyssenkrupp, 3D printing is expected to create $100 billion in value in the ASEAN region by 2025. Quality will play a central role in expanding this developing process, with technologies such as 3D scanning and computed tomography (CT) for measuring internal geometries. Additive manufacturing is a key area of strategic importance for Hexagon. The recent acquisition of CT software provider Volume Graphics adds advanced measurement capabilities to Hexagon’s already comprehensive solution portfolio in the additive space, which also includes software for generative design and additive process simulation.
The expected widespread adoption of smart technologies suggests 2020 will mark a major step forward on the industry 4.0 journey.
Meir Noybauer, Business Development Manager, ISCAR
Throughout the year 2020, the industry as we know it will shift towards smart factories with IoT (Internet of Things) cyber connectivity, and AI (artificial intelligence) and robotics technologies, that will most likely be developed in the main industrial hubs as part of the fourth industrial revolution (Industry 4.0).
Additive Manufacturing and other advanced manufacturing technologies will continue to grow and replace conventional methods for machining automotive, aerospace and energy parts, and facilitate new opportunities for complicated part designs that were previously unrealizable.
The global search for clean energy and low-emission mobility is leaning towards newer and harder materials, which challenge ISCAR to develop advanced machining technologies, such as SiAlON ceramics and super alloy materials, while using high and ultra-high coolant pressure to boost productivities to higher levels never seen before.
The medical sector will be one of the emerging industry segments, with sophisticated implants using advanced materials and machining technologies jointly developed by ISCAR engineers and leading medical implant companies throughout Europe, the US and Eastern Asia.
The automotive segment will continue to be a global industry leader, while transitioning from conventional combustion to small hybrid-high efficiency engines and electric e-drive cars and implementing other clean mobile technologies, specifically for electric charging infrastructures which have not yet been applied in many countries.
Stefano Corradini, Group Director, Sales & Marketing, Marposs
The year 2020 appears to be one of the most challenging years of the last decade, both in the Asia Pacific and worldwide.
The combination of trade wars and their impact on several geographic areas and market sectors, social turmoil in various countries, and many technological changes as consequence of increased environmental concerns, may have a significant negative effect on the general economic situation.
Automotive Manufacturing Evolution
Being a significant part of Marposs business somehow related to the automotive sector, we see the evolution from internal combustion engine (ICE) to electromobility as one of the biggest driver of the economic uncertainty. We prefer, anyway, to see this as an opportunity to offer our existing and new customers an extended panel of solutions, which are moving from our traditional measuring sector to a broader concept including several type of testing equipment (mainly leak test using different type of tracer gas extended also to fuel cells), as well as inspection applications (non-destructive, vision, and similar), and control systems to monitor the whole manufacturing process of the core components of the NEVs/BEVs (new/battery energy vehicles), such as battery cells, modules and packs, battery trays, and electric drive units (EDU) including electric motors; and end of line testing.
We are willing to become a preferred partner of BEV manufacturers and suppliers as we have been for decades for traditional combustion engines, offering them our technical know-how, our innovation culture, and our worldwide organization for sales and after sales.
Steve Bell, General Manager, ASEAN, Renishaw (Singapore) Pte Ltd
Smart manufacturing technologies increase visibility and transparency to manufacturing operations, allowing manufacturers to get the overall picture of their productivity and competitiveness, to make faster changes in response to market-based threats or opportunities. This requires a range of intelligent process control solutions throughout the factory, to ensure high standards of repeatability. The key is going digital—connecting physical manufacturing processes with the digital technology to make decisions about process improvement on the shop floor, or on mobile devices.
Flexible and Customised
Additive manufacturing plays a major role in the Industry 4.0 revolution, allowing manufacturers the flexibility to build highly customised parts. Renishaw’s additive manufacturing technologies continue to evolve, aiming to provide users the flexibility to use, change and manage different metal materials, enables users to adapt to meet market demand and configure processes to achieve optimal performance.
Focus on Automotive Industry
Ensuring businesses are equipped and ready to navigate the evolving automotive manufacturing landscape, Renishaw’s manufacturing solutions provide the speed, flexibility, and ease of use to help companies adapt their production capabilities for the evolving electric future. From multi-sensor rapid scanning of machined castings to material analysis of fuel cells, we will continue to support customers on the road from internal combustion engine (ICE) to electric vehicles (EV).
