Monday, February 23, 2015

Renishaw Renscan 5 Axis System on Wenzel LH87 - Inside Look From Early Adopter Turbocam

Renscan5 allows Turbocam to do continuous, 
automated measurement of complex turbo machinery 
components, collecting 1000s of points to verify from.
TURBO CAM "high fives" revolutionary inspection technology 

Leader in five-axis turbo machinery production quickly adopts new five-axis Renishaw inspection system, gains faster throughput, greater CMM utilization, and easier programming. 

Constantly changing surface geometries, pin-wheeling shapes and tight, intricate features make turbomachinery components — impellers, blades and blisks — some of industry's most complex and exacting shapes. TURBOCAM International achieved leadership in this specialized field by mastery of five-axis machining and five-axis programming software. However, efficient inspection of ever increasing numbers of complex parts was frustrated by slow, tedious, stop-and-go measurement inspection on a legacy 3+2 axis coordinate measuring machine (CMM). 


"Renscan5 transformed part measurement and inspection from a bottleneck to an enabler for TURBOCAM" says,
 Dave Romaine, Quality Assurance Manager 
Changing 3-D part geometries required many different probe orientations, plus frequent stylus and tip changes for difficult to reach features, explains Dave Romaine, Quality Assurance Manager. "We would have to stop the CMM and calibrate each re-orientation of the probe. That was compounded as we inspected multiple blades around a part."

As five-axis experts TURBOCAM staff, we're quick to see the potential of a revolutionary scanning system from Renishaw that makes possible automated, programmable five-axis measurement at speeds and accuracies never before possible by CMMs. The Renscan5™ scanning system offered the capability for continuous five-axis interpolated motion, comparable to TURBOCAM's five-axis machine tools. 

In January 2007 TURBOCAM became one of the first adopters of the new Renscan5 continuous five-axis inspection capability. Installed on a new Wenzel LH8.10.7 bridge-type CMM at the company's Dover, New Hampshire, USA plant, Renscan5™ transformed part measurement and inspection from a bottleneck to an enabler. 

5 Axis Gives Higher Throughput Production & Reduced Staff

 

High-speed continuous probing routines are reducing programming time, set-up time and measurement time by 50 percent and more. Besides faster throughput, Renscan5 time-savings allows the taking of many more data points for greater measurement precision and frees up CMM time for qualification of turned blanks and in-process checks before final machining passes. 

Those powerful advantages led TURBOCAM in early 2008 to become the first company worldwide to add a second Renscan5 CMM, a larger Wenzel LH10.12.8, this time at a new facility in nearby Barrington. In this new facility, Renscan5 is an "essential resource" says Romaine, that is being developed to support higher-throughput production generated by around-the-clock, reduced-staff manufacturing.  

Wenzel America did the installation of Renscan5 on both the new CMMs. 

TURBOCAM is a preferred supplier of both production and prototype bladed parts to aerospace, automotive and industrial turbomachinery OEMs. CMM inspection assures that critical parts for turbochargers, jet engines, compressors and gas turbines meet demanding accuracy specifications. Part precision and uniformity are critical in providing dynamic balance, directed airflow and long, reliable service at high rotational speeds.  

Renscan5 uses two patented hardware breakthroughs to speed part checking, generate more data points for analyzing part form, and increase available CMM run time: 


"Active" probe head provides infinite positioning capability


Named REVO™, a powered head provides infinite positioning capability between simultaneous coordinated motion in vertical and horizontal rotary axes. This allows the low-mass two-axis head, a 3-D measuring device in its own right, to perform most of the motion during inspection routines. Infinite positioning allows continuous motion, optimizes part access, and delivers high accuracy part measurements. The active head avoids dynamic errors caused in rapid acceleration/deceleration of the larger mass of a CMM structure. Low-mass, low-inertia design allows Renscan5 to measure at up to 500 mm/sec vs. conventional CMM scanning that is typically limited to 5-15 mm/sec to avoid dynamic errors. 

