Inspection and
quality control frequently constitute
the largest portion of production costs
for many industries. Enormous savings
can be attained by improving the accuracy
of measurement in these processes. There
is a growing need for improved measurement
solutions which offer higher precision,
speed and accuracy and provide better
in-process measurement of moving objects,
resulting in lower costs for better
products.
Optimet's sensors overcome the limitations of many existing measurement devices, and in many cases provide the only comprehensive solution for complex measurement problems. Optimet's sensors are the critical building blocks for many metrological systems. The final products or applications can be developed either by Optimet or by a co-development partner.
Optimet's sensors have been adopted by over 80 QC equipment manufacturers in Europe, USA and the Far East.
Optimet sensors are highly dominant in aerospace, automotive, dental, plastics, rubber, FPD and mechanical tools industries.
QA/QC
In Process Inspection
Reverse Engineering
Dental CAD / CAM
Articles
QA/QC 3D AND PROFILE MEASUREMENTS
Quality Control involves examining the geometrical compliance or compatibility of a part with the original plan or drawing. Presently QA/QC systems are primarily based on contact probes, as 3-D non-contact sensors have not been able to meet the high precision requirements of many applications. However, existing contact probes do not operate at the high speeds that these measurements require. Optimet sensors provide an answer to both these issues, therefore holding a great advantage in this market, as a 3-D non-contact system that is both sufficiently precise and fast.
Turbine blade inspection:
Leading edge measurement Multiple sections of aerofoil blade profiles can be measured simultaneously on both sides and data compared with input design data. The Conoprobe's ability to measure steep angles enables the system to address blade edge profiles. Single edge profiles can be measured or depending on blade twist 3D profiles of the full blade length can be produced.
Tire groove inspection
High speed inspection of deep tyre grooves is performed in seconds. The collinear technology and steep angle measurement capabilities provides the unique solution for a perfect defects profile comparison .
Filling level
In process inspection of liquid and solid (balls or powder) material height inside tubes is measured by comparing the distance between tube rim with the filling inside.
The precise position of the tube rim is calculated by measuring the radius of the rim by following its precise shape, then the distance to the powder/tiny balls is easy to measure due to the collinear properties of the Conoprobe technology . This procedure has been adopted in hazardous and sterile environments at high speed movement.
Miniature Plastic Gear Inspection
Gear inspection of miniature plastic gears is a difficult task for the conventional touch probe due to the small size of the object which requires a very delicate procedure.
The very high precision, small spot size and angle measurement coverage, provided by the Smart HD, reduces setup time and enables to inspect the gear in a fraction of the time taken by conventional methods.
IN-PROCESS INSPECTION
Finding defects in- process permits immediate correction of the procedure and saves considerable re-processing costs. Currently the prime technology in use is the triangulation sensor. By overcoming the poor resolution to working range and angle coverage limitation of triangulation and other technologies Optimet sensors fulfill a wide range of tasks which were not possible in the past.
The unique capabilities of Optimet's technology in handling difficult shapes or working through a third party objective lens enables the creation of a much larger market for such applications as manufacturing or assembly operations
Optimet sensors in general and the ConoLine LS in particular are designed to operate under harsh environmental conditions such as high temperatures and strong background illumination.
Optimet's sensors have been successfully integrated by leading manufacturers in the steel, aerospace, FPD, beverage cans and welding industries.
Roller concentricity
The diameter and concentricity of a cylindrical roller are critical parameters tested on line. If the centre of the object is known, a single sensor is sufficient for the measurement whose result is evaluated with the position of the centre point or the axis. If the position of the centre point is not known, the diameter is measured directly using two sensors. On large objects two or more sensors are also used to check for tilt or bumps.
Tin can inspection
The only gage in the market providing simultaneous profile of both the top and bottom surfaces of features such as the score residual or coin thickness of beverage can ends. It provides higher detail information than X-rays and vision. It quickly takes a large number of readings to give a comprehensive and accurate picture of the end progression process, including the score residual.
Autofocus in welding applications
The autofocus assembly is a unique solution which permits to keep the welding laser in optimum focus by accurately positioning the focus lens exactly at the required clearance .It measures directly in the welding point during the welding, jointing or fusing process with a pulsed laser and readjusts the focus lens immediately, when necessary. Because of the coaxial nature of the solution, it can measure inside grooves, holes and on steep slopes.
Roughness Measurement
Roughness measurement of metal sheets is an essential procedure in the manufacturing process of Steel. The roughness measurement requirements are very high while the sensor must be kept at a long distance from the measured surface. This task is resolved by using four Smart HD sensors measuring the roughness on both sides at different areas of the metal plate at the required distance.
