5-axis probe speeds up QC scan

Kawasaki encourages motorcycle enthusiasts to "let the good times roll," but good times of another sort are rolling at the company's small engine plant, where two 5-axis scanning probe systems are slashing CMM inspection and probe calibration times, and speeding up QC feedback for machining of small engine components. The 5-axis Renishaw REVO systems, installed on Mitutoyo Crysta-Apex 121210 CMMs, replaced two PH10 articulating heads using SP25 scanning probes on traditional 3-axis CMMs. The REVO-equipped CMMs have cut inspection times by half or more on scanning intensive applications, eliminated the need for custom probe configurations, cut probe calibration times from six to seven hours to about 45 minutes, and added new capability to collect large amounts of form measurement data, improving part quality. Of primary importance, the REVO systems have greatly increased inspection throughput, data quality and flexibility of the QC department, enhancing its value as a strategic support asset to both manufacturing and R&D.

 Kawasaki production system
Kawasaki utilises automation in many die cast and some machining operations, accomplished through the integration of Kawasaki robots. On one of the crankcase lines, robots load raw materials and unload finished parts that are placed into inventory for assembly to draw upon. Machined parts include aluminium, cast iron and steel.
The QC lab is responsible for inspecting 125 different mass-produced parts, as well as vendor parts and those produced for engineering development. The environmentally controlled lab is located adjacent to the machining lines, and parts intended for routine inspection are delivered on carts or via train (an electric vehicle towing several trolley carts). Critical components may be hand delivered for priority inspection during a line changeover or if an operator suspects a problem.

5-axis scanning advantage
Kawasaki bought a new Mitutoyo Crysta-Apex 121210 in 2009 with the REVO system installed from the factory, and retrofitted an identical machine in 2010, after the first machine was up and running with all the part programs.
The REVO 5-axis scanning probe head can collect up to 6000 data points/sec. It is engineered for high-speed precision measurement of contoured surfaces and complex geometries requiring high-volume data collection to validate fit and form with high accuracy. It uses two rotary axes, one in the vertical plane and one in the horizontal, for infinite rotation and positioning. Five-axis software drives the measuring head and synchronises its motion with the linear axes of the CMM. Look-ahead algorithms drive the probe path and CMM in coordinated continuous motion. The head adapts position while measuring on the move, maintaining stylus tip contact with changing contours at scanning speeds of up to 500 mm/sec.
What would take 3-4 minutes with an SP25 probe, Kawasaki is measuring in 10 seconds with the REVO. The REVO scanning heads have all but eliminated the need for touch probing. Now 95% of inspections utilise scanning, with no "time penalty" as before, allowing Kawasaki to collect so much data that it challenges the speed of computers doing the analysis. The REVO probe can also do "head touch" probing or be used for traditional machine-touch probing when the situation calls for touches.
 "With scanning inspections, our production and engineering people have a lot more confidence that the data is valid," JC Watts, Quality Control Technical Group Supervisor said. "With touch probing it is easy to get one speck of dirt that causes an out-of-round condiAir Jordan XI 11 Wool