REVO repositions continuously on the fly, simultaneous with measurement, unlike indexing heads which first must be locked into position, after which the CMM provides the measuring motion. On complex parts, says Romaine, "Hundreds of calibrations have now been eliminated, saving us hours of calibration time." 

Renscan5 allows the CMM's three-axis platform to be used primarily to "rapid" the REVO head into position for measurement. Where CMM motion is required for a measurement routine, it can usually be limited to a single linear axis and performed at constant velocity, minimizing dynamic effects on accuracy from acc/dec and inertia. 
Unique laser correction allows Renscan5 to 
measure parts at ultra-high-speeds and acc/dec 


Laser-corrected probing on the Revo


REVO employs industry's first laser-corrected "Tip Sense" probing. A laser mounted within the head sends its beam down a hollow stylus to a reflector at the tip. The return beam is received by a position sensor and any deflection is used to calculate true tip position. This allows REVO to perform a complete part inspection routine in a continuous operation without recalibration or stylus changes. "Only one probe is typically used to measure an entire part with no tip change time," says Romaine. Tip Sense probes deliver 1 micron accuracy at 250 mm from the axis of rotation. Sizes are available providing probe reach to 500 mm. 

While the previous 3+2 axis CMM at TURBOCAM provided a two-axis head, vertical changes in probe angle could only be made in 2.5 degree increments, then calibrated and fixed at the position for measuring. "As we inspected more blades around a part, such as a blisk, it would obviously require more and more probe orientations and calibration. Programming, access, stylus change, and calibration were incredibly painful," notes Romaine. 

TURBOCAM uses Renscan5 for both point-to-point probing to verify feature location and size and for contact scanning of part surfaces for shape and form data. "On point to point we are able to gather more data simply because the head can orient to any angle and it's a very simple set-up to get more points," says Romaine.



Nick Dean, TURBOCAM Product Engineer/CNC Programmer, 
uses teach points to create a five-axis program for inspection 
of a shrouded impeller 
Renscan5 high-speed scanning greatly increases data points. "Previously we might collect 50 or 100 points spaced over a blade," he says. "Now we can collect hundreds or thousands of points with a scan." In scanning mode, the probe moves continuously, adjusting to programmed changes in part geometry. REVO gives TURBOCAM up to 4000 points/sec in scanning mode.

"Increased point data allows us to see a more complete picture of what we're manufacturing," says Romaine. "We can see deviations better as they increase and decrease along a blade or around a part. This lets us better trouble-shoot our manufacturing process." As an example, he notes that TURBOCAM has been able to detect tooling breakdowns based on Renscan5 surfacing data.

Helping to reduce measurement time for higher utilization, the Renscan5 system includes a UCC2 universal CMM controller with patented MoveScan™ software that synchronizes, smoothes and speeds motion between the CMM and the REVO head. MoveScan drives the probe to the surface of the part in the shortest distance by looking ahead to go-to points and blending moves into smooth, continuous motion.

Parts inspected on the CMMs range from small impellers just 2" in diameter to 36" diameter, multi-vane components. TURBOCAM produces more than 400 different bladed part designs a year for compressor, turbine and pump OEMs.   

Reduced programming time for 5 axis inspection

 

"Just as important as the inspection advantages," stresses Romaine, “are the programming benefits. This has been exciting. We've been able to apply our five-axis machine tool programming methods to drastically reduce programming time for five-axis inspection. This is only possible because of the infinite indexing of REVO and its programmability through the I++ DME protocol." 

Renscan5's I++ interface gives the UCC2 controller cross-platform compatibility with measurement software packages and maintains user choice of CMM and software. On complex parts such as blisks (integral hub and blades machined from a monolithic blank), notes Romaine, "What used to take three days to program now takes three hours. The biggest time savings have come in programming and set-up, even more than run time." 