SIEMENS DIGITAL INDUSTRIES SOFTWARE
Alex Teo, Managing Director, Southeast Asia, Siemens Digital Industries Software
The maturity of manufacturing supply chains in Asia has undoubtedly exerted pressure on the metalworking industry to be more competitive than ever. Demand for steel in Asia is expected to rise by an average of 1.5 percent in 2020, and will likely see effects such as rising operating costs necessitating the move for businesses to look for technology driven solutions to relieve some of these operational strains. In particular, Southeast Asia is an exciting region for growth, with markets such as Malaysia, Vietnam, and Singapore making strides in realising their Industry 4.0 visions through digitalisation. In 2020, we also launched a Technical Competency Hub in Penang, the first in the region, which serves as a platform for Siemens to help companies, especially SMEs, begin their digitalisation journey in order to meet the needs of the new economy.
Using digital twins, manufacturers will be able to explore more economical and structurally enhanced materials. By leveraging physics-based simulations, supported by data analytics in an entirely virtual environment, the expansion of production capacity in Asia can be further encouraged. This means that manufacturers can optimise their choice of materials by testing and analysing combinations of different metals and alloys digitally before using additive manufacturing technologies such as powder bed fusion to produce these components faster and more reliably, reducing the need and cost for real prototypes.
Siemens’ end-to-end additive manufacturing solutions cover CAD/CAM/CAE models that enable product design and simulation of production processes and planning, preparation, and verification of the print jobs. Simulation and 3D modelling allow for advanced complexity of design and quality, ultimately resulting in fewer distortions and errors. The goal is flawless execution when parts come out of a factory, ready for certification. The full additive challenge covers the entire value chain: product design, production process, and performance.
Using customisable solutions for pressing, transporting, positioning and press safety, in combination with simulation for the entire spectrum of metal forming, businesses can proactively advance with components working seamlessly together. This collaboration increases the cost-effectiveness of all production processes in all sectors, reducing energy costs.
The economic environment for the international and German machine tool industry remains difficult now and in the coming months. After eight years of high economic activity in the international machine tool industry, global demand for capital goods has calmed considerably after the fourth quarter of 2018. The reasons for this have already been identified and discussed many times. The economic distortions, in particular the trade war between the United States and China, are boosting the already sharp drop in demand. The increasing protectionism at all levels is affecting world trade and international supply chains. Finally, the structural shift in the automotive industry towards new drive technologies is causing further problems. It is still questionable at what pace and extent development is progressing and which technologies will be used in the future. The entire scenario is unsettling the industry worldwide. Companies have become very cautious, and they are shifting their investments.
Because of these, incoming orders in the international machine tool industry fell sharply in all regions in the first nine months of 2019. According to initial estimates, orders worldwide fell by 21 percent. Asia declined by 24 percent, while Europe lost 19 percent of its orders. Contracts in America, which is particularly the United States, held up best, if we can say so. They went down 18 percent in comparison to the previous year. In Germany, with its high dependence on exports, incoming orders fell by 23 percent by October in 2019, the most recent available data. This applies equally to domestic and foreign orders.
Markets to Stabilise
Oxford Economics, the VDW’s forecasting partner, expects this trend to stabilise in the best case scenario for 2020. At 2.5 percent, global economic output is expected to be slightly below the increase in 2019. With 2.1 percent, industrial production will grow more strongly than the current year. This also applies to investments. Stabilisation is also expected for the whole German economy. Industrial production, which is expected to shrink in 2019, is likely to turn slightly up again. This means that incoming orders in the machine tool industry will probably go through the bottom in the course of the coming year.
Machine tool consumption, a late indicator, will remain negative in all regions. Asia is the exception. Manufacturers can draw new hope from the fact that the election results in Great Britain have now provided certainty about the island’s exit date from the European Union. Then, the negotiations on a tariff agreement can begin and hopefully lead to a good end. There is also movement in the trade conflict between the United States and China. Should a consensus be reached, the world economy will reach new momentum as well.
Nicola Minelli, Branch Manager of Marposs Singapore, speaks to Asia Pacific Metalworking Equipment News (APMEN) about the challenges and opportunities in the Philippine market, and provides his outlook on the country’s metalworking industry.
