automated inspection of cold formed bolts troy d. wells / cmfgt inden 5303 fall 1999
TRANSCRIPT
Automated Inspection of Cold Automated Inspection of Cold Formed BoltsFormed Bolts
Troy D. Wells / CMfgT
INDEN 5303
Fall 1999
Hilti Plant 5Hilti Plant 5• Plant Operations
– Opened in Tulsa, OK in 1979– Employment 165
• Products Produced– Carbide Tipped Masonry Drill Bits (for hammer drills)
– DX Pins (nails for powder actuated tools)
– Anchors• Kwik Bolts (expansion bolts)
• HDI (drop in anchors)
• HAS (chemical anchors)
Automated Inspection NeedsAutomated Inspection Needs
• NUPIC – Annual Audits– Final Inspections
• Definition: The Number of Parts Produced Without any Failures Divided by the Total Number of Parts Produced.
• Goal is 98%
• Current is 94%• Failures-lost parts, rejects, scrap
Production Methods for Kwik BoltsProduction Methods for Kwik Bolts• Cold Forming
– FX45 production standard=10,000/hr• Ø1/4” x L 1 3/4” - 3 1/4”• Ø3/8” x L 2 1/4” - 3 3/4”
– 750 production standard=5,400/hr• Ø1/4” x L 4 1/2”• Ø3/8” x L 5”• Ø1/2” x L 2 3/4” - 5 1/2”
– 1012 production standard=3,000/hr• Ø3/8” x L 7”• Ø1/2” x L 7”• Ø5/8” x L 3 3/4” - 10”
• Ø3/4” x L 4 3/4” - 12”
• Screw Machining• Ø1” x L 6” - 12”
Production MIPProduction MIPM a n u f a c t u r i n g
a n dI n s p e c t i o n P l a n
A 1 0 0 0 2
R e v . P
2 o f 2
P l a n t 5 M I P N u m b e r S h e e t
C o l d F o r m / T h r e a d S e e B e l o w *W o r k C e n t e r D e s c r i p t i o n W o r k C e n t e r N u m b e r
1 2 - K B I I C o l d F o r m / T h r e a dI t e m N a m e O p e r a t i o n D e s c r i p t i o n
A
L ±0.5
K +3.0/-0
All DimensionsBefore Plating
All Dimensions Metric Except P.D.
0.2RMin.
Letter - I.D.
1.5 Min.
12.70
Min.
Ref.
2.7 ±0.5
9.45 ±
0.25
-1
12.8
±0.10
9.75 ±
0.10
11.3 ±0
.25 +.25/-0R
12.65
±0.20
29.3 ±0.35
3.5 ±0.5
View A
11.05
Min.
Burr Max. 0.5
8° ±3
0' 19.8 / 20.6
30° ±5°
1/2
- 13 U
NC(P
.D. -.
437 /
.442
)(M
.D. -1
2.36 /
12.66
)
11.30
+0.10
/-0.15
M a n u f a c t u r i n ga n d
I n s p e c t i o n P l a n
A 1 0 0 0 2
R e v . P
1 o f 2
P l a n t 5 M I P N u m b e r S h e e t
C o l d F o r m / T h r e a d S e e B e l o w *W o r k C e n t e r D e s c r i p t i o n W o r k C e n t e r N u m b e r
1 2 - K B I I C o l d F o r m / T h r e a dI t e m N a m e O p e r a t i o n D e s c r i p t i o n
N o . F e a t u r e / A c t i v i t y F i x t u r e / T o o l i n g / G a u g e F . C l a s sC l a s s
F r e q . R e s p .0 1 1 2 . 8 0 + 0 . 1 0 / - 0 . 1 0 G a u g e 0 2 6 5 1 1 5 4 H O p e r
0 2 9 . 7 5 + 0 . 1 0 / - 0 . 1 0 G a u g e 0 2 6 5 1 1 5 4 H O p e r
0 3 1 2 . 6 5 ± 0 . 2 0 G a u g e 0 2 6 5 1 1 5 4 H O p e r
0 4 1 1 . 3 0 + 0 . 1 0 / - 0 . 1 5 C a l i p e r N O p e r
0 5 2 9 . 3 ± 0 . 3 5 G a u g e 0 2 6 5 1 1 5 3 H O p e r
0 6 2 . 7 ± 0 . 5 0 G a u g e 0 2 6 5 1 1 5 3 N O p e r
0 7 L ± 0 . 5 0 G a u g e 0 2 6 5 1 1 4 7 H O p e r
0 8 K + 3 . 0 / - 0 . 0 G a u g e 0 2 6 5 1 1 5 6 H O p e r