The ability to apply five-axis programming expertise makes it much easier and faster to provide programs for part inspection, increasing machine utilization for a wide range of parts, he says. While Renscan5 integration is still evolving, he estimates the CMM utilization has already increased between 30 and 50 percent.

By automating and simplifying inspection, Renscan5 has changed not only utilization, but also uses and users of CMM inspection, according to Romaine. 

First, it greatly reduces need for operator intervention in changing probe orientation. "This has been a big benefit and is definitely one of the selling points of the machine," he says. Second, the simplicity of Renscan5 in conjunction with the CMM software makes it possible for machinists and operators to directly measure in-process parts without the need for an inspector to run the CMM. "They simply need to put the part on the table and call up the appropriate program," he says. "We do inspections of turned blanks and perform in-process check before final machining passes," he notes. 


About Turbocam

 

TURBOCAM has manufacturing operations in the U.S., England and India and is certified to ISO 9001:2000 and other quality standards in those operations. It brings comprehensive partnering resources to prototype and development work, offering world-class capabilities in five-axis machining, metallurgy, aerodynamics, geometric modeling and analysis, and software — and now five-axis part quality inspection and documentation.  


The Barrington TURBOCAM plant was created for round-the-clock unmanned manufacturing of large numbers of bladed parts for a variety of applications such as air compressors, gas expanders, air cycle machines, jet engines, turbine driven power sources, and even artificial hearts. TURBOCAM Automated Production Systems (TAPS) specializes in meeting market demand for impellers and blisks machined from wrought aluminum, stainless steel and titanium alloys, enabling higher performance and reliability than cast components. TURBOCAM offers production capacity for 250,000 to 300,000 impellers a year (which includes high volume manufacturing of turbocharger impellers for the automotive industry in the TAPS division). 
About Renishaw

To find out more about Renishaw’s range of CMM products, including its CMM retrofit service, visit www.renishaw.com/cmm. 

Sources: 

Renishaw.com

Article Originally appeared in Renishaw Case Study: 
Turbo Cam "high fives" revolutionary inspection technology




Creating an Ideal Standard CMM Starts with the Ideal Customer Experience - The Villa Marburg

Precision Metrology & Ideal Customer Experience - It’s All in the Details

The Villa Marburg, Heigenbrücken, Germany
The Villa Marburg, Heigenbrücken, Germany


The Villa Marburg is a 5 Star hotel located in the small picturesque town of Heigenbrücken, Germany. Built in 1884 as an Inn for the local lumber industry, it is less than 5 km from the Wenzel factory.

The Wenzel family decided to purchase the hotel in 2002 to provide lodging and hospitality for customers, employees and other guests visiting the Wenzel Group’s world headquarters.







Located  45 minutes outside of Frankfurt, the Villa-Marburg has lodging for 80, boasts 3 restaurants, and a conference center which is used not only by the Wenzel Group, but also local companies and civic groups.

The luxury hotel also boasts the only golf simulator in the area, allowing guests a unique way to relax after a long day.

Creating the industry’s ideal CMM means the ideal customer experience too.

At first glance it may seem odd that a precision manufacturing company would own a hotel, but when you take the Wenzel family’s dedication to creating the ideal standard in an otherwise commoditized industry it makes complete sense. 

Operating the Villa-Marburg means the same attention to detail and care that goes into building Wenzel machines, goes into creating the total customer experience.

When a customer visits for training, demonstrations, or machine run-offs, we are assured the entire experience is absolutely ideal. The normal inconveniences of travel do not interfere with their work or create a less than ideal experience when they visit Wenzel’s World Headquarters.

“I know when a customer visits the factory, they will be taken care of,” says Drew Shemenski, Regional Sales Manager for Wenzel America.

Traveling is not always easy and can be quite tiresome, especially internationally. So it’s nice to know that we have colleagues creating an ideal environment to make their trip easy and help them in any way. It allows the guests to relax so they can focus on the job they came to do.”

