Interface is designed to connect Renishaw ML10 laser calibration system and EC10 environmental compensator unit to PCs via an industry standard USB connection.
Renishaw's new DX10 interface is designed to connect its market leading ML10 laser calibration system and EC10 environmental compensator unit to PCs via an industry standard USB connection. The DX10 is a reliable high speed communications device, transmitting data at 5kHz to Renishaw's Laser10 software and new QuickView motion analysis software. Suitable for both laptop and desktop PCs, the new DX10 interface avoids the need for PCMCIA or internal PCI interfaces, which are gradually being phased out of mainstream PCs in favour of USB connectivity.
For dual axis data capture from the ML10 laser interferometer, a user can simply use 2 DX10 interfaces which can be plugged into 2 separate USB ports or a separate hub.
Replacing Renishaw's existing PCM20 (PCMCIA) card as the standard system interface, the DX10 unit is compatible with Windows XP and service pack 1 and 2.
The new DX10 interface kit includes a 3m USB cable, DX10 driver and installation CD-ROM.
* Note - Renishaw's ML10 laser interferometer measurement system is used by some of the largest OEMs and end users in industries such as metal cutting, semiconductor processing, flat panel display production and biotechnology.
The ML10's unique properties ensure that the system provides a linear position reading resolution of just 1.24nm, a range of up to 40 m and accuracy better than 1 ppm.
This combination of resolution, accuracy and range makes the laser interferometer an ideal tool for characterising the performance of motion systems, both large and small.
Saturday, February 10, 2007
Measuring dynamic movements in machinery alignment
An off-line- to -running fixture combined with a shaft alignment system makes it possible to measure dynamic movements on machines from hot to cold or vice versa.
Dynamic changes in the rotating machinery from an Off Line toRunning condition, needs more attention. There is no such thingas 'identical' machines having identical dynamicmovements. One cannot ignore the possibility of horizontalmovement, assuming growth will be symmetrical and only accountingfor the thermal effects.
Shaft alignment has mostly been carriedout in off-line operating conditions.
However, machine conditionschange from the time they are off line to running under normaloperating conditions.
Some of these changes are due to processforces (fluid pressures, airflow, etc.).
The most notable ofthese changes is the change in the temperature of the machinebearings and supports.
Dynamic changes are difficult tocalculate.
Two 'identical' machines may showdrastically different alignment changes from Off Line to Running.Great care must be taken when calculating the changes in thealignment condition of machines.
Just because two machines appearidentical and serve the same function does not ensure they willexhibit the same operational characteristics.
Several methodshave been used to measure the changes in the shaft alignment oftwo or more machines.
Although widely used, 'hot aligningmachines', only measures changes in the shaft alignment duesolely to the changes in the machines' temperature.Discharge pressure, shaft torque, multiple machines operating inparallel, electrical loading of a generator, etc., can also playan important role in the change of the alignment condition fromOff Line to Running.
The changes will mostly be seen in theHorizontal Plane, but could also affect the Vertical Alignment.
Amachine that operates exposed to large changes in temperaturecould exhibit extreme changes in its shaft alignment as thetemperature changes.
Coupled machines need to be set to coldalignment targets that will reflect the actual changes in theshaft alignment.
This will lead to lower vibration levels,increased mean time between failures, decreased maintenancecosts, and increased production.
Fixturlaser's extensiveresearch into the problems of dynamic movement has resulted in arevolutionary new alignment method.
Fixturlaser L2R off-line- to-running fixture combined with a FixturlaserShaft alignmentsystem makes it possible to measure dynamic movements on machinesfrom hot to cold or vice versa.
Changes in machinery alignmentare mirrored by changes in the alignment of the L2R brackets.
Bymeasuring and documenting the initial position of the bracketsthe actual online changes in the alignment values can be measuredwhen the machine is online under normal operating conditions.Alignment costs are small compared to production loss, shouldcritical machinery fail.
Poor alignment is one of the leadingcontributors to premature rotating machinery failure, often as aresult of too little attention being paid to dynamic movements.Fixturlaser have, through extensive tests, showed that inaddition to cold alignments, the actual dynamic movements ofmachinery need to be considered when aligning.
