Maximise factory efficiency using multisensor measuring

Nowadays, new materials and manufacturing methods allow complex parts to be manufactured with tight tolerances and free-form surfaces. Multi-axis computer numerical control (CNC) machine tools run unattended, generating curves and finishes that match the originating computer-aided design (CAD) files. At the same time, metrology instrumentation  has progressed along several supporting paths.

One such improvement in the metrology area is in the realm of multisensor measurement systems that use two or more sensor technologies to measure a part in a single setup. Multisensor systems contribute to lean manufacturing processes.

Multisensor metrology systems extend measuring capabilities so more measurements are possible on a single machine.  For example, video measurement uses magnified images of parts to determine important dimensions in, on or between parts.

Multisensor measuring machines

The simplistic description of a measurement machine with more than one sensor does not do justice to the state of today’s multisensor measuring machines. Industry seems to have settled on some combination of optical, laser and touch-probe sensors as the definition for a multisensor measurement system, but now there are more.

Microsensors use very different technologies to provide measurements not possible because of physical limitations of the other three technologies. Now that designers and manufacturers are able to combine geometric, prismatic shapes with free-form contours, have critical clearance holes or locating points, and have important relationships at numerous positions on the part, measurement systems have adopted use of multiple sensors to deal with this complexity.As companies consider the use of multisensor metrology, it is important to recognise that not all implementations are the same. An important consideration is how well integrated the sensors are in the system software. The best implementations calibrate all the sensors so they can be used at any point in a measurement routine. Poor implementations may require that each sensor be calibrated prior to each use. Effective implementations process and analyse data from any sensor, easily handling video edge points, laser point clouds and scanning touch-probe data in a single measurement routine.

OGP Feather Probe? micro-sensor mounted on SmartScope? Apex Micro measures 0.009”
diameter holes on fuel injector nozzles

Well-designed multisensor measurement systems improve lean manufacturing processes. By doing more on a single machine, potential bottlenecks are eliminated. When considering multisensor alternatives, find out which sensor technologies are available and how well integrated they are as a system. There is a difference between a machine with multiple sensors and a multisensor measurement machine. The specific part application will help make the best choice, and affect the lean manufacturing process.

Multiple machines vs. multiple sensors

Any measurement machine based on single sensor technology is optimised for performance with that particular sensor. Take a CMM with a touch-trigger probe. The mechanical design allows access to a fixed part from a number of directions with a tactile probe. Video measuring systems, on the other hand, are optimised to image parts and features so they can be measured accurately. This means they include surface and backlight illuminators not required on the CMM. Other measurement systems have similar design requirements and associated constraints. A multisensor measurement system has supporting mechanisms such as illuminators for video and change racks for touch probes.

From the metrology perspective, having access to each of the types of measurement systems mNew Arrivals