For more information on the Villa-Marburg visit:
or visit them on Facebook here:

Metrology, The Big Game, Gemba and Armchair Coaching vs. Being There

Wenzel’s 20th Annual Sales Conference  
By Drew Shemenski

While most of you were probably making last minute runs for Game Day refreshments, the Wenzel America team was arriving to Wenzel’s company-owned, 5-star hotel, called the Villa Marburg in Heigenbrucken, Germany.

Every year Wenzel Group’s global sales teams converge on this tiny Bavarian hamlet about 35 miles east of Frankfurt in central Germany for an annual International Sales Conference. It’s our yearly forum for staff and dealers to learn about new technology and strategies and get to know our far-flung colleagues from across the globe.

When we arrived at Villa Marburg on Sunday there was a picturesque snowfall blanketing the surrounding hills and valleys near the Wenzel factory. The first day was pretty informal as we reacquainted ourselves with our colleagues from Wenzel’s global network and adjusted to the time change.

It began with an address from our Co-CEO, Mr. Frank Wenzel who has jointly led our company with Dipl.-Kff Dr. Heike Wenzel since 2006.  His talk began with an overview of the past year’s activities, discussion of the results, and a look ahead at what is to come.

As a global metrology company our future is very much tied to manufacturers worldwide. On that note, Mr. Wenzel summarized what 2014 looked like in that sector and the indicators of what look like continued fast growth in 2015 especially in North America and China.

It was apparent from the CEO’s closing remarks that this second-generation leadership maintains the strong vision toward long-term growth and stability set forth by Werner Wenzel in 1968.

Great Football, Great Content and Gracious Hosts

This year the 20th annual event happened to take place on Big Game weekend.

Winning the Precision Metrology Game
RT @DavidWallace: PHOTO 
http://t.co/ygHeVP3N0r
Luckily our German hosts understood the American obsession with our version of “football” and graciously threw our delegation a small “Big Game” viewing party after the first day overview ended.  So we did not miss the two most exciting (and second guessed) minutes of football in recent memory.

The remaining days of the meeting were a balanced mix of presentations and hands-on demonstrations designed to educate the sales teams in the latest products, their place in the market, and the benefit for an end customer. There was a lot of great content. * (Get an inside look at a few pieces at the end of the article.)

Winning teams aren’t coached from a couch - Gemba & “Being There”

So, why am I focusing this blog post on our annual sales meeting? What does it have to do with you?

And, what is the point of investing the time in travel and being away from our offices, customers, and families?

After all, it’s 2015 and we’ve got so much technology to be connected…

Why not just hold a series of webinars? What’s the point?

Simply put, you can’t replace the experience of Gemba - BEING THERE.


It’s no different than the Big Game. Whether we were watching from our couches or from the stands - we’re just spectators.

We may have seen every play of the game and think we knew everything that was going on…and I’m sure we all have an opinion about that last play…. but even if we were in the stands, unless we were down on the field with the players, coaches and the whole team, any play call we made would have likely been worse.

Business is no different.

We can learn about our products, our strategies and plans remotely. We can write emails to our colleagues to tell of mutual successes and ask for regional news by phone, but none of those actions can replace being there - Gemba.

In fact, I think it’s safe to say that those remote communication tools are as effective as they are, because we have met in person.

That personal interaction is what makes the other tools we all have work as well as they do. Without some shared background and a personal interest, the chain of emails can easily become noise, the phone calls going to voicemail.

What has this got to do with you - our customers and your needs?

I think the same rules apply for the relationships between customers and vendors. We can email you the latest product catalog. You can read about our technology and testimonials in this very newsletter.

But none of that can replace being there.

Walking your manufacturing floor.

Talking to the people who do the work.

Seeing how you make your parts.

This is where the ideas come from.

This is where solutions are created.

Where partnerships are made.

Where visions are shared.

Without gemba, without being there, the product catalogs go in the trash.

The calls end up going to voicemail.

The game ends.

Not with an amazing play by a rookie, whose life will be forever changed, but in frustration and stagnation, and no chance of ever making it to the Big Game. 