Since its establishment in 1952 in Bologna, Italy, Marposs S.p.A. has been producing standard and custom made systems for industrial applications to measure and control dimensions, geometries and surface quality of mechanical components, as well as leak test or visual inspection and for control and monitoring of the machining process on every type of machine tool.
The Group now has around 80 offices in 25 countries, with a total of 3,700 direct employees. It caters to machine tool makers as well as provides solutions for the automotive, aerospace, energy, biomedical, and technology industries.
In Southeast Asia in particular, Marposs is present in Singapore (for covering the markets of Philippines, Johor, Batam, Indonesia), Kuala Lumpur in Malaysia, and Bangkok in Thailand, which is also the main office in the region.
During the recent PDMEX 2019 exhibition in Manila, Philippines, Nicola Minelli, Branch Manager of Marposs Singapore, speaks to Asia Pacific Metalworking Equipment News (APMEN) about the challenges and opportunities in the Philippine market, and provides his outlook on the country’s metalworking industry.
WHAT OPPORTUNITIES ARE YOU SEEING IN THE PHILIPPINE MARKET?
Nicola Minelli (NM): It is definitely an important market — it may be even more important in the future for two main reasons: one, the Philippines is moving towards high-end production—it is no longer a place where you can mass produce cheap products. So, manufacturers need to invest in high-end systems to create better products and more efficiently. And second, in my opinion, even though we are happy with our overall market here, there are still a lot of companies here that we do not know yet and that represent new business opportunities for us.
WHAT ABOUT THE CHALLENGES?
NM: Yes, competition is always around. Marposs is the only company who can offer a full range of gauging and inspection solutions for mechanical manufacturing. We have actually quite a lot of specific competitors, for particular product ranges, but overall, we are proposing to our customers a wide range of portfolio that, if you don’t get to sell one thing, maybe there is opportunity for something else.
FROM YOUR PERSPECTIVE, WHAT INDUSTRIES HERE STAND OUT IN TERMS OF GROWTH?
NM: Our core business is the automotive industry. We have long lasting business relations with all main automotive players in the area, based on similar strong connections with their headquarters abroad. The automotive sector worldwide is going through a huge process of transition to the electro-mobility and this will come surely in this area, too. Marposs is able to provide new solutions also for this new challenge, with the target to remain a first-class supplier of the whole automotive supply chain.
I also see aerospace growing. For the time being, for us, those two industries—automotive and aerospace—are what’s growing here.
WHAT ARE THE MAIN CHALLENGES OF YOUR CUSTOMERS, AND HOW DO YOU HELP THEM ADDRESS THOSE?
NM: Technically, they are not so much of a challenge for us. The biggest effort is often to convince Customers to choose higher value solutions compared with some basic ones. Because somehow, you have to justify the investment. If you offer any solution at a higher cost, you have to justify it. We have different situations where you have to understand what the customer might need. Just an example, they may be using bore gauges for checking parts. You can offer some system that is faster and more accurate—but more expensive. So, you have to justify why they need to adopt the faster, more accurate system. And I would say, almost 90% of the time, the customers’ main concern is the price/value ratio.
WHAT TRENDS ARE YOU SEEING IN THE SOUTHEAST ASIA MARKET?
NM: The trend now is that everybody is pushing for Industry 4.0. Everybody wants data collection or statistical analysis, or the possibility of the transfer of data directly from the gauge to a server and so on. I think this one is the main trends now.
WHAT IS YOUR STRATEGY TOWARDS THIS TREND?
NM: For a long time, we have been offering these possibilities, these features. In the past, very few companies—especially American companies—actually made use of statistical analysis. Now, this request is more widespread, and more customers are looking at it. But, to have in place automatic systems for data collection needs further studies; you need to understand which data you need to collect. Because you can collect everything—you can have information on everything. But, eventually, what do you really need?
Maybe for the time being, this trend is not so much present yet in the Philippines, but it definitely is a strong trend in Singapore.
WHAT IS YOUR OUTLOOK FOR METALWORKING INDUSTRY IN THE PHILIPPINES?
