Information Technology Tools for Metrology

J. Raja

Center for Precision Metrology

University of North Carolina at Charlotte

Outline• Manufacturing in the global age• IT tools in metrology - Efforts at UNCC

– Internet based Analysis software– Surface texture Database– Information system– Peer-to-peer file sharing– Tool boxes for process and function– Uncertainty and gage R&R– Gage management software

• Future directions• Conclusions

Business models in manufacturing industries

• Traditional Model– Vertically integrated– Design, Manufacturing and Assembly

• Distributed Manufacturing Model– Design and Assembly– Manufacturing of key components (3Cs, 5Cs)

• Virtual model– Some design and assembly– Emphasis on brand (Marketing, Distribution and

services)

Henry Ford’s vertically integrated facility

Ford River Rouge Complex

The complex included dock facilities, blast furnaces, open-hearth steel mills, foundries, a rolling mill, metal stamping facilities, an engine plant, a glass manufacturing building, a tire plant, and its own power house supplying steam and electricity.

IRON ORE

Manufacturing in the global age

• Remarkable progress in IT in the last decade

• Manufacturing goes global• Need for sharing information

across geographical boundaries

• Monitor data real time for diagnostics

• Quickly deploy solutions to the industry

• Share documents, data and results between academia and industry

Crankshaft

Engine

Bearing

Made in USA!

IT in Metrology – the last 30 years

Src: Taylor Hobson and Mahr-federal web sites

Historical Surface Metrology Measurement Spectrum

Micro-burrs &Torn Material

Roughness Straightness Dimension(Size & Position)

Microscopy(Visual Assessment)

Sharp-Stylus(Roughness)Instruments

Special PurposeInstruments

Surface Plate(layout) Instruments& Gauges

Current Metrology Measurement spectrum

Micro-burrs &Torn Material

Roughness Straightness Dimension(Size & Position)

Microscopy(Visual & Digital Assessment)

Sharp-Stylus(Roughness)Instruments

Waviness

Roundness &CylindricityInstruments

CoordinateMeasuringMachines(CMM's)

Efforts at UNCC

IT Tools for Metrology

Internet based Analysis software

Database

Peer-to-peer file sharing

Information System

Toolboxes

Process specific

Functional toolbox

Uncertainty(GUM)

Gage management software

Visualization tool using VRML

Visualization controls for viewing profiles

Internet based Surface Texture Analysis Software

Internet based analysis software

• A surface texture analysis system capable of accessing data from a database over the Internet

• Comprehensive set of filters and user defined filtering schemes for surface profile diagnostics

• Collection of advanced tools for surface texture analysis

• Tools for comparing profiles

• Visualization tools for multiple profiles

• Tools for process specific analysis

• Providing a common analysis package for data from different sources

• A template for the development of recipes for detailed analysis

Analysis Tools Developed• Filters

– Gaussian

– TwoRC

– BandPass

– RKFilter

– Functional Filtering

• Curvature removal• Amplitude Dist.• Power Spectrum• Parameters (ISO)

• Compare Two Profiles• Correlation Function

– Auto, Cross

• Multiple File Analysis• Multiple File Formats

– Mahr, Talysurf, Federal, SDF

• Special Tools– Generate and Analyze turned

profiles

– Multiple Cutoffs

– Removing Asperity

– Wavelet Analysis

Internet based software – raw data & slope removed profile

Roughness, waviness and form

Multiple cutoffs

Surface Texture Database

Surface Texture Database

• Organize surface texture data for analysis

• Process mapping: collect comprehensive data long period of time

• Use data over extended time to develop process knowledge

Entity Relationship Diagram

MEASUREMENT

InstrumentName TraceLength

DriveSpeed TipRadius TipForce

ToolFeed

MeasureNo

MeasurementDate

Additional_ Information

MeasurementTime

Temperature

ProbeRange

Resolution

Range

GENERATES

PART

PartNo

Company

PartDate Additional_ Information

PartTime

PartName

PRODUCES

N

M 1

1

N

Additional_ Information

SURFACE_FUNCTION

Description

Symbol SurfaceNo

1

Pa ANALYSIS_

DATA Pz

Psk

Pku

Rms_Slope

Sm

Pv

Pp

Pt

Pq

1

HAS N

PROCESS

1

Process_Name

Depth _Cut

Tool Speed

ToolRadius

ToolFeed

ToolLife

ToolChange

Temperature

Machine_Tool_ FileName

ProcessNo

DATA_FILE

Format

Spacing

DataNo

FileName

NumberPoint

CONTAINS INCLUDES

MACHINE_TOOL

MachineNo

Additional_Information 1

N

Filename

Features• Remote and local data upload to the database• Upload data to surface analysis program• User privilege and Password protected storage

space• Customized Database fields• Ability to read commercial data formats• Extensive query capability• Data file management

Component Interaction

Database

Surface Analyzer

Application

Instrument B

Web Browser

The User

Client

Instrument C ..n..

