Quality January 2011

January 2011, Volume 50/Number 1 www.qualitymag.com

V I S I T J O E G I B B S R A C I N G | S E E p . 8 0 F O R D E TA I L S

W E N Form and Surface

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CONTENTS

JANUARY 2011 VOLUME 50/NUMBER 1

DEPARTMENTS 6

From the Editor 50 Years in the Making

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Industry News

Source: Mahr Federal Inc.

ASQ 2011 Manufacturing Survey Reveals Brighter Outlook  X-ray Inspection Systems Markets Increasingly Diverse

28 FEATURES

 PMA Report Forecasts Few Economic Changes in Coming Months

18 Face of Quality 50 YEARS OF QUALITY

26 The Pros and Cons of Optical Comparators The reason comparators have not changed much in 85 years is because the fundamental technology behind an optical comparator is elegantly simple, and it simply works.

QUALITY MEASUREMENT

28 Driving to the Finish The automotive industry has special needs that make dedicated surface finish gages a necessity.

QUALITY TEST & INSPECTION

38 Data Leads to Good Leak Test Decisions Through the adoption of new leak testing approaches that provide comprehensive data about the entire leak test cycle, manufacturers can get more out of their leak test.

44 Laser Doppler Vibrometers Rewrite the Book Laser vibrometry is rewriting how today’s engineers measure vibration in the lab, on the production floor and in the field.

52 Spectroscopy Simplified Advances in FT-IR spectrometers and software enable improved sample verification and increased confidence in QA/QC testing.

QUALITY MANAGEMENT

56 The Need for ISO 13485 The increasing need for quality medical devices is matched by the need for compliance with ISO 13485: 2003.

The Quality Profession Continues to Evolve

20 Other Dimensions Certificates of Confusion

22 Quality 101 CAD Overlay Inspection Basics

24 Quality Innovations 3-D Inspection in Color

58 Case Study  Accuracy in Production  An Upgraded Inspection Process

66 Quality Products 78 Classifieds 79 Advertising Index

NEXT MONTH  Noncontact Inspection  Machine Vision  Enterprisewide Software  Quality Leadership 100

ABOUT THE COVER The fact is that nothing is 100% sealed; everything leaks, whether it is supposed to or not. The challenge for manufacturers is to determine whether the leakage is acceptable from product quality and regulatory compliance perspectives. Source: Sciemetric Instruments

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QUALITY | January 2011

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Measurably Different Fetura® Vision Metrology Systems set the new benchmark for throughput and precision Fetura Vision Metrology Systems combine the world’s fastest optical zoom technology with powerful software and precision mechanics to offer a notable advantage in offline inspection and quality control productivity. • Image Navigator streamlines maneuvering around complex parts • Color edge detection finds edges that grayscale cannot • Intelligent lighting automatically cally sets intensity for optimal imaging aging Discover the Q! • Visual Basic scripting speedss customized programming WEST • Optional laser autofocus and d scanning for surface analysiss Booth 2273 • Multipoint autofocus streamlines mlines detailed surface topography • Optional PowerMatch software compares direct to CAD

MD&M

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O N L I N E TA B L E O F C O N T E N T S

JA N UA R Y 2011

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QUALILITT YMAG.COM February 23, 2:00 p.m. ET A Streamlined 3-D Approach A municipal ice rink recently contracted an engineering firm to install new cooling equipment in the mechanical room. The challenge for the engineers was to limit the downtime while updating the old cooling unit. The firm was able to quickly perform updates with minimal disruption of the structures’ functions through 3-D laser scanning. Becoming a Lean Machine IBM is transforming its manufacturing into a leaner, more efficient operation. By using deep business analytics, simplifying its offerings and product development and implanting test clouds, the company is cutting costs and getting products to market more quickly. Quality Bingo A twist on the classic game, Quality Bingo is meant to enhance employee productivity by educating its players. The game encourages workers to improve metrics and meet goals to support continuous improvement efforts.

Introduction to Precision Ultrasonic Thickness Gages and Applications

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Ultrasonic Testing Solutions Trends in Eddy Current Video Measurement

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QUALITY | January 2011

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Look closer.

Optically measure complex shafts in seconds. Diameter, length, geometry and form. Automatically. To microns. CNC flexibility to handle any shaft Submicron repeatability ■ Simple, high-speed operation ■ Easy to program ■ Shop-floor ready ■ ■

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Precision is Our Business.

F RO M T H E EDI TOR

B Y GIL L IA N C A MP B E L L

50 Years in the Making W

Gillian Campbell is editor of Quality Magazine. Gillian can be reached at [email protected].