NM: It will be better. I have been coming to the Philippines for a very long time, and compared to the past, the industry has become much more interesting. I am expecting this trend to continue in the future as well. I have also been participating since long time to this exhibition; in the beginning, it was just a small show, with just few distributors. Now, you can see a lot of manufacturers coming here. I am very optimistic about the future of the industry here in the Philippines.
Marposs is strongly supporting the DIGIMAN project, an initiative that aims to address the industrial scenario, outlined by the Industry 4.0 paradigms, through the development of Cyber Physical Systems. These systems respond to market demands with a framework that embraces and completes the machine (physical part) by pairing an Augmented Manufacturing Platform or AMP (Cyber Part). The platform interfaces with processes and machines, through appropriate modules with high engineering content, which then formalises the knowledge of operators and experts while leveraging learning skills.
The Industry 4.0 plan promotes the development of intelligent and connected products to create systems that are part physical and part virtual (Cyber Physical Systems). A recent estimate states that by 2020, the value of 4.0 solutions, proposed by the supplier ecosystem, will be around €420 billion. Approximately 80-100 percent of production facilities could be using these solutions by 2025, with a potential annual cost savings of US$900 billion to US$2.3 trillion.
The main objectives of the DIGIMAN project are the ability to improve, even in real-time, the quality of products and the ability to infer on the state of the process (machines and components) by proposing improvement strategies (Virtual Operator). The partnership between MUSP (manufacturing process expert), MISTER (IoT and software solution expert), and CNR-ISTEC (ceramic materials expert) is complemented by an industrial partnership: machine and component manufacturers as well as end-users.
Marposs, a provider of precision equipment for measurement and control, has joined 5G-SMART, a H2020 project funded by the European Commission, which aims to unlock the value of 5G for smart manufacturing through demonstrating, validating and evaluating its potential in real manufacturing environments.
5G-SMART will test the most advanced 5G-integrated manufacturing applications such as remote-controlled industrial robotics, wireless process monitoring in manufacturing, and mobile robotics, by bringing first ever 5G deployments into real manufacturing setups: at an Ericsson factory in Kista, Sweden; at the machine hall of the Fraunhofer Institute of Production Technology (IPT) in Aachen, Germany; and at a Bosch semiconductor factory in Reutlingen, Germany.
Marposs contributes its expertise in machine and process monitoring and will provide the equipment for the first real 5G trials in manufacturing at the Fraunhofer IPT premises.
5G-SMART will go beyond the trials and develop new 5G features targeting the needs of the smart factory, like the integration of 5G with time-sensitive networking and critical cloud platforms, enabling flexible software development while providing low latency and high reliability.
To further accelerate take-up of 5G in the manufacturing ecosystem, 5G-SMART will explore new business models, identifying the potential for factory owners, operational technology suppliers and mobile network operators.
Over the course of more than two years, a multidisciplinary team consisting of ICT and 5G suppliers Ericsson and Cumucore; network operators Orange and T-systems; wireless communication technologies and components provider u-blox; operational technologies suppliers ABB, Bosch, Fraunhofer IPT, and Marposs; factory operators Bosch; and academia—University of Lund, University of Valencia, Budapest University of Technology and Economics—will show how 5G can boost smart manufacturing.
Asia Pacific Metalworking Equipment News is pleased to conduct an interview with Mr. Stefano Corradini, Group Director Sales & Marketing at Marposs regarding current trends in the metrology and manufacturing industry.
Could You provide us with an overview of the current trends regarding metrology in manufacturing?
In general, the trends in metrology follow those in manufacturing, so the most important trends are the increase of precision, flexibility and full process control. In the automotive sector, the new challenge presented by electromobility is shifting the focus to upgraded leak test controls to protect batteries and electric components from deteriorating conditions. Marposs provides a wide range of metrology solutions and is able to give answers to all above challenges.
With increasing digitalisation of the manufacturing sector, how has Marposs kept up with these trends to remain competitive?
IoT, smart factory and industry 4.0 focuses on the same objective: providing every possible information on the manufacturing process to the controller. Marposs provides measuring devices to be fitted on virtually every type of manufacturing line, including cutting and deformation machines, as well as die casting and extrusion lines; those provides electronic information to the machine controller which can be used to improve the manufacturing efficiency. Marposs also provides dedicated softwares to help customers elaborate, manage above data and improve production quality.
What are the main challenges faced by the metrology industry in Asia?
