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A product overview of theRenishaw Equator programmable gauge Denis VasilescuDecember 2016 Application Engineer

MAIN TITLE

Agenda for presentationWhy it existsWhat it doesHow it worksWhere it is used

AGENDA/OUTLINE

The current state of industrial metrologyMeasurements in manufacturing is segregated into domains: quality assurance and process control.

The current state of industrial metrologyQuality assurance is measurement of finished parts to verify if it meets the engineering specifications for fit and function.

The current state of industrial metrologyQuality assurance typically makes use of coordinate measurement machines (CMMs) for their flexibility of measurement and capability for geometric dimensional analysis.

CMMs typically reside in a climate controlled room, far away from the temperature and environmental harshness of the shop floor, and they require special training to operate.

The current state of industrial metrologyQuality assurance typically measures geometric dimensions; special classifications such as roundness, flatness, parallelism, and runout, which describe the form and orientation of entire surfaces according to ASME

The current state of industrial metrologyProcess control is the measurement of unfinished parts to check if the manufacturing process is on target and to correct it if it is not.

The current state of industrial metrology

Process control typically measures linear dimensions such as diameters, lengths, and heights which are all essentially the average distance between two opposing points.

The current state of industrial metrology

Process control typically make use of gauges; robust measurement instruments for the shop floor that derive their accuracy from a master part.

The current state of industrial metrologyOne particular class of gauges for mass production are hard gauges, which are custom built for one single part and one particular set of dimensions

The current state of industrial metrologyHard gauges typically have multitudes of individual touch sensors (LVDTs) that make single point contacts for each dimension.

Hard gauges, because of their custom nature, are very efficient but cannot accommodate design deviations.

A converging set of problemsTechnical advancements lead to every more complex part designs with tighter tolerances, all of which drives the need for more frequent quality assurance checks of geometric dimensions

Complex parts tend to go through many design revisions well after manufacturing has begun, which drives the need for flexible gauges

Increasing global competition drives the need for automated process control to minimize scrap

Lean operating philosophies and cost-cutting practices drive the attempt to do process control and quality assurance in the same step on the same instrument

but CMMs are too slow and too fragile for the shop floor, and hard gauges are too limited for complex dimensions and cannot adapt to design revisions!

The solution to converging problems:

Operates like a CMM by collecting 3D points with a single scanning probe and analyzing complex geometric dimensions

Functions like a gauge by deriving accuracy from a master part, giving it immunity from temperature effects

Mechanically robust and measures fast, allowing for use on the shop floor for process control like a gauge

Reprogrammable and versatile to quickly accommodate print changes and job changes

The solution to converging problems:Mass produced measurement instruments for measuring mass produced parts

More cost effective than either a CMM or a custom hard gauge

Integrates with programmable logic controllers and robots for automated part loading/unloading

Integrates with machine tool offset softwares for automated wear compensation

Integrates with statistical process control softwares for automated monitoring and traceability

:a new class of measurement instrument

The patented parallel kinematic mechanism design

The general design is a parallel kinematic mechanism (PKM), which is designed to carry a light inertial load at very fast speeds.

Three sets of parallel passive legs constrain the end effector (the head) to pure translation in XYZ with no pivoting

Three separate motorized legs drive the end effectors position.

The patented parallel kinematic mechanism designThe three drive legs have Renishaw linear encoders and scale directly on the strut, which allows for no loss of motion feedback and tight motion control.

Every single mechanical element on the gauge ends in a spherical joint

Spherical joints ensure that the struts can only be in tension or compression, never bending

Allows for incredible stiffness in a small frame

PKMs are fast and compact, which is why they are favored for pick-and-place robots. But only Renishaws patented design gives them excellent metrology.

Compare to a serial kinematic mechanism: bridge CMM

Z AxisMinimal bending forces: probe deflection (0.2 N/mm)High need for stiffness & straightnessAluminium or ceramic rail carried on aluminium or cast iron carriage50 to 600 Lbs Typical weight

Compare to a serial kinematic mechanism: bridge CMMX AxisBending forces from weight of Z axis assemblyHigh need for stiffness & straightnessBending issues solved by massAluminium or granite rail carried on aluminium or cast iron carriage100 to 2000 Lbs Typical weight

Compare to a serial kinematic mechanism: bridge CMMY AxisSignificant bending forces from weight of carrying Z & X axesHigh need for stiffness & straightnessBending issues again solved by massGranite block or granite with steel/aluminium frame300 to 8000 Lbs Typical weight

Compare to a serial kinematic mechanism: bridge CMMAdd it all up1,000 to 12,000 Lbs. dedicated to straight, square motion in 3 axes of a 4 ounce probe with .2 N/mm of forceDesign constantly fighting dynamics of bendingDesigns metrology very dependent on straightness and squareness of the build

The comparative gauging principle

For all the features and capabilities packed in, the Renishaw Equator gauge is simple to operate

Gauging, mastering, and software start up can be operated with the press of a button using a mouse or a hardware button interface shown right.Operating the Equator gauge

The onscreen software can display simple messages such as Pass/Fail

It charts the live trends in dimensions and temperature for monitoring when it is time to remaster

Detailed reports for each part is stored on the controller, can contain traceability such as operator name and serial number, and can be sent to a serverOperating the Equator gauge

Where is it used?At the end of 2016, well over a thousand Equator gauges have been sold worldwide since its product launch in 2012, with the bulk of them in the United States of America.

Ownership ranges from a handful to a dozen per plant, to hundreds across an organization. Highest ownership in one plant is 200!

The vast majority of US customers consider it a huge competitive advantage and keep it a well guarded secret.

Where is it used?A classic case story is Conroe Machine out of Conroe Texas. Equator gauged 100% of parts, fully automated including tool offsetting.

Equator paid itself off in 18 days by the throughput gains and scrap reduction!

:a new class of measurement instrument

Any Questions?

For future inquiries visit www.Renishaw.com/gauging

or call (847) 286-9953