usesconnects

displays

insertsinserts

Instrument A

inserts

inserts

queriesreturns

InsertDeleteUpdate

Internet based Form analysis software

Roundness & Cylindricity

• Polar & Linear Roundness plot

• Filter– 2RC

– Gaussian

– Spline

– FFT

– FFT Bandpass

• LS, MI, MC & MZ Algorithms for Roundness

• LS Algorithm for Cylindricity

• Power Spectrum & harmonics

• Comparison of two different profiles

• Multi-filters using One Cutoff

• Multi cutoffs using One Filter

Roundness Analysis System

Filtering of Roundness Data

Cylindricity Analysis System

Straightness & Flatness

• Least Squares and Minimum Zone Straightness

• Display of Straightness Profile

• Least Squares & Minimum Zone Flatness

Issues with the Applet version

• Computing done on client machines

• Speed not satisfactory

• Firewall problem

• Database access slow

• System does not allow the creation of multiple DB user account

The servlet version• Three-tier architecture

– DB, application server and servlet

• Thin client• Run on firewall environment because client only

sees html pages• Support multiple user accounts• Speed issue resolved• Supports access to user log files for administration

purposes

The servlet software:3-tier architecture

User

Web Application (Metrology software

application) Database

HTTP JDBC

DatabaseServlet Application Server

The customizable database

• User can customize database fields based on specific application

• Can interface with analysis software

A milestone: A new server

• Spring 2001: Server installation

• The software can now be accessed at

http://www.sfmg.uncc.edu/metrology

The common interface to the software

Process and Functional Toolboxes

Toolboxes for process and function

Tool boxes for surface metrology

Generic Process Tool box

Turning toolbox

Plateau-honing toolbox

Grinding toolbox

Functional Tool box

Analyticaltools

Inferenceengine

DB

Analyticaltools

Statisticaltools

DB

Process specific toolboxes

• To build a process specific toolbox for diagnostic applications

• Toolbox will have a knowledge base and also have an inference engine to perform diagnostics like tool wear, feed changes etc.

• Build a toolbox for turning, grinding and plateau-honing

Turning Example

Effect

Parameters Ra, Rsk, Rku, RqPower SpectrumAutocorrelationEnvelop variations

Predictive logic

Cause

Tool wearFeed change

Monitor profile variations

Turning Example• Develop a model that describes cause-effect

relationship– The data for this model will come from many sources –

experiments, literature, industry etc– This data will serve as the knowledge base for the inference

engine

• Prototype model will be built in Matlab that implements the predictive logic

• Database design to handle large quantities of data• Final version of the software will be deployed over the

internet

Functional toolbox - Objective

• To build a toolbox with a collection of advanced analysis tools for functional correlation studies

• The toolbox will include statistical tools, analytical tools along with database support

Peer to peer file sharing

Peer-to-Peer file sharing

• Provide the users a mechanism to share data file between peers in a network

• Provide the users a search engine where they can search data files from other peers on the network based on surface parameters and instrument names

• Provide the users analysis tools and a data file library

Peer-to-Peer file sharing

Measurement in Germany

Measurement in India

Measurement in US

Peer to peer search engine interface

Downloading interface

Information System

Information System

• Content Management Process

• Editorial board to review and approve content

• Centralized web-based application approach

Surface Metrology Content• Instruments: information regarding instruments used to measure

surface texture• Parameters: definition of surface parameters• Filters: filter types and how they can be used• Standards: International standards• Process: relationship between process parameters and surface

and form parameters• Function: relationship between function and surface and form

parameters• Classic Papers• Case Studies• Other Links

Content ManagementContent provider uploads, edits or deletes content via web interface and submits update

Content provider sets a content type and applies attributes relative to this type and submits document

Content editor modifies document properties, as appropriate, and if necessary, approves content, which is then submitted

Site administrator submits site content to a stage server for review

Content is deployed, either automatically, or manually to production server(s)

Collaborative Filtering System

• Collaborative filtering systems make use of reaction and opinion of people that have already seen a piece of information to make predictions about the value of that piece of information for people who have not yet seen it.

• Collaborative filtering systems can guide the users to relevant resources or resources that have best quality in context.

Features

• Recommendation Engine• Top N List • Generalized and categorized Search• Information is put in categories

Uncertainty, Gage R&R and Gage Management tools

Uncertainty and Gage R&R

• Currently developing an Internet based uncertainty analysis tool based on GUM

• Also developing tools for performing gage R&R on the web

• These tools would allow a large manufacturing company to store and access uncertainty and gage repeatability data, thereby aiding the measurement assurance process

Gage Management software

• Currently in the process of designing a gage management tool for storing data related to gage calibration and maintenance

Technology Transfer

• In the process of transferring the servlet version of the software to Caterpillar’s Manufacturing and Logistics Division for use on their intranet

In Summary

IT Tools for Metrology

Internet based Analysis software

Database

Peer-to-peer file sharing

Information System

Toolboxes

Process specific

Functional toolbox

Uncertainty(GUM)

Gage management software

Future directions• Internet and web based technologies are becoming

increasingly popular.• They will become the medium of information

exchange in the coming years.• Transition from stand alone computing to local

intranet will be driven by economic and legal issues

• Commercial products are slowly in the process of supplying a server with instruments

• Communication between different databases and networks will become an issue and XML based languages will be necessary

Conclusions

• Presented the work done at UNC Charlotte over the last six years in the area of building a framework for doing remote metrology

• Built a platform to support distributed manufacturing and product development

• Information technology tools enable better communication between experts in academia and industry and provides access to experts anywhere in the world

Conclusions

• Change in the business models will influence manufacturing and metrology, requiring the use of such data sharing and analysis tools

• Internet based systems, client-server computing and peer-to-peer data sharing will be more common tools in the future