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elcome to our golden anniversary. Quality Assurance, as we were originally known, launched in 1962, back at the early stages of the space exploration program and the dawn of man in space. As people watched a space capsule take off, many wondered: will it work? Then, upon re-entry, when the astronaut was fished from the ocean, one thought dominated: what if the cable snaps? As W.F. Schleicher, the magazine’s first publisher and editor, pointed out, “The prayer and hope that the thing and all its parts will work is the culmination of many long nights of work; the finale to a monumental formula of quality assurance, men and natural laws. By the innocent phrase, ‘will it work?’ dangles life—and liberty.” While, at the time, the space exploration program was an extreme example of all things coming together to prove its weight in quality, today we rarely wonder “will it work?” We just assume that whatever we buy—a car, computer, cell phone, lamp or tape dispenser—will work, rarely giving quality a second thought unless there’s a recall. In 2010 there were various recalls because quality standards weren’t met, but many of those recalls were because corners were cut, and quality standards were glossed over or ignored altogether. It sent a loud and clear message to everyone from management to consumers that quality is a necessity and in place for a reason. As I look back at the magazine’s original mission statement, the message we sent 50 years ago still resonates today. Take a look at this passage from our inaugural issue.

Quality Assurance believes: …nothing is more important to America than the quality of its products. …a sound quality assurance program increases efficiency, decreases costs, meets competition, increases sales and reduces the profit squeeze. …quality is management’s concern, with which it must live, think and sleep. From management it must permeate every corner of the plant. …quality assurance people are the fastest growing group of professionals in industry—and none in industry is more important. To unify all aspects of quality assurance; to broaden knowledge and understanding of management and quality assurance professionals; to continually reiterate the importance of quality to America; to oppose and perversion of the quality assurance function; and to continually champion new techniques, greater efforts and always superior products… With the exception of the number of people involved in the quality field and the fact that we now reach a global audience, the message remains very much the same. What’s your take on how quality has changed—or stayed the same—over the years? Send along your thoughts to [email protected], or share with other members of the Quality community at the Quality Magazine LinkedIn Group page, the Quality Facebook page and on Twitter at http://twitter.com/QualityMagazine.

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QUALITY | January 2011

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CORPORATE DIRECTORS Publishing: Timothy A. Fausch Publishing: John R. Schrei Corporate Strategy: Rita M. Foumia Information Technology: Scott Kesler Marketing: Ariane Claire Production: Vincent M. Miconi Finance: Lisa L. Paulus Creative: Michael T. Powell Directories: Nikki Smith Human Resources: Marlene J. Witthoft Conferences & Events: Emily Patten Clear Seas Research: Beth A. Surowiec

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TOUGH

DITTO

Engineered to get its hands dirty Different people have different uses for force measurement equipment, but durability is a universal requirement. Consider the all-new Series 5 digital force gauge from Mark- 10. With key design features such as an overload-protected load cell, shock-resistant circuit board mounting, and narrow gaps in the all-aluminum housing, this gauge is engineered for your toughest jobs. Add to this an industry-leading sampling rate of 7,000 Hz, USB data output, 1,000-reading memory with statistics, ±0.1% full scale accuracy, and a rugged allaluminum housing. The Series 5 – engineered to be tough enough for anybody’s toolbox. To learn more, visit us at www.mark-10.com or call us at 888-MARK-TEN.

FORCE & TORQUE MEASUREMENT

INDUSTRYNEWS | Business News | Coming Events | People News | Mergers |

COMING EVENTS FEBRUARY 8-10 MD&M WEST Anaheim, CA Canon Trade Shows (310) 445-4200 www.canontradeshows.com 28–3/1 2011 LEAN AND SIX SIGMA CONFERENCE Phoenix, AZ (800) 248-1946 sixsigma.asq.org

APRIL 5-7 AERO DEF Anaheim, CA SME (800) 733-3976 aerodef.sme.org 11-13 QUALITY CONFERENCE Charlotte, NC Quality Magazine (888) 530-6714 www.qualitymagconference.com 19-21 FUNDAMENTALS OF RANDOM VIBRATION AND SHOCK Testing College Park, MD Equipment Reliability Institute (805) 564-1260 www.equipmentreliability.com/ vibration_course1.html

ASQ 2011 MANUFACTURING SURVEY REVEALS BRIGHTER INDUSTRY OUTLOOK

• 73% expect no mandatory furlough days. In 2010, 72% indicated they did not have to take furlough days.

