Metrotomography University Uppsala OPT [Kompatibilitetsläge]
Transcript of Metrotomography University Uppsala OPT [Kompatibilitetsläge]
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Metrotomography
A tool for optimization of business processesp
10.11.201010.11.2010
R lf B iRalf BenningerProduct Manager
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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
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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 3Carl Zeiss IMT GmbH, Ralf Benninger, IP-L
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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
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Carl Zeiss Industrial Metrology
Coordinate Measurement Machines, Sensors, Software
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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 6Carl Zeiss IMT GmbH, Ralf Benninger, IP-L
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The METROTOM® - Family
METROTOM® 800 METROTOM® 1500
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Technology
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Typical applications
3D-Volume
data
Reverse Engineering
CAD-Comparison
Defectanalysis
Dimensional Metrology
3D CAD3D CAD
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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 10Carl Zeiss IMT GmbH, Ralf Benninger, IP-L
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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
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Measurement Uncertainty
Tolerance
N i lNominal Value
Measurement Uncertainty
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y
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Measurement Performance
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Accuracy is depending mainly on right calibration of the projection geometry!
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Geometrical distortion
Axis calibration
Geometric calibration
Detector calibration
Wire phantom Geometry phantom
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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.
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high subvoxel accuracy!
(5 µm error)
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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
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High Number of Acceptance Tests
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METROTOM Customers
RWTH Aachen,
d !
Uni Kosice (SK),
Teknologisk Institut (DK)
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… and many more!
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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 19Carl Zeiss IMT GmbH, Ralf Benninger, IP-L
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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
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Example: very complex case of a plug connector
More than 500 inspection characteristic!
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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.
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Non-destructive measuring
Example:Example:
Complete inspection of a plastic plug connector consisting of threeconsisting of three different materials.
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What can be measured?
All kind of features and elements, tolerances (shape tolerances (shape and location), ….
PTB-certified
Software!
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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
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VDA First part inspection report Presentation protocol
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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
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Flatness plot Graphic protocol
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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
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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
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Mold correction
CAD mold actual + correction
Multiple Iteration cycle!
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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
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Mold correction
CAD 3D mold actual +
correction
ypcorrection
30-70% saving of time
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Defect Analysis
NDT technology Defect analysis is often usedfor the first check of the
tcomponent.
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Quantitative und Qualitative Porosity Analysis
axial frontal
The Porosity Analysis helps to find defects and to optimize process parameter
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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
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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
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Assembly control of a insulin pen
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Assembly control of a insulin pen
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Assembly control of a insulin pen
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Assembly control of a insulin pen
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Assembly control of a insulin pen
13.12.2010 37Carl Zeiss IMT GmbH, Ralf Benninger, IP-L
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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 38Carl Zeiss IMT GmbH, Ralf Benninger, IP-L
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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
13.12.2010 39Carl Zeiss IMT GmbH, Ralf Benninger, IP-L
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13.12.2010 40Carl Zeiss IMT GmbH, Ralf Benninger, IP-L