Dynamic changes in the rotating machinery from an Off Line toRunning condition, needs more attention. There is no such thingas 'identical' machines having identical dynamicmovements. One cannot ignore the possibility of horizontalmovement, assuming growth will be symmetrical and only accountingfor the thermal effects.
Shaft alignment has mostly been carriedout in off-line operating conditions.
However, machine conditionschange from the time they are off line to running under normaloperating conditions.
Some of these changes are due to processforces (fluid pressures, airflow, etc.).
The most notable ofthese changes is the change in the temperature of the machinebearings and supports.
Dynamic changes are difficult tocalculate.
Two 'identical' machines may showdrastically different alignment changes from Off Line to Running.Great care must be taken when calculating the changes in thealignment condition of machines.
Just because two machines appearidentical and serve the same function does not ensure they willexhibit the same operational characteristics.
Several methodshave been used to measure the changes in the shaft alignment oftwo or more machines.
Although widely used, 'hot aligningmachines', only measures changes in the shaft alignment duesolely to the changes in the machines' temperature.Discharge pressure, shaft torque, multiple machines operating inparallel, electrical loading of a generator, etc., can also playan important role in the change of the alignment condition fromOff Line to Running.
The changes will mostly be seen in theHorizontal Plane, but could also affect the Vertical Alignment.
Amachine that operates exposed to large changes in temperaturecould exhibit extreme changes in its shaft alignment as thetemperature changes.
Coupled machines need to be set to coldalignment targets that will reflect the actual changes in theshaft alignment.
This will lead to lower vibration levels,increased mean time between failures, decreased maintenancecosts, and increased production.
Fixturlaser's extensiveresearch into the problems of dynamic movement has resulted in arevolutionary new alignment method.
Fixturlaser L2R off-line- to-running fixture combined with a FixturlaserShaft alignmentsystem makes it possible to measure dynamic movements on machinesfrom hot to cold or vice versa.
Changes in machinery alignmentare mirrored by changes in the alignment of the L2R brackets.
Bymeasuring and documenting the initial position of the bracketsthe actual online changes in the alignment values can be measuredwhen the machine is online under normal operating conditions.Alignment costs are small compared to production loss, shouldcritical machinery fail.
Poor alignment is one of the leadingcontributors to premature rotating machinery failure, often as aresult of too little attention being paid to dynamic movements.Fixturlaser have, through extensive tests, showed that inaddition to cold alignments, the actual dynamic movements ofmachinery need to be considered when aligning.
One man can operate accurate alignment system
Fixturlaser AB, Molndal has developed a new and highly accuratesystem for positioning and aligning machines and production lineinstallations. The new Fixturlaser Level is a laser based'one-man-level' system, which meets high mechanical andaccuracy levelling requirements. The one-man-level makes ahelping hand redundant, since the system consists of a selflevelling, scanning laser transmitter and a high resolutionreceiver.
The laser transmitter, T310, generates a laser planewhich is level or plumb to level.
The laser plane can also belocked to specific receiver values, the receiver then controlsthe transmitter by either IR or cable communication.
This featureis very helpful in unstable environments, e.g when performingmeasurements on-board ship and on high rising constructions, suchas harbour cranes.
The Level can be operated with one or morereceivers and can be fully integrated in the Fixturlaser systemutilising the display unit as a data collector.
All units arepowered by standard batteries or AC-adapter.
The receiver can bepowered by the Display Unit when connected.
The laser transmitter, T310, generates a laser planewhich is level or plumb to level.
The laser plane can also belocked to specific receiver values, the receiver then controlsthe transmitter by either IR or cable communication.
This featureis very helpful in unstable environments, e.g when performingmeasurements on-board ship and on high rising constructions, suchas harbour cranes.
The Level can be operated with one or morereceivers and can be fully integrated in the Fixturlaser systemutilising the display unit as a data collector.
All units arepowered by standard batteries or AC-adapter.
The receiver can bepowered by the Display Unit when connected.
Laser scanner unseats templates and save money
US-based Lear Corporation has realised savings of $240,000 injust one seat manufacturing programme by replacing atemplate-based inspection system with a laser scanning one. Using3D Scanners' ModelMaker software, Lear inspects automotiveseats during design and manufacturing. Before, Lear compared asample seat with a series of contoured plastics templates whichshoed the original styling guidelines.
Typically nine templateswere needed for each seat, and the seat had to line up within 6mmunder manual 'GO, NO-GO' inspection.
Total templatecost for a seat programme with 29 seat configurations was some$104,000.
An inspection stand could cost $22,000 and fivedifferent stands would be needed.
Two sets of stands - costing$220,000 - would be needed if a seat style were produced in twodifferent factories.
Lear chose the ModelMaker system, whicheliminated the templates and the stand cost is now $15,000instead of $22,000.
The system is based on a 3D laser sensor, aposition-sensing device on which the sensor is mounted, a PC andsoftware.
The software extracts displays and manipulates thesensor data.
Lear chose the FaroArm with seven degrees of freedomto reach any point in the seat.
In operation, the sensor ispositioned to show a laser light line across the seat, and ismoved across the area to be checked and the data is displayed onthe PC screen.
Laser scanning is much faster than making templatemeasurements, so Lear now scans a number of customer-approvedseats and averages the data to set manufacturing tolerances.Scanning provides real X, Y and Z co-ordinates.
If a seat area isout of tolerance, manufacturing personnel can see exactly howmuch it is in error.
The scanning system is more accurate thanthe template system (gaps between template surfaces and seatareas would have to have been measured manually) and readilywarns of any drift away from the 'mean'.
Also thescanning system is immediately adaptable to seat modifications.
Typically nine templateswere needed for each seat, and the seat had to line up within 6mmunder manual 'GO, NO-GO' inspection.
Total templatecost for a seat programme with 29 seat configurations was some$104,000.
An inspection stand could cost $22,000 and fivedifferent stands would be needed.
Two sets of stands - costing$220,000 - would be needed if a seat style were produced in twodifferent factories.
Lear chose the ModelMaker system, whicheliminated the templates and the stand cost is now $15,000instead of $22,000.
The system is based on a 3D laser sensor, aposition-sensing device on which the sensor is mounted, a PC andsoftware.
The software extracts displays and manipulates thesensor data.
Lear chose the FaroArm with seven degrees of freedomto reach any point in the seat.
In operation, the sensor ispositioned to show a laser light line across the seat, and ismoved across the area to be checked and the data is displayed onthe PC screen.
Laser scanning is much faster than making templatemeasurements, so Lear now scans a number of customer-approvedseats and averages the data to set manufacturing tolerances.Scanning provides real X, Y and Z co-ordinates.
If a seat area isout of tolerance, manufacturing personnel can see exactly howmuch it is in error.
The scanning system is more accurate thanthe template system (gaps between template surfaces and seatareas would have to have been measured manually) and readilywarns of any drift away from the 'mean'.
Also thescanning system is immediately adaptable to seat modifications.
Laser displacement sensor measures problem surface
Laser displacement sensor measures problem surfaces MatsushitaElectric Works has enhanced its range of measurement sensors byintroducing the new SUNX HL-C1 laser measurement system. Usingcharged coupled device (CCD) based technology, the sensor is ableto quickly and precisely inspect surfaces that have historicallyposed problems for analogue based non-contact measurementequipment. Black rubber and specular objects, including glass andwafers, can now be reliably and accurately measured using the newSUNX HL-C1 laser based measurement system.
Suitable applicationsfor the HL-C1 series include measurement of the eccentricity ofsteel shafts, co-planarity of IC pins, thickness measurement ofbrake discs and tyre tread measurement.
Containing an extremelycompact controller, the unit can accept the connection of up totwo measurement sensor heads.
This allows thickness measurementto be carried out easily using built in calculation functions.The sensor heads themselves are available in two styles: one formeasurement of diffuse type surfaces, including black rubber andmachined metal; and the other for specular objects such as glassand highly reflective surfaces.
Both styles offer two measurementranges and are capable of measuring to accuracies of 1micron.Configuration of the controller can be performed using either acompact touch screen console or PC based configuration softwarevia the built in RS232C communications port.
This port can alsobe used to transmit measurement data to a third party device, orthe internal decision-making capability can be utilised andinformation accessed via digital I/O connections.
Suitable applicationsfor the HL-C1 series include measurement of the eccentricity ofsteel shafts, co-planarity of IC pins, thickness measurement ofbrake discs and tyre tread measurement.
Containing an extremelycompact controller, the unit can accept the connection of up totwo measurement sensor heads.
This allows thickness measurementto be carried out easily using built in calculation functions.The sensor heads themselves are available in two styles: one formeasurement of diffuse type surfaces, including black rubber andmachined metal; and the other for specular objects such as glassand highly reflective surfaces.
Both styles offer two measurementranges and are capable of measuring to accuracies of 1micron.Configuration of the controller can be performed using either acompact touch screen console or PC based configuration softwarevia the built in RS232C communications port.
This port can alsobe used to transmit measurement data to a third party device, orthe internal decision-making capability can be utilised andinformation accessed via digital I/O connections.
Object dimensioning as easy as scanning barcodes!
Datalogic's VS8000 is a device for object volume measurement representing a valid alternative to traditional automatic measurement systems for materials handling applications.
With Datalogic's VS8000 Dimensioning systems are becomingmore and more popular among parcel carriers and postal servicesaround the world. Goods are becoming lighter, and containers andtrucks are more often full before becoming too heavy. Volume, notweight is increasingly becoming the limiting factor.
The same istrue for warehouses where capacity is given in volume andconveyor systems are more often limited by volume rather than byweight.
In this scenario, traditional weight-based tariff systemsare no longer appropriate and carriers and postal services areincreasingly adopting volume based price tariffs.
Whereverparcels in different sizes, shapes and weight are collected,transported, stored and distributed, cost-effectiveness dependson achieving the optimal utilisation of the available space forwarehousing and of equipment for transportation.
Accuratelyestablishing the size of the various packages is always thebiggest bottleneck in parcel handling.
Datalogic's solutionis the VS8000 - a device for object volume measurementrepresenting a valid alternative to traditional automaticmeasurement systems for materials handling applications.
Based onthe mechanical and optical architecture of Datalogic'sDS8100 laser scanner, the VS8000 scans at speeds of up to 2000scans per second and covers a standard measurement area of 800mmx 800mm, providing an extremely fast and reliable dimensions andvolume estimation of objects moving along the conveyor.
The veryhigh scan speed and real time processing features allow beltspeeds of up to 5 metres per second, enabling the gap betweenparcels to be reduced to only 50mm.
The VS8000 can be rapidlyintegrated in omni-directional reading stations, with nomodifications to existing structures.
Set-up is fast and easywith the intuitive Monitor Configuration Program.
With theVS8000, Datalogic offers an excellent alternative to existingdimensioning systems.
The VS8000 is more cost-effective andeasier to use and install than traditional measurement systemsand, above all, makes new process automation and optimisationcapabilities available to all materials handling operators.
With Datalogic's VS8000 Dimensioning systems are becomingmore and more popular among parcel carriers and postal servicesaround the world. Goods are becoming lighter, and containers andtrucks are more often full before becoming too heavy. Volume, notweight is increasingly becoming the limiting factor.
The same istrue for warehouses where capacity is given in volume andconveyor systems are more often limited by volume rather than byweight.
In this scenario, traditional weight-based tariff systemsare no longer appropriate and carriers and postal services areincreasingly adopting volume based price tariffs.
Whereverparcels in different sizes, shapes and weight are collected,transported, stored and distributed, cost-effectiveness dependson achieving the optimal utilisation of the available space forwarehousing and of equipment for transportation.
Accuratelyestablishing the size of the various packages is always thebiggest bottleneck in parcel handling.
Datalogic's solutionis the VS8000 - a device for object volume measurementrepresenting a valid alternative to traditional automaticmeasurement systems for materials handling applications.
Based onthe mechanical and optical architecture of Datalogic'sDS8100 laser scanner, the VS8000 scans at speeds of up to 2000scans per second and covers a standard measurement area of 800mmx 800mm, providing an extremely fast and reliable dimensions andvolume estimation of objects moving along the conveyor.
The veryhigh scan speed and real time processing features allow beltspeeds of up to 5 metres per second, enabling the gap betweenparcels to be reduced to only 50mm.
The VS8000 can be rapidlyintegrated in omni-directional reading stations, with nomodifications to existing structures.
Set-up is fast and easywith the intuitive Monitor Configuration Program.
With theVS8000, Datalogic offers an excellent alternative to existingdimensioning systems.
The VS8000 is more cost-effective andeasier to use and install than traditional measurement systemsand, above all, makes new process automation and optimisationcapabilities available to all materials handling operators.
HMC undergoes a second rebuild
A heavy duty Cincinnati HMC has been rebuilt again,this time employing the capabilities of Renishaw's calibration and machine tool performance testing systems.
HMC undergoes a second rebuild In 1989, Leeds-based Dana Spicerneeded a large, heavy duty CNC machining centre, to mill, drill,and bore the ends of 2-metre long axle beams, for heavy off-roadvehicles. The ideal machine, with a bed length of 5-metres, wouldallow pendulum machining, thereby increasing production. However,new machines of this type were costly and resulted in the companyapproaching rebuild specialist Murrall and Lang for a solution.Ten years later, it was 'd�j� vu' for theBirmingham-based company, when it welcomed the opportunity toonce again re-manufacture the machine, but this time employingthe capabilities of Renishaw's calibration and machine toolperformance testing systems.
Murrall and Lang had alreadymodified a 2-metre machining centre to accommodate pendulummachining in the summer of 1989 and convinced Dana Spicer of thecost benefits.
With a contract signed, a Cincinnati 20HC 2500(2.5 metre) travelling-column horizontal machining centre wasfound in the USA that would machine these parts, if equipped witha suitable front base.
The volume of the axle components dictatedthat a pallet shuttle system would be economic, allowingunloading and loading whilst machining continued.
To accommodatethis, Murrall and Lang designed a special shuttle table with twoindex tables and fixtures, and a CNC movement of 2.5m from oneposition to the other.
Suitable guarding protected the operator.Therefore, in addition to the usual horizontal axes of X(2500mm), Y (1000mm) and Z (600mm) and the shuttle axis, themachine has two indexing axes giving a total of 6 CNC axes.
Thisconfiguration was arrived at after joint discussions when themachine was first modified in 1990.
After producing axles fornearly a decade and having questioned the ability to maintain themachine, Dana Spicer - having once again considered new products,which still proved very costly - decided to have the machinere-manufactured by Murrall and Lang for a second time.
Havingexperienced the benefits of Renishaw's QC10 ballbar systemsin the 1990's, Murrall and Lang had no hesitation inutilising this technology and purchasing Renishaw's ML10laser calibration system to aid the re-manufacture 'asnew', of the Cincinatti HMC for a second time.
Partner, BobMurrall explained.
'We had successfully produced a machineto Dana Spicer's tolerance specifications in 1990 using asecond-hand Hewlett Packard (HP) calibration system.
Today, HPequipment is neither cost-effective nor comparable to thetechnological capabilities of the Renishaw systems.''It was our experience of the QC10 ballbar system, that ledus to invest in the ML10 laser calibration equipment,' addedMr Murrall.
'The ballbar is so reliable, it automaticallyidentifies, quantifies and prioritises machine tool errors.
Inseeing it used here, many of our customers, including DanaSpicer, have subsequently invested in the technology.' TheY2K re-manufacturing process included a complete mechanicalrebuild, with all worn parts being reconditioned or replaced, acomplete rewiring, the fitting of new digital axis and spindledrives, and a new Siemens 840D CNC control.
The process took lessthan six months and fully met customer specification.
To improvereliability, the customer wanted to maintain accuracy by axiscalibration and compensation.
This required the use of theRenishaw laser calibration system; part of Murrall andLang's quality control system.
'When you arere-manufacturing a machine, your alignments should be well withinachievable levels of adjustment, allowing the alignments set bythe original manufacturer to be achieved.
In fact, the QC10ballbar and ML10 laser system allow us to achieve tightertolerances than was possible when the machine was firstmanufactured.
Whatever we attain here, we can reproduce at thecustomers' premises.
The Renishaw ML10 laser calibrationsystem is portable, easy to use and has built-in temperaturecompensation, allowing our customers to machine components farmore accurately than once possible,' continued Mr Murrall.At Dana Spicer, the 20hp Cincinnati machine, with spindle speedsof 3300rpm, is fed by two 30-tool chain-based magazines.
Axlebeams are machined from forgings which tend to vary in size dueto the forging process.
To obtain the best metal conditions, oncethe component is mounted in the fixture, a spindle mountedRenishaw MP700 high accuracy probe is used to check length androtation.
Corrections are applied automatically to find thecomponent centre, and if necessary to rotate the programdimensions, so as to produce the best component from the forging.'The rebuild option allows a company to purchase a specificmachine at a third of the cost of a new machine.
HMC undergoes a second rebuild In 1989, Leeds-based Dana Spicerneeded a large, heavy duty CNC machining centre, to mill, drill,and bore the ends of 2-metre long axle beams, for heavy off-roadvehicles. The ideal machine, with a bed length of 5-metres, wouldallow pendulum machining, thereby increasing production. However,new machines of this type were costly and resulted in the companyapproaching rebuild specialist Murrall and Lang for a solution.Ten years later, it was 'd�j� vu' for theBirmingham-based company, when it welcomed the opportunity toonce again re-manufacture the machine, but this time employingthe capabilities of Renishaw's calibration and machine toolperformance testing systems.
Murrall and Lang had alreadymodified a 2-metre machining centre to accommodate pendulummachining in the summer of 1989 and convinced Dana Spicer of thecost benefits.
With a contract signed, a Cincinnati 20HC 2500(2.5 metre) travelling-column horizontal machining centre wasfound in the USA that would machine these parts, if equipped witha suitable front base.
The volume of the axle components dictatedthat a pallet shuttle system would be economic, allowingunloading and loading whilst machining continued.
To accommodatethis, Murrall and Lang designed a special shuttle table with twoindex tables and fixtures, and a CNC movement of 2.5m from oneposition to the other.
Suitable guarding protected the operator.Therefore, in addition to the usual horizontal axes of X(2500mm), Y (1000mm) and Z (600mm) and the shuttle axis, themachine has two indexing axes giving a total of 6 CNC axes.
Thisconfiguration was arrived at after joint discussions when themachine was first modified in 1990.
After producing axles fornearly a decade and having questioned the ability to maintain themachine, Dana Spicer - having once again considered new products,which still proved very costly - decided to have the machinere-manufactured by Murrall and Lang for a second time.
Havingexperienced the benefits of Renishaw's QC10 ballbar systemsin the 1990's, Murrall and Lang had no hesitation inutilising this technology and purchasing Renishaw's ML10laser calibration system to aid the re-manufacture 'asnew', of the Cincinatti HMC for a second time.
Partner, BobMurrall explained.
'We had successfully produced a machineto Dana Spicer's tolerance specifications in 1990 using asecond-hand Hewlett Packard (HP) calibration system.
Today, HPequipment is neither cost-effective nor comparable to thetechnological capabilities of the Renishaw systems.''It was our experience of the QC10 ballbar system, that ledus to invest in the ML10 laser calibration equipment,' addedMr Murrall.
'The ballbar is so reliable, it automaticallyidentifies, quantifies and prioritises machine tool errors.
Inseeing it used here, many of our customers, including DanaSpicer, have subsequently invested in the technology.' TheY2K re-manufacturing process included a complete mechanicalrebuild, with all worn parts being reconditioned or replaced, acomplete rewiring, the fitting of new digital axis and spindledrives, and a new Siemens 840D CNC control.
The process took lessthan six months and fully met customer specification.
To improvereliability, the customer wanted to maintain accuracy by axiscalibration and compensation.
This required the use of theRenishaw laser calibration system; part of Murrall andLang's quality control system.
'When you arere-manufacturing a machine, your alignments should be well withinachievable levels of adjustment, allowing the alignments set bythe original manufacturer to be achieved.
In fact, the QC10ballbar and ML10 laser system allow us to achieve tightertolerances than was possible when the machine was firstmanufactured.
Whatever we attain here, we can reproduce at thecustomers' premises.
The Renishaw ML10 laser calibrationsystem is portable, easy to use and has built-in temperaturecompensation, allowing our customers to machine components farmore accurately than once possible,' continued Mr Murrall.At Dana Spicer, the 20hp Cincinnati machine, with spindle speedsof 3300rpm, is fed by two 30-tool chain-based magazines.
Axlebeams are machined from forgings which tend to vary in size dueto the forging process.
To obtain the best metal conditions, oncethe component is mounted in the fixture, a spindle mountedRenishaw MP700 high accuracy probe is used to check length androtation.
Corrections are applied automatically to find thecomponent centre, and if necessary to rotate the programdimensions, so as to produce the best component from the forging.'The rebuild option allows a company to purchase a specificmachine at a third of the cost of a new machine.
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