Asia is not much different from other part of the Industrial world as described in the first question. Compared with other areas, some countries in Asia have a bigger growth rate in the industrial sector. This makes improved production quality even more critical since it goes in combination with production increase, thus creating a bigger challenge for every player involved.
How can they be overcome?
The answer is much easy: investments! To be able to provide successful solutions and to be an appreciated partner for the manufacturing industry, it is necessary to invest in new technologies, solutions and in human resources to support the growing demand. Marposs has ventured into both paths by investing in both internal R&D and acquiring hi-tech companies providing solutions complementary with our traditional ones, thus increasing our proposal to the market as well as our organisation. Today, Marposs is a group of companies accounting more than 3,500 employees and is present in 80 locations across 25 different countries. In Asia, we are present in China (with more than 700 people and local production site), Japan (since 1970 and with 150 people), South Korea, India, Thailand, Malaysia, Singapore, Taiwan and also Vietnam since 2016, where the market is growing really fast. Almost 50 percent of Marposs sales per year are delivered to Asia.
Moving forward, where do you think the industry is headed in the next 5 to 10 years?
Really difficult to say, given the multiple uncertainties of these days. For sure, the trend moving towards increase electromobility will contribute to manufacturing challenges in the next few years, changing not only the life of people living in the big towns, but also the industrial paradigms in all sectors relating to automotive. Marposs is also ready to face the challenge, having developed dedicated solutions to improve manufacturing of main EV components such as batteries (modules, packs, trays, etc), drive units and ultra-light chassis components.
Unlike present laser technology, traditional methods are based upon electronic probes that touch the part to measure the outside diameter, which is the dimension that must be accurately gauged. Alternatively, different types of air-probes can also be used to avoid any contact with the part and to allow through-feed operation. Both of these methods have some severe limitations especially when flexibility and through-feed gauging capability are concerned. Contributed by Marposs.
From the mid 80’s, Aeroel introduced a new family of measuring equipment based on laser light technology. This was break through over the existing technology since it featured extraordinary flexibility, better measuring accuracy and higher working speeds.
Laser Technology Sets New Performance Standards
The high accuracy laser gauge is the heart of these systems which measures, without contact, the outside diameter of the part while it is moved through the laser beam.
The most important features of such a system are listed below:
Large measuring range: the height of the scanning area can be as high as 78 mm: every part whose diameter is included between 0 and 80 mm can be measured with the same unit and without the need to pre-set the gauge to a varied diameter range.
Through-feed measuring capability: as a result of the contact-less technique and The optical design, the workpiece does not need to be accurately placed within the beam. Moving or vibrating parts can be gauged with utmost accuracy!
Short measuring time: the high scanning frequency enables 1500 samples per second, each one with few µm repeatability. By averaging several samples the repeatability can be boosted to ±0.4µm in 0.01 s or, even better, to ±0.07 µm in 1 s (figures guaranteed in a ±2 µm interval, 95,44 percent confidence level).
No measuring drift: an exclusive and patented self-calibration device cancels any measuring drift and guarantees permanent gauge accuracy. The time wasting task of periodical re-mastering is no longer required. In addition, the exclusive Aeroel NO-VAR technology allows automatic compensation of the measuring error due to ambient temperature change, making possible applications in a workshop environment.
Application On Centreless Grinders
The above listed features yield excellent results when laser gauges are used as post-process measuring equipment at the output of centreless grinding machines or N.C. lathes, to measure the diameters of parts like small shafts, piston pins, rolls, shock absorber rods, steering racks and a lot of other components to be used in the automotive or home appliance industry.
The Grindline Systems have been specially designed by Aeroel to accommodate these applications, giving to the customer a complete turn-key solution.
The laser gauge is installed at the output of the grinder, to measure the finished part after the process. The parts coming out of the machine are cleaned by blowing away the water+oil emulsion, which could otherwise affect the measurement accuracy: a significant development effort has been made to assure suitable cleaning by using specially designed air-cleaning devices, included in the Grindline Systems. After cleaning, the parts pass through the measuring field of the laser gauge: the part can be supported and moved by a belt conveyor or by the gantry loader that feeds the machine; in some other cases they simply push each other over “V” shaped rolls.