That’s what this weekend was for us, connecting and being there. And helping our people and your people and our companies make it to the Big Game, in whatever industry we find ourselves.


*The inside scoop on some of our latest developments included:

  • Quartis R11 features new tools for managing multiple horizontal arm CMM systems. One seat of software can manage up to 8 arms.

  • Geartec is launching new software tools for inspecting camshafts and rotors on the WGT Gear CMM series of machines. This will allow for easy inspection of these specialized parts with minimal programming time.

  • Pointmaster 5.4 can now perform a full simulation of your inspection run with the Shapetracer 3D laser scanner, before you run the scan. This will verify all angles and positions used during the scan, even on highly sculpted parts.


ISO 10360 - What’s so special about this CMM certification?

What is ISO 10360? And why is it so important? 
coordinate measuring machine
Essentially, this is the international standard of measurement verification that specifies the acceptance tests for verifying the performance of a coordinate measuring machine (CMM) used for measuring linear dimensions as stated by the manufacturer.


It also specifies the re-verification tests that enable the user to periodically re-verify the performance of the CMM.  These tests are vital in ensuring your CMM is and stays precise and accurate.

Even though this has been the accepted standard since 1994 internationally, not all coordinate measuring machine manufacturers abide by this certification.  There are other standards we mention below that are sometimes used. They are not only less rigorous than the ISO 10360 standards, but they make it impossible to compare one CMM to the next because it is not the standard.


coordinate measuring machine
Wenzel America is an accredited 17025 calibration provider, which means we provide 10360 calibrations on all CMMs we sell.  As a verified certifier, we can, and do perform these tests for our customers and ourselves.
Is there more than one ISO 10360 test?
Since 1994, ISO 10360-2 specifies three uncertainties: volumetric length measuring uncertainty (MPEE); volumetric probing uncertainty (MPEP); and volumetric scanning error (MPETHP). (MPE is the acronym for Maximum Permissible Error.)  Each of these is tested against the standard.

coordinate measuring machineA set of five calibrated gage blocks is used to verify a coordinate measuring machine’s MPEE. Measurements are taken in seven different locations (position and direction) within the CMM’s measuring volume for the test. For each of the seven locations, the length of each of the five gage blocks is measured three times for a total of 105 measurements. All 105 measurements must be within the stated tolerance specified by the manufacturer.

What does this mean for you?

By using a 10360 calibration for your company, it allows you to compare CMM performance between all the machines at your company, as well as, new machines you may desire to purchase. This world standard is more demanding than VDI/VDE 2617, ASME B89.




The table below shows all the various components of the ISO 10360 standards:
ISO 10360-1:2000
Geometrical Product Specifications (GPS) -- Acceptance and re-verification tests for coordinate measuring machines (CMM) -- Part 1: Vocabulary
ISO 10360-1:2000/Cor 1:2002
ISO 10360-2:2009
Part 2: CMMs used for measuring linear dimensions
ISO 10360-3:2000
Part 3: CMMs with the axis of a rotary table as the fourth axis
ISO 10360-4:2000
Part 4: CMMs used in scanning measuring mode
ISO 10360-4:2000/Cor 1:2002
ISO 10360-5:2010
Part 5: CMMs using single and multiple stylus contacting probing systems
ISO 10360-6:2001
Part 6: Estimation of errors in computing Gaussian associated features
ISO 10360-6:2001/Cor 1:2007
ISO 10360-7:2011
Part 7: CMMs equipped with imaging probing systems
ISO 10360-8:2013
Part 8: CMMs with optical distance sensors
ISO 10360-9:2013
Part 9: CMMs with multiple probing systems
ISO/DIS 10360-10.2
Part 10: Laser trackers for measuring point-to-point distances
ISO/DIS 10360-12
Part 12: Articulated arm coordinate measurement machines (CMM)
For more information about Wenzel America’s ISO 10360 certifications, services and products just click here: http://wenzelamerica.com/questions
Sources: