Bart Boeckmans

Determination of Aspect Ratio Limitations, Accuracy and Repeatability of a Laser Line Scanning CMM Probe

Coordinate measurement machine (CMM) probing techniques can involve direct mechanical contact (e.g., tactile probing) or diverse non-contact principles (e.g., laser line scan probing). For some applications, contact methods are not capable of measuring fast enough to ensure 100% quality controlled parts. A laser line scanning probe uses a laser triangulation-based method to acquire 3D measurement points on a workpiece relative to a sensor. Mounting the sensor in a 3D coordinate frame, e.g., in a CMM provides enough information to fully examine the workpiece. These techniques are most commonly exploited in medical industry and industries involving plate materials. A high data density and measurement speed are significant advantages when measuring free-form surfaces by laser line scanning, making the process much more time-efficient. However, high-precision geometrical features (such as cylinders, spheres, etc.) must be measured for locating and aligning the free-form shapes. The accuracy of the equipment therefore has to be assessed. Probe Maximum Permissible Error (MPEP) values below 10 μ m have been reported for cutting-edge laser line scanners. This paper compares the major influences on measurements on cylindrical features. First, the aspect-ratio limitations are considered by comparing two inherently different techniques. The stable inspection of reference features is important, while trying to maximize the spatial extent of the measured features. Second, the measurement method is analyzed in two ways: by using a limited sample of the features to increase stability and eliminate interference from neighboring features; by varying the number of scan tracks, which greatly affects the measurement time.

ISO 10360 verification tests applied to CMMs equipped with a laser line scanner

Within the field of quality control and dimensional metrology, the evolutions in the domain of production processes are triggering more use of non-contact measurement equipment to assure faster feature assessment where possible. This led to the development of for instance laser line scanners. The standardization of these new tools follows these novel evolutions. As the coordinate measuring systems (CMSs) which include coordinate measuring machines (CMMs) with its diversity in measurement probes widens its spectrum, the ISO 10360 standard series is rearranged and split up in more parts, covering specific probe groups. The previously mentioned laser line scanners, that can be equipped on a CMM, are integrated within ISO 10360-8 which applies for CMMs equipped with optical distance sensors. This paper is an example of how to interpret and apply this standard to a specific optical distance sensor. This has to be done by taking into account the sensor’s characteristics. The intrinsic properties in the technique require an in-depth look at the recommended guidelines within the standard. Furthermore, the guidelines are adapted to use the same capabilities of the laser line scanner, which are used for measuring, without eliminating the uncertainties present in practical use of the sensor. The verification tests and their implementation are discussed, adapted to the sensors needs and performed on a state-of-the-art CMM. The verification parameter results are determined, presented and critically evaluated.

Metrology Performance of Laser Line Scanning of Additive Manufacturing Fixtures Based on Geometrical Product Specification (GPS)

To gain a maximum benefit of high-speed optical scanning in the metrological calibration of emerging AM (Additive Manufacturing) fixtures it is necessary to investigate the metrology performance of laser line scanning in particular on coordinate measuring machines (CMMs) based on new generation of Geometrical Product Specification standard. A set of designed experiments was set up both on an actual fixture and artefacts manufactured by the Additive Manufacturing company, Materialise-RapidFit+. It enables to identify the influence of a fixture’s geometrical characteristic, material, colour, transparency and roughness, as well as of the alignment of the part coordinate system (PCS) mathematically relating to the machine coordinate system (MCS). Performance measures that were tracked included inspection accuracy, measuring repeatability and time consumption. Results demonstrate that the laser line scanning strategy enables to lower the time consumption in the order of 49% for a fixture with six locators mounted on it and a PC with 128GB RAM, especially providing a superior accuracy performance for complex geometries compared to a tactile measuring strategy.

Computed tomography: a powerful imaging technique in the fields of dimensional metrology and quality control

X-ray computed tomography (CT) is slowly conquering its space in the manufacturing industry for dimensional metrology and quality control purposes. The main advantage is its non-invasive and non-destructive character. Currently, CT is the only measurement technique that allows full 3D visualization of both inner and outer features of an object through a contactless probing system. Using hundreds of radiographs, acquired while rotating the object, a 3D representation is generated and dimensions can be verified. In this research, this non-contact technique was used for the inspection of assembled components. A dental cast model with 8 implants, connected by a screwed retained bar made of titanium. The retained bar includes a mating interface connection that should ensure a perfect fitting without residual stresses when the connection is fixed with screws. CT was used to inspect the mating interfaces between these two components. Gaps at the connections can lead to bacterial growth and potential inconvenience for the patient who would have to face a new surgery to replace his/hers prosthesis. With the aid of CT, flaws in the design or manufacturing process that could lead to gaps at the connections could be assessed.