REVERSE ENGINEERING
Reverse Engineering refers to the ability to reproduce the shape of an existing object. It is based on creating a digitized version of objects or surfaces which can later be turned into molds or dies. It is a very common procedure which has diverse applications in various industries. It is used to make copies of objects such as mechanical spare parts, molds for art objects, jewelry and the mint industry.
Optimet's unique solution has been chosen by Nobel Biocare, a world leader in innovative restorative and esthetic dental solutions, for their new optical CAD/CAM scanner, providing clear advantages for dental laboratories such as scanning of steep angulations and undercuts, thereby, opening up new opportunities such as scanning of implant bridges and impressions.
Metal ornamentation and ceramics
Reliable and fast reconstruction of art industrial designs is accomplished using the Conoprobe's unique capabilities to measure holes, grooves and steep angles on diffusive and shiny metal surfaces.
Jewelry
Accuracy and fidelity requirements of art related applications , such as coins, medals and jewels are met by precise replication of shapes, angles and small features provided by the Conoprobe .
Leather
Reproduction of leather type surfaces is achieved by using high definition Conoprobe sensors with extreme small size laser spot and high accuracy.
Lasts
Shoe last physical models created by crafts are reproduced with emphasis on complicated shapes of toes, and heels.
These parts are scanned with very steep angles over a large working range. This process is accomplished in a very short time due to the high precision measuring capabilities along the full size of the last and the collinear nature of the scanning technology avoiding blind areas around heels or toes.
Dental CAD / CAM
In dental CAD/CAM applications, dental restorations such as crowns, bridges, abutments, provisional restorations, implant based bridges and framework, are designed by a dedicated CAD software, based on an accurate 3-D scan of dental casts (gypsum), impressions and other models. The individualized restorations are then manufactured out of special advanced ceramic materials (Zirconia, Alumina), Titanium and other metal alloys by CNC machines.
The 3D data used for planning dental objects is obtained from single dies, batches of single dies and wax-up replicas scanned with the Procera™ Scanner. The scanner can scan one sided or double-sided impressions with deep cavities in the front teeth.
Together with special software algorithms the scanner enables extraction of the positioning of implants at very high accuracy for CAD design and manufacturing of implant based frameworks and bars.
Individualized Procera Bridge on implants based on CAD/CAM Procedures and 3D scans
Individualized Procera Bridge on natural teeth based on CAD/CAM Procedures and 3D scans
Courtesy of Nobel Biocare
Scan results (STL surfaces) of gypsum dies (one or batch):
Novel on-line surface quality control for hot slabs(Arcelor and University of Oviedo)
The prototype developed is able to detect, automatically, two different kinds of defects: surface cracks and inclusions/pores.
On Line Measuring in PM complex Parts by Conoscopic Holography(University of Oviedo)
A measuring method and system that meets the increasing demand for tighter geometrical tolerances and shape defects has been developed. This non-contact method allows on line measuring of complex sintered parts in a precise, fast, robust, flexible and economic way.
3D Scanning of Artworks(CNR – INOA)
A review of 3D scanning techniques currently adopted in the diagnostics of artworks and paintings; the ConoProbe is used for MicroProfilometry.
Development of Effective Measurement Method for Burr Geometry (Konkuk University)
Triangulation, conoscopic holography and white light interferometry methods are analyzed and compared for effective measurement of micro burr geometry, which is formed in micro drilling. “For measuring the sharp edges of burr, Conoprobe sensor by conoscopic holography method is recommended by comparing the measurement performance with other non contact measurement methods”.
An Effective Visualization and Analysis Method for Edge Measurement (Rosmark-Steel)
The terminology burr defines undesirable result of plastic deformation formed in machining process causing degradation of the accuracy and functionality of the product and its assemblies.
Abrasive Jet Machining for Edge Generation (University of Michigan)
The edge with a consistent and precise shape is important for highly stressed mechanical components. This study investigates the generation, measurement, and definition of edges.
Tool Geometry Measurement System(University of Michigan)
Objectives: To develop a new non-contact 3-D drill geometry measurement system which will measure: drill bit geometry, drill flute cross section profile, drill wear.
Drilling of Fiber-Reinforced Plastics - Tool Modeling and Defect Prediction(California-Berkeley University)
Fiber reinforced polymer (FRP) composites have been steadily replacing metals as choice engineering materials for various applications. This report discusses a model to analytically estimate the edge defect in drilled FRP laminates.
Laser sensor motion control system with application to engine valve seat metrology In the last decade, computer-based systems for the comparison of microscopic firearms evidence have been the subject of considerable research work because of their expected capability of supporting the firearms examiner through the automated analysis of large amounts of evidence… This work analyzes the advantages and disadvantages of a 3D-based approach by proposing an approach and a prototype system for firearms evidence comparison that is based on the acquisition and analysis of the 3D surface topography of specimens, with particular reference to cartridge cases.
Medical & Dental applications