Online Metrology Intelligent control for a modern manufacturing - - PowerPoint PPT Presentation

Online Metrology –

Intelligent control for a modern manufacturing process

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As a Solution partner, our strength is our deep understanding of manufacturing processes and increasing productivity by different précised means.

Amit K. Choudhary Business Manager India Measurement & Automation Products Division

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Current Market Status

 Majority of auto OEMs are retooling the lines to meet BSIV to BSVI transition  Tolerances are getting tighter  Volumes are increasing drastically  Industries are striving towards Industry 4.0  Every one wants to eliminate human error and automate processes.

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Buying more equipment (machines, robots, etc.), employing more people Buying smart & intelligent machines? What do we mean by these smart machines? How are they different than what we have on our shop floor today? Are they any different?? …Are we looking at Industry 4.0 as hope OR

• pportunity?

Is it just the case of …

Industry current requirement's & key objective’s

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S.No Production Quality

1 In process Setting of Tool wear drifts To eliminate bottle neck at CMM Lab. 2 Zero rejection To supply inspection data asap to help production give correction 3 In process setting of Position drifts w.r.t drawing datums To check parts as per quality drawing inclusive of dimensional and GD&T parameters like circularity, flatness etc. 4 Having inspection data at Point of manufacturing To record data for future traceability 5 Operation wise data to avoid taking any action correction before going for next OP 6 Lesser dependency on end of line inspection just for segregating parts for OK and Not OK 7 Achieve better Cp & Cpk values always.

Current Manufacturing Process

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What do you think, Will adding Robots and automating the material handling will solve the issue ?

However there is a difference in automating machine tending and automating the complete process

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Hurdles that can occur in an automated transfer line

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Elements affecting majorly in any automated line

Temperature fluctuations on shop floor over the day and months

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Other factors that causes process variations are

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Tool wear Machine thermal dynamics Environment Material

Robots and automation alone cannot meet the required yield Even though we believe we are becoming more efficient, we are in-fact decreasing efficiencies

Process control is THE ONLY way to achieve greater efficiency

What is the Renishaw Equator™ Gauge?

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Consider inspection on the shop-floor

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What is the Renishaw Equator™ Gauge?

• Equator is a comparative gauge
• Not an absolute metrology device like a CMM.
• A comparator for medium to high volume

gauging

• Robust – proven on the shop-floor and

thermally ‘insensitive’

• Versatile - Able to switch between multiple

parts (Not Tailor made like multi gauge)

• In Process Tool Wear compensator
• In Process Position (w.r.t. different datums)

compensator

• Form measurement at Shop Floor (GD&T)

The role of Renishaw Equator™ Systems on the shop-floor

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As a standalone Gauging System

 Allows manual or automatic in-process corrections at point of manufacture  Targets key manufacturing operations  Reduces the need for end of line sample inspection for QA

As part of an Automated Cell

 Delivers all the benefits of a standalone Equator  Connection to robots and controllers eliminates human error and boosts throughput  Parts can be sorted and palletised  Full lights-out manufacturing is achievable

Traditional manufacturing Environment

High labour cost Skilled operators Remote QC area Queuing Low productivity High quality costs

Major Challenges to incorporate automated process control

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Current Manufacturing Process

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How Equator can play a vital role

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How Equator can make a difference?

• Can Inspect part just after manufacturing (100 plus Equator running in Indian shop

floor, also more than 4000 Equators running globally)

• Get RESULTS AT POINT OF MANUFACTURING – Multiple form of results can be

displayed 1. Results wrt to quality drawing similar to what you get from high end scanning CMM 2. Results wrt to production / process setting drawing. (For eg. Production supervisor will not be much interested to learn what the parallelism is between to opposite planes, rather he will be interested to know the Angle between planes to take corrective action) 3. Tool Wear data (eg CNC No 045 – Tool No – 5 – Wear 30 microns, height 10 microns) 4. Position control data (eg CNC No 045 – Line no 65 – G54 needs a correction of 68 microns in X and 48 microns in Y) 5. Live update of the process flow.

Ultimately what we want is to manufacture all OK parts as close to nominals and have better Cp & Cpk

Smart Factory Process flow

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• 1. Inspect every 3th or 5th part coming out from

Line.

• 2. Only inspect CTQ parameters – Cover only

tight tol features TOOL wise. Eg. If 9 tools required for manufacturing crank case than measure only 9 features having tight tolerance.

• 3. Update Tool Wear from the results
• 4. Update Positions wrt datums and distances

from the results.

In Line Process Control

Inspect all parameters on CMM once a week/fortnight .(customer can decide frequency)

Post Process Verification / Certification

Future factory – our view

Intelligent manufacturing Direct process control High productivity Lower quality costs Highly automated Low labour costs

IPC –Intelligent Process Control Software

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Cockpit

Process setting Process Foundation

Challenges in crank case manufacturing

• Bore size
• Coordinates
• Milling Height/Depth
• R face

OP10 OP10 OP20 OP20 OP30 Washing M/c

Post process Monitoring In process Control Machine health checkup (Pitch error) Tool setting Thermal Growth in Z Axis 100% inspection on Shop floor Frequency based inspection of all parameter

Conventional method CMM, Multi Gauge, Height Gauge, Air Gauge, Zoller Tool setter COMPONENT Details

PROCESS CONTROL SOLUTION FOR CRANK CASE

Quality Gate with “OK” Marking

Cockpit

LH Crankcase Line RH Crankcase Line Quality Gate with “OK” Marking

Cockpit

Challenges in crank case manufacturing

• Bore size
• Coordinates
• Milling Height/Depth
• R face

OP10 OP20 OP30

Washing M/c

Conventional method CMM, Multi Gauge, Height Gauge, Air Gauge, Zoller Tool setter

COMPONENT Details

PROCESS CONTROL SOLUTION FOR CRANK CASE

Cockpit

LH Crankcase Line RH Crankcase Line

Quality Gate with “OK” Marking

Alternate solution used in the industry

Gauging for LH Gauging for RH

Comparison against Equator

• Two gauging system required
• Investment up 40L
• Every year calibration & AMC
• No provision to add feature
• No GD&T feature inspection
• Not feasible to check coordinates

(Dependency on CMM)

• Suitable only for dedicated

component

OP10 Mazak VTL OP20 Mazak VMC OP 30/40 Mazak J500 Vari axis OP20 Mazak VMC OP20 Mazak VMC OP20 Mazak VMC

Intelligent Process Control Intelligent Process Control

OP20 Doosan VMC OP20 Doosan VMC OP10 Doosan VMC OP10 Doosan VMC

SPC Display screen 2 SPC Display screen 1

Renishaw Process control solution : Equator 500 with IPC

Line 1 Line 2

Process Control solutions for 5C

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The Solution Process for Transmission shaft

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Cut a part Measure the part Calculate the tool offset Automatically feed back 100% of tool offset

First part

The Solution Process

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Continuously cut parts Measure the parts Calculate average tool offset of X parts Automatically feed back ~70-100% of tool offset

All other parts

Tool Offset Window in Equator

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Example IPC – One to One

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Ethernet cable

Automated close loop feedback for Tool Offset

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Tool Offset Window in Equator confirming the offset value, Tool No and Machine. Tool Offset Window in Machine Tool Controller confirming the offset value, Tool No and Machine.

Close loop feedback for Tool Offset ensuring consistently controlled process

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Industry current requirement's & key objective’s

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S.No Production Quality

1 In process Setting of Tool wear drifts To eliminate bottle neck at CMM Lab. 2 Zero rejection To supply inspection data asap to help production give correction 3 In process setting of Position drifts w.r.t drawing datums To check parts as per quality drawing inclusive of dimensional and GD&T parameters like circularity, flatness etc. 4 Having inspection data at Point of manufacturing To record data for future traceability 5 Operation wise data to avoid taking any action correction before going for next OP 6 Lesser dependency on end of line inspection just for segregating parts for OK and Not OK 7 Achieve better Cp & Cpk values always.

How Renishaw will help meeting the objectives

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S.No Production Renishaw Remarks

1 In process Setting of Tool wear drifts Can get exact data for Tool wear, can be compensated either manual or automatically using IPC software 2 Zero rejection In collaboration with EQ and MT Probe which will take part work offset precisely, we can achieve Zero rejection 3 In process setting of Position drifts w.r.t drawing datums Possible with EQ 4 Having inspection data at Point of manufacturing Yes 5 Operation wise data to avoid taking any action correction before going for next OP Possible, Single EQ can be utilized in a cell of all 8 machines. 6 Lesser dependency on end of line inspection just for segregating parts for OK and Not OK Not required at all, as we will be having report of full parameters as well 7 Achieve better Cp & Cpk values always. Yes

How Renishaw will help meeting the objectives

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S.No Quality Renishaw Remarks

1 To eliminate bottle neck at CMM Lab. Yes as the measurement cycle time is way faster than CMM and not required control temp of 20 degrees, it can take all load of CMM 2 To supply inspection data asap to help production give correction Yes – Instant data at Point of manufacturing available 3 To check parts as per quality drawing inclusive of dimensional and GD&T parameters like circularity, flatness etc. Possible, It has same CMM software and can output results at par with any CMM 4 To record data for future traceability Possible 5 To have a secondary support (Shop floor CMM) at par to help sharing load at Lab CMM Equator plays dual role of In process setting at the shop floor also measures part unlike CMM thus catering requirements from both departments.

Thank you

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