MILWAUKEE, WI—The second annual American Society for Quality (ASQ) Manufacturing Outlook Survey shows a majority of manufacturers are optimistic about an economic uptick in 2011 at their organizations. The survey conducted by ASQ reveals 68% of respondents employed in the manufacturing sector predict their organizations will experience revenue growth. Despite the economic landscape, a year ago 64.7% of respondents predicted that revenue would grow in 2010. This year 67% indicated that their organizations experienced revenue growth in 2010. More than 1,200 manufacturing professionals from the United States and Canada responded to the online survey. The two areas from the survey that showed the most promise were in the area of payroll and operational budgets. Eighteen percent expect a pay freeze in 2011, compared to 44.8% in 2010 at their organizations. In addition, 18% predict mandatory budget cuts in 2011, whereas 35.2% did in 2010. Other findings include: • 48% expect of a salary/merit increase • 47% expect organizations will continue to create processes to reduce costs, down from 61.3% in 2010 • 42% expect their organizations to maintain current staff levels • 42% expect that additional staff will be brought on in their companies

As organizations made sacrifices to survive a down economy, the survey inquired whether staff reductions or other cutbacks implemented in 2010 negatively impacted the quality of the products and services delivered. Thirty three percent of respondents believed that the quality of their products and services was negatively impacted, and 32% believed that the quality did not suffer. Respondents also were asked what one tip they would give to manufacturers to ensure revenue growth in 2011. The top four tips, similar to the 2010 outlook, from respondents were: • To continue to participate in continuous improvement practices and increase use of quality processes • To increase customer satisfaction • To implement more lean processes • To reduce costs and eliminate waste.

X-RAY INSPECTION SYSTEMS MARKETS INCREASINGLY DIVERSE MOUNTAIN VIEW, CA—According to a recent Frost & Sullivan report of the X-ray inspection systems market for nondestructive testing applications, the evolution to new applications has driven the uptake of X-ray inspection systems. While advancements in technology and emergence of new application areas are making a strong case for X-ray inspection systems, it is the

MAY 1-5 ANTEC 2011, Boston, MA Society of Plastics Engineers (203) 740-5452

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QUALITY | January 2011

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ASSOCIATION NEWS  The National Tooling and Machining Association (NTMA) and Precision Metalforming Association (PMA) appointed new leaders and announced a convention in March 2011 that will mark one of the largest gatherings of small- and medium-sized manufacturing executives in recent history. NTMA appointed David Tilstone as its new president. Tilstone brings more than 35 years of metalworking experience to the role. He previously held leadership positions with Kennametal and Extrude Hone, where he focused on developing and implementing growth strategies and improving operating results. NTMA and PMA will join the Association for Manufacturing Technology (AMT) and the American Machine Tool Distributors’ Association (AMTDA) to co-host the Manufacturing for Growth (MFG) Meeting March 3-6, 2011, in Chandler, AZ. The convention brings together business owners and executives from around the country to combine resources and explore opportunities to reestablish manufacturing as a primary engine driving the U.S. economy.

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rising standard of quality and safety of critical structural components that is expected to bring in the revenues. Recent industrial disasters, such as the oil spill in the Gulf of Mexico, have placed the spotlight on the need for stringent quality control programs. Reacting to such incidents, governments across the globe have announced plans to strengthen laws to prevent industrial debacles. The aerospace industry, in an effort to fulfill high standards of safety and quality, has traditionally been the first to adopt the latest advances in X-ray technology intended for the field of medicine, said the analyst of this research. Examples of these advances are high volume, safety critical inspection applications, repair and maintenance applications, and precision 3-D material analysis. Apart from rising usage in key enduser industries such as aerospace, oil and gas, and automotive, new applica-

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“4600” SERIES 14'' VERTICAL BEAM Heavy-duty steel construction 4'' x 8'' or 4'' x 12'' travel stage • Erect image • Exclusive “Gothic Arch” bearings • .00005''/.001mm scale resolution • 3-position lens turret • •

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IND U ST RY N EW S

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BUSINESS NEWS  Nikon Metrology Inc. (Brighton, MI) opened a Western regional sales office in Irvine, CA. The facility will serve as a sales and demonstration center for current and potential Nikon Metrology customers in California, Arizona, New Mexico, Utah, Colorado, Nevada, Idaho, Wyoming and Texas. The office will be home to nearly a dozen Nikon Metrology employees who will provide customer support and sales demonstrations for customers.  The more than 300 employees who work at Eriez headquarters (Erie, PA) have set a safety record after instituting a companywide employee awareness program. According to president and CEO Tim Shuttleworth, Eriez employees have worked at least 730 days straight without a lost-time accident, surpassing the old mark of 259 days.  QMI-SAI Global (Cleveland, OH) announces the release of a new training course, Understanding and Transitioning to AS 9100 Rev C. This new course is designed to identify the differences between AS 9100’s Revision B and Revision C, and provide the necessary guidance for companies to make the transition between the two. It also will prove valuable to