During the pass through the beam, the laser gauge carries out hundreds of measurements distributed along the axis of the piece. Thanks to exclusive advanced processing and filtering techniques, the Grindline software only extracts those measurements carried out on diameters specified by the operator, thus ignoring shape irregularities that might otherwise compromise the result.
Chamfers, grooves, threads, through holes and even drops of emulsion on the workpiece are not able to deceive the system. Several diameters can be measured on parts ground by plunge type grinders or average diameter and taper on parts ground by through-feed machines.
The values measured by the laser gauge are displayed and compared with nominal diameters and their tolerances, pre-programmed by the operator in the electronic control unit. Dimensions of each component can be stored in a “product library” and instantly retrieved by the operator every time production changes.
If the wear condition of the grinding wheel results in an excessive deviation from the nominal diameter, a series of “increase” or “decrease” pulses automatically corrects the grinding wheel position, thus keeping the part size within tolerance.
To achieve optimum control, the Grindline software automatically takes into account the pieces already machined that are between the grinding wheel and the laser gauge; in addition any out of tolerance part can be easily discarded thanks to GO/NO-GO signals provided by the control unit.
The results of all measurements are stored and processed in real time: simple but effective statistical reports can be printed to prove product quality and process capability.
The Benefits Of The Grindline System
In conclusion, the Grindline systems have proved to be a simple and effective solution in most cases where on-line check and machine feed-back is required, giving important advantages over traditional equipment.
Excellent flexibility: the system enables measurement of a wide number of different diameters and types of components without specific dedication. Thanks to through-feed operation, the part can be gauged without having to stop and extract it from the line, an operation that usually involves complicated and costly handling.
Zero defect production: the real time adjustment of the machine and the discarding of every out of tolerance piece eliminates “returns” for diameter non- conformity.
Quality certification is made easier: the on-line capability makes sample measurement systems obsolete, since 100 percent checking is possible. By connecting the system to an existing SPC network, real time data can be processed to certify product quality and process capability.
Cost effective solution: thanks to simpler application requirements and minimum cost of associated mechanics, the overall price to performance ratio is very competitive compared to traditional solutions.
Marposs’ Provaset T3 is the ideal leak tester for all industrial production sectors and quality labs.
A dedicated software to collect and manage data can be provided together with the equipment.
It possesses a full colour 7” LCD display touchscreen, more than 300 test programmes and test sequences and enables the user to control external automations. The system also contains an interface with barcode and QRcode readers and printers and the possibility to record the tests on USB memories or via Ethernet. This makes it a complete and suitable instrument for the most modern production applications.
Wide full scale versions are available in the following parameters: up to 30 bar; 300 l/min; vacuum and high measurement resolution: up to 0.1 Pa; 0.01 cm3/min.
Existing applications in the mechanic field include: axels, cylinders, flanges, gears, motor reducers, pumps etc.
The Metal Cutting Industry is central for the growth and development of the Indian manufacturing Sector because it includes several segments from machine tools to cutting tools, from saw blades to laser machines, from plasma cutters to water jet cutters, from accessories and metrology equipment to lubricants and everything in between.
The Economic Times, through its Best Brands awards series, endeavors to highlight brands that have gained customers’ confidence and maintained their positions. And to be a part of ‘The Economic Times Best Brands in Metal Cutting Industry 2018 Initiative’, companies will have to fulfill several criteria such as having considerable presence both across the country and in the international market. Additionally, they should also be focused on Innovation, Technology and Service, as well as possess positive and consistent business performance.
Thus, it is with these considerations in mind that the Economic Times has awarded Marposs India as one of the Best Metal Cutting Brands in 2018 in the category of “Metrology Solutions”.
The event took place on September 21 at Le Meridien, in Bangalore, India, and the award was collected by Mr. Sood, General Manager of Marposs India.
Marposs Corporation has launched a maintenance, repair and overhaul inspection and tooling solution, the i-Wave2 Handheld Gage, designed primarily for easy usage. With its 4.57 cm colour display and wireless bluetooth technology, users are able to obtain measurements without the aid of a computer.
Depending on its head, the gage is capable of measuring inner and outer diameters, depths and distances, making it suitable for gauging features such as rivet holes, bores and bearings, to name a few. The gage’s measuring resolution of 0.0001 mm helps to minimise human error and save time.