José A. Yagüe-Fabra

Dimensional measurement of micro-moulded parts by computed tomography

Computed tomography (CT) is progressively assuming an important role in metrology applications and great efforts are being made in order to turn it into a reliable and standardized measuring technology. CT is typically used for non-destructive tests, but it is currently becoming very popular for dimensional metrology applications due to its strategic advantages such as the capability of performing measurements on both the components surface and volume, allowing inspection possibilities to otherwise non-accessible internal features. This paper focuses on the dimensional verification of two micro-injection moulded components, selected from actual industrial productions, using CT metrological tools. For this purpose, several parts have been measured with two different CT machines, and the results have been compared with the measurements obtained by other measuring systems. The experimental work carried out and the analysis of the results provide valuable conclusions about the advantages and drawbacks of using CT metrology in comparison with other measuring systems when these techniques are employed for the quality control of micro-moulded parts.

Traceability of On-Machine Tool Measurement: A Review

Nowadays, errors during the manufacturing process of high value components are not acceptable in driving industries such as energy and transportation. Sectors such as aerospace, automotive, shipbuilding, nuclear power, large science facilities or wind power need complex and accurate components that demand close measurements and fast feedback into their manufacturing processes. New measuring technologies are already available in machine tools, including integrated touch probes and fast interface capabilities. They provide the possibility to measure the workpiece in-machine during or after its manufacture, maintaining the original setup of the workpiece and avoiding the manufacturing process from being interrupted to transport the workpiece to a measuring position. However, the traceability of the measurement process on a machine tool is not ensured yet and measurement data is still not fully reliable enough for process control or product validation. The scientific objective is to determine the uncertainty on a machine tool measurement and, therefore, convert it into a machine integrated traceable measuring process. For that purpose, an error budget should consider error sources such as the machine tools, components under measurement and the interactions between both of them. This paper reviews all those uncertainty sources, being mainly focused on those related to the machine tool, either on the process of geometric error assessment of the machine or on the technology employed to probe the measurand.

Design Optimization for the Measurement Accuracy Improvement of a Large Range Nanopositioning Stage

Both an accurate machine design and an adequate metrology loop definition are critical factors when precision positioning represents a key issue for the final system performance. This article discusses the error budget methodology as an advantageous technique to improve the measurement accuracy of a 2D-long range stage during its design phase. The nanopositioning platform NanoPla is here presented. Its specifications, e.g., XY-travel range of 50 mm × 50 mm and sub-micrometric accuracy; and some novel designed solutions, e.g., a three-layer and two-stage architecture are described. Once defined the prototype, an error analysis is performed to propose improvement design features. Then, the metrology loop of the system is mathematically modelled to define the propagation of the different sources. Several simplifications and design hypothesis are justified and validated, including the assumption of rigid body behavior, which is demonstrated after a finite element analysis verification. The different error sources and their estimated contributions are enumerated in order to conclude with the final error values obtained from the error budget. The measurement deviations obtained demonstrate the important influence of the working environmental conditions, the flatness error of the plane mirror reflectors and the accurate manufacture and assembly of the components forming the metrological loop. Thus, a temperature control of ±0.1 °C results in an acceptable maximum positioning error for the developed NanoPla stage, i.e., 41 nm, 36 nm and 48 nm in X-, Y- and Z-axis, respectively.

Experimental Approach for the Uncertainty Assessment of 3D Complex Geometry Dimensional Measurements Using Computed Tomography at the mm and Sub-mm Scales

The dimensional verification of miniaturized components with 3D complex geometries is particularly challenging. Computed Tomography (CT) can represent a suitable alternative solution to micro metrology tools based on optical and tactile techniques. However, the establishment of CT systems’ traceability when measuring 3D complex geometries is still an open issue. In this work, an alternative method for the measurement uncertainty assessment of 3D complex geometries by using CT is presented. The method is based on the micro-CT system Maximum Permissible Error (MPE) estimation, determined experimentally by using several calibrated reference artefacts. The main advantage of the presented method is that a previous calibration of the component by a more accurate Coordinate Measuring System (CMS) is not needed. In fact, such CMS would still hold all the typical limitations of optical and tactile techniques, particularly when measuring miniaturized components with complex 3D geometries and their inability to measure inner parts. To validate the presented method, the most accepted standard currently available for CT sensors, the Verein Deutscher Ingenieure/Verband Deutscher Elektrotechniker (VDI/VDE) guideline 2630-2.1 is applied. Considering the high number of influence factors in CT and their impact on the measuring result, two different techniques for surface extraction are also considered to obtain a realistic determination of the influence of data processing on uncertainty. The uncertainty assessment of a workpiece used for micro mechanical material testing is firstly used to confirm the method, due to its feasible calibration by an optical CMS. Secondly, the measurement of a miniaturized dental file with 3D complex geometry is carried out. The estimated uncertainties are eventually compared with the component’s calibration and the micro manufacturing tolerances to demonstrate the suitability of the presented CT calibration procedure. The 2U/T ratios resulting from the validation workpiece are, respectively, 0.27 (VDI) and 0.35 (MPE), by assuring tolerances in the range of ± 20–30 µm. For the dental file, the EN < 1 value analysis is favorable in the majority of the cases (70.4%) and 2U/T is equal to 0.31 for sub-mm measurands (L < 1 mm and tolerance intervals of ± 40–80 µm).

