What makes for a good measurement solution for the shop floor?

Quick response times and direct feedback make measurement technology integrated into production attractive. For the solution to be successful, mechanical engineering, ergonomics and service must result in a sustainable overall concept.

Published in Quality Engineering Plus (in September 2020)

Measurement technology has been changing from a measurement room to a manufacturing environment or to a fully automated production line for some time. The exciting question now is, what does this mean for the measuring machine? Or to put it more broadly: What does this mean for the measurement solution in the future?

Many manufacturers appreciate the benefits of measurement in production. The material flow is easier to handle, and the results are available much more quickly to people who can intervene immediately — the workers. This reduces waste, as workers can counteract trends before it is too late.

What distinguishes manufacturing and measurement rooms?

Production requirements differ in important aspects from the quality sector, in particular in terms of operation, the environment and the required reliability. Ideally, the operator carries out the measurement himself near the manufacturing machine. Simple operation and immediately available, easy-to-read results leave time for the essentials, production. This is where software with intuitive control elements and clear reports and trend analyses is in demand. There are already solutions that differentiate between programmer and operator and partially automate programming.

Go with the flow

For short distances, the measuring machine is close to the manufacturing machine and therefore a small footprint is required. With modern manufacturing methods and design technologies such as topology optimization and FEM simulations, the machines can be built extremely compact and easy and the control and electronics can be integrated into the machine.

A modern manufacturing measuring machine is optimised for a minimum floor space (here just 2.3 m²) and ergonomically designed for easy operation.

However, it is often small things, such as a cleverly integrated probe changer for maximum measurement area, that make the difference for the operator. In the case of portal machines, for example, a level end of the base plate on all sides can be decisive for easy loading. This makes it easy to integrate the machine into the existing hall in any orientation.

Measurement technology in sync with production

In production, the cycle determines the speed, whereas up to now the focus has been on accurate and traceable measurement. How do you deal with this now, because the more precisely you want to measure, the more time is usually required. Fortunately, there are highly accurate measurement systems in which the measurement can be imaged using very rapid head movement and optical sensors that capture large areas extremely quickly with sufficient accuracy.

Schematic classification of measurement systems according to speed and accuracy.

And if this is still not enough, you can use a fast comparator or operate the measuring machines in a faster mode. Repeatability is maintained here and trends can continue to be observed. The measurements are compared with exact absolute values in random sample measurements.

Life Is What Happens While You're Making Plans

Production is also changing profoundly. Rapid series change and demographic change are fundamentally changing the framework conditions. It is therefore important to find a sustainable solution:

• flexibility
  Retrofitability for sensors and easy relocation offers adaptability in a new series
• Automability:
  Preconfigured automation solutions from the manufacturer or pre-equipment make the machine easy to expand
• Monitoring options
  Online monitoring tools are already standard and provide the basis for predictive maintenance

Reliability through excellent and predictable service

The prettiest machine is of no use when it is stationary. Especially in manufacturing, people are used to planning with high availability and to represent this reliably and predictably through service contracts. In the end, the overall package is decisive: Of course, an attractive purchase price is important, but reasonable operating costs (cost-of-ownership) and availability as soon as the machine is in normal operation are at least as important.

In addition to reliable mechanical engineering and worldwide availability of parts, manufacturers already offer modular service programs that offer many advantages:

• Latest software
• Guaranteed response time
• Predictable costs
• Expanded warranties

It is precisely these aspects that accompany the user in everyday processes.

Robust engineering

The manufacturing environments we encounter with customers are as diverse as the parts. In machine design, machines suitable for workshops pay attention to several new aspects compared to the measurement room.

• Temperature behavior:
  The selection of materials and the connection of the individual components is essential for changing the machine as evenly as possible. The residual errors are then recorded in complex measurements in the climate chamber (see figure) and can be eliminated through compensation during measurement.
• 24/7 operation:
  Drive and guidance systems that are as proven and robust as possible are used here. The installation position can also be decisive for dirt resistance, such as vertical installation of the measurement systems and protected drive rods (see illustration).
• Vibrations:
  Many years of experience with customers show that air bearings are also suitable for the production environment. In difficult environments, air-cushioned, active damping or particularly robust linear guides are used.

Left: A manufacturing measurement solution undergoes extensive tests in climate chambers and vibration measurement stations until it is ready for the workshop. Right: Small details are important, such as protected standards and drive units. The installation position also plays a role.

There is no single solution here, which is why we and other manufacturers also offer an entire portfolio of machines and options.

In the end, the package is decisive

Of course, high-quality mechanical engineering with sensors tailored to the respective application is a prerequisite. Important points are added so that this becomes a round measurement solution:

• ergonomics: The solution is efficient when it fits into the material flow
• Operating concept: The operator can operate the solution reliably
• Future security: The machine is easy to adapt to new processes and can be expanded with modern sensors
• Cost of Ownership: Reliable and predictable service with modern software make everyday life easier

If the package is right, you will enjoy your measurement solution.