0 9 9 . 4 5 ± 0 . 2 5 C a l i p e r N O p e r
1 0 3 . 5 0 ± 0 . 5 0 C a l i p e r N O p e r
1 1 L e t t e r S t a m p - S e e * V i s u a l N O p e r
1 2 1 9 . 8 0 / 2 0 . 6 0 @ 1 1 . 3 0 ± 0 G a u g e 0 2 6 5 1 1 5 2 H O p e r
1 3 8 d e g ± 3 0 m i n G a u g e 0 2 6 5 0 8 9 3 H O p e r
1 4 1 2 . 7 0 M i n R e f . , 1 . 5 M i n G a u g e 0 2 6 5 0 8 9 3 N O p e r
1 5 0 . 2 5 + 0 . 2 5 , - 0 R . G a u g e 0 2 6 5 0 8 9 3 N O p e r
1 6 1 1 . 0 5 M i n . G a u g e 0 2 6 5 0 8 9 3 N O p e r
1 7 B u r r M a x 0 . 5 0 p e r m i t t e d C o m p a r a t o r ( N o t i n c l u d e d i n O . A . L . ) N O p e r
1 8 1 / 2 - 1 3 U N C ( P . D . 0 . 4 3 7 ” , 0 . 4 4 2 ” ) G a u g e 0 2 6 5 1 1 5 5 H O p e r
1 9 1 / 2 - 1 3 U N C ( M . D . 1 2 . 3 6 / 1 2 . 6 6 ) G a u g e 0 2 6 5 1 1 5 4 H O p e r
2 0 R e m o v e a n d r e c o r d a l l c o i l w e l d s V i s u a l O p e r
2 1 O t h e r f e a t u r e s V i s u a l / C o m p a r a t o r O p e r
2 2 O p e r a t o r i n s p e c t i o n f r e q u e n c y 3 p c s . / 0 . 5 H o u r O p e r
* I t e m N u m b e r S i z e L ± 0 . 5 + 3 . 0 - 0 . 0 I . D .
D r a w i n gN u m b e r
W . C .N u m b e r
0 0 2 9 0 7 7 2 1 / 2 x 2 3 / 4 6 9 . 9 3 2 C 0 0 2 9 0 7 7 1 1 9 4 0 0
0 0 2 9 0 7 7 3 1 / 2 x 3 3 / 4 9 5 . 3 3 2 E 0 0 2 9 0 7 7 1 1 9 4 0 0
0 0 2 8 8 5 3 4 1 / 2 x 3 3 / 4 9 5 . 3 5 7 E 0 0 2 9 0 7 7 1 1 9 4 0 0
0 0 2 9 0 7 7 7 1 / 2 x 4 1 / 2 1 1 4 . 3 3 2 G 0 0 2 9 0 7 7 1 1 9 4 0 0
0 0 2 8 8 5 4 1 1 / 2 x 4 1 / 2 1 1 4 . 3 7 6 G 0 0 2 9 0 7 7 1 1 9 4 0 0
0 0 2 9 0 7 7 8 1 / 2 x 5 1 / 2 1 3 9 . 7 3 2 I 0 0 2 9 0 7 7 1 1 9 4 0 0
0 0 2 8 8 5 4 2 1 / 2 x 5 1 / 2 1 3 9 . 7 7 6 I 0 0 2 9 0 7 7 1 1 9 4 0 0
0 0 2 9 0 7 7 9 1 / 2 x 7 1 7 7 . 8 1 0 2 L 0 0 2 9 0 7 7 1 1 9 6 0 0
O . B y e R e v . L e v e l K L M N O P
I s s u e r M C R N o . 3 2 1 3 3 5 1 3 3 6 2 3 3 6 8 9 3 8 3 0 3 8 6 1
1 2 - J u l y - 9 1 I n i t ’ l P 5 E o b P 5 E o b P 5 E o b P 5 A o b P 5 A o b
K
Common RejectsCommon Rejects
Failure Mode Reject Scrap
Head Form out of round 0.90% 0.40%
Thread Length 2.80% 0.01%
Burr Ring 2.12% 0.00%
Bite Marks 1.70% 0.07%
Selection CriteriaSelection Criteria
• J. Teegarden, Modern Machine Shop 1998– Number & Type of features to be inspected– Throughput requirements– Level of accuracy required– 100% inspection or audit methods– Operator skills– Portability (gauge vs. workpiece)– Inspection environment– Workpiece condition– Workpiece material– Data output format– Budget
Inspection MethodsInspection Methods
• Current– Manual & Semiautomatic
• Non-Contact - Contact– Vision Systems– Mechanical
• In-process - Post-process
Planning BudgetPlanning Budget
• Non-Contact– Basic System $15,000– Automated System $100,000
• Contact– Basic System $15,000– Automated System $50,000
Gauge DesignGauge Design
• Robot
• Transfer Station Style
• Features to be Inspected
• Cycle Time
• Operator Feedback