Self-Calibrated In-Process Photogrammetry for Large Raw Part Measurement and Alignment before Machining

Photogrammetry methods are being used more and more as a 3D technique for large scale metrology applications in industry. Optical targets are placed on an object and images are taken around it, where measuring traceability is provided by precise off-process pre-calibrated digital cameras and scale bars. According to the 2D target image coordinates, target 3D coordinates and camera views are jointly computed. One of the applications of photogrammetry is the measurement of raw part surfaces prior to its machining. For this application, post-process bundle adjustment has usually been adopted for computing the 3D scene. With that approach, a high computation time is observed, leading in practice to time consuming and user dependent iterative review and re-processing procedures until an adequate set of images is taken, limiting its potential for fast, easy-to-use, and precise measurements. In this paper, a new efficient procedure is presented for solving the bundle adjustment problem in portable photogrammetry. In-process bundle computing capability is demonstrated on a consumer grade desktop PC, enabling quasi real time 2D image and 3D scene computing. Additionally, a method for the self-calibration of camera and lens distortion has been integrated into the in-process approach due to its potential for highest precision when using low cost non-specialized digital cameras. Measurement traceability is set only by scale bars available in the measuring scene, avoiding the uncertainty contribution of off-process camera calibration procedures or the use of special purpose calibration artifacts. The developed self-calibrated in-process photogrammetry has been evaluated both in a pilot case scenario and in industrial scenarios for raw part measurement, showing a total in-process computing time typically below 1 s per image up to a maximum of 2 s during the last stages of the computed industrial scenes, along with a relative precision of 1/10,000 (e.g., 0.1 mm error in 1 m) with an error RMS below 0.2 pixels at image plane, ranging at the same performance reported for portable photogrammetry with precise off-process pre-calibrated cameras.

Procedure for geometrical errors identification in machine tool

This article presents a procedure to determine any of the 21 geometrical errors of a three axes machine tool (MT) taking into account the machine architecture. This verification technique is based on the utilisation of a 1D ball artefact and a self-centring probe, though it could be easily generalised to be used with a laser tracker. Most of the times, users are not interested in evaluating all the errors of their MTs but a subset. In this way, this procedure allows to any potential user the evaluation of any single error by providing a systematic method to obtain the needed equations and the experimental points to measure, as opposed to volumetric error compensation techniques where the work area is globally evaluated and the focus is shifted from the determination of each MT geometrical error to the reduction of the total error in every point. In that case, relevant information related with the physical values of each error is not preserved.

3D Measurement Simulation and Relative Pointing Error Verification of the Telescope Mount Assembly Subsystem for the Large Synoptic Survey Telescope

An engineering validation of a large optical telescope consists of executing major performing tests at the subsystem level to verify the overall engineering performance of the observatory. Thus, the relative pointing error verification of the telescope mount assembly subsystem is of special interest to guarantee the absolute pointing performance of the large synoptic survey telescope. This paper presents a new verification method for the relative pointing error assessment of the telescope mount assembly, based on laser tracker technology and several fiducial points fixed to the floor. Monte-carlo based simulation results show that the presented methodology is fit for purpose even if floor movement occurs due to temperature variation during measurement acquisition process.

Analysis of Surface Extraction Methods Based on Gradient Operators for Computed Tomography in Metrology Applications

Among the multiple factors influencing the accuracy of Computed Tomography measurements, the surface extraction process is a significant contributor. The location of the surface for metrological applications is generally based on the definition of a gray value as a characteristic of similarity to define the regions of interest. A different approach is to perform the detection or location of the surface based on the discontinuity or gradient. In this paper, an adapted 3D Deriche algorithm based on gradient information is presented and compared with a previously developed adapted Canny algorithm for different surface types. Both algorithms have been applied to nine calibrated workpieces with different geometries and materials. Both the systematic error and measurement uncertainty have been determined. The results show a significant reduction of the deviations obtained with the Deriche-based algorithm in the dimensions defined by flat surfaces.

Use of Lean techniques in health care in Spain to improve involvement and satisfaction of workers

The purpose of this study was to improve the organization of work, reduce physical effort, and obtain greater satisfaction of workers in the Pre-analytical Area of the Clinical Biochemistry Service at the Miguel Servet University Hospital of Zaragoza, in Spain, by applying Lean techniques. Such techniques were applied in two steps to obtain a final situation where the reduction of the space occupied, the required physical effort, and the work time is clear. The satisfaction of the workers was analyzed during the whole process by means of surveys, concluding that the sum of all the improvements managed to increase the satisfaction of the professionals. One key aspect to get these results was to use always the information and opinions of the staff making them feel the protagonists of the process. For that, it was essential the role of the agent of change that fundamentally sought the involvement of professionals in the improvement processes. Another key point was the careful application of Lean techniques always little by little, by applying small changes that became habits and achieved permanent results. In conclusion, in this work, a methodology to improve involvement and satisfaction of workers in health care has been presented and validated.

Geometrical Characterisation of a 2D Laser System and Calibration of a Cross-Grid Encoder by Means of a Self-Calibration Methodology

This article presents a self-calibration procedure and the experimental results for the geometrical characterisation of a 2D laser system operating along a large working range (50 mm × 50 mm) with submicrometre uncertainty. Its purpose is to correct the geometric errors of the 2D laser system setup generated when positioning the two laser heads and the plane mirrors used as reflectors. The non-calibrated artefact used in this procedure is a commercial grid encoder that is also a measuring instrument. Therefore, the self-calibration procedure also allows the determination of the geometrical errors of the grid encoder, including its squareness error. The precision of the proposed algorithm is tested using virtual data. Actual measurements are subsequently registered, and the algorithm is applied. Once the laser system is characterised, the error of the grid encoder is calculated along the working range, resulting in an expanded submicrometre calibration uncertainty (k = 2) for the X and Y axes. The results of the grid encoder calibration are comparable to the errors provided by the calibration certificate for its main central axes. It is, therefore, possible to confirm the suitability of the self-calibration methodology proposed in this article.