those organizations seeking initial certification to AS 9100C. Attendees will experience practical workshops and simulations to develop the proper understanding of the material and enable an efficient implementation within their organizations.  Geomagic’s (Research Triangle Park, NC) reverse engineering and 3-D inspection software has been validated by the National Institute of Standards and Technology (NIST). The test verifies accuracy of features in the company’s software for a geometry used in Geomagic Studio 12 and Geomagic Qualify 12. NIST is accepted and recognized as an indicator of accuracy for technology and in setting and testing technological standards. The evaluation covers least-squares fitting methods in both Geomagic Studio and Geomagic Qualify. It was tested on 240 datasets representing geometry types including lines, circles, spheres, cylinders and cones.  Restor Metrology (Leesburg, FL) has achieved accreditation to ISO/IEC 17025 and ANSI/NCSL Z540.3-2006 for calibration services. Restor Metrology provides test equipment calibration and repair services to companies in Florida and across the United States. The company produces covers thousands of products from hundreds of manufacturers. Its capabilities include RF and microwave to 50Ghz, EMI/ EMC, general purpose electrical, mechanical, physical/ dimensional and fiber optics.

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QUALITY | January 2011

tion areas such as food safety inspection hike the demand for X-ray equipment. However, despite the increasing applications and growing need for greater productivity, quality and accuracy of inspection, the global economic downturn has caused end users to scrutinize maintenance and inspection budgets. Although there are numerous advantages offered by digital X-ray, customers’ unwillingness to move away from triedand-tested techniques such as filmbased inspection restrains short-term market growth potential and leads to limited investment in new technologies. Although the transition to a filmless future is a continuous and ongoing trend in the X-ray inspection market, film continues to play a crucial role in meeting the nondestructive testing needs of customers, notes the analyst. Particularly, in such trying economic conditions, companies with lower financial resources are unwilling to make large investments in digital radiographic technology. To attract higher investments, X-ray inspection vendors have to work closely with standards bodies and customers to understand their specific needs while leveraging advancements in technology to provide easy-to-use solutions.

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ContourGT-X8 Optical Profiler ContourGT-K1 Optical Profiler

NPFLEX 3D Surface Metrology

Dektak 150 Stylus Profiler

A New Name. A New Dawn of Innovation. Our name is now Bruker. The Veeco Metrology Business; AFM, Optical Profiler and Stylus Profiler product lines have successfully become part of the Bruker family. And, while our name has changed, the team, commitment and dedicated support for our full line of solutions remain. Our current facilities and worldwide team are now supplemented by Bruker’s 50 years of scientific instrumentation leadership, vast resources, over 4500 employees and 90 locations across the world. We are excited at the new possibilities, the continued commitment to our customers and the dedication to advancing the tools and solutions for the measurement and collection of nanoscale information. We are Bruker.

For more information visit www.bruker.com, email [email protected], or call +1.520.741.1044 / 800.366.9956.

Innovation with Integrity

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BUSINESS NEWS CONTINUED  CIMx Software (Cincinnati, OH) and Dynafact Software Inc. (Parry Sound, Ontario, Canada), announced a strategic technology partnership. Dynafact is integrating its finite capacity scheduling engine with CIMx’s Manufacturing Execution Software (MES) suite. The CIMx Interax suite controls the production process, from the creation of routings, quality control plans and work instructions through the execution and management of orders on the shop floor.  Illinois Tool Works Inc. (Glenview, IL) has acquired North Star Imaging Inc. (NSI, Rogers, MN). The terms of the transaction were not disclosed. NSI is a developer and manufacturer of nondestructive testing systems and software for industrial and research applications. NSI develops computed tomography and digital radiography imaging systems technologies. NSI’s systems are used in life sciences, military/defense, aerospace, security, research/education, industrial and electronics markets.  Objet Geometries Ltd. (Rehovot, Israel), the 3-D printing for rapid prototyping and additive manufacturing company, announced today that it has achieved ISO 13485: 2003 certification for medical devices. ISO 13485 specifies requirements for a comprehensive quality management system for the design and development, production, installation and servicing of medical devices. This international standard confirms Objet’s ability to provide the medical industry with 3-D printers and related services that meet the regulatory requirements applicable to medical devices.

Ultimate Gauging Freedom M1 Multi Wave is the MOST ADVANCED manual bore gauge available • Uses latest Bluetooth® Wireless transmission technology • Repeatability of 0,5 micron (0.000020 inch) guaranteed • IP67 shop floor protected • Communicates with Marposs Bluetooth® electronic devices • Communication range 10 meters (33 feet) • Ultimate quality and precision guaranteed • Marposs reliability and cost effectiveness always • Instantly measure up to 7 diameters – with one click! • Cable free & powered by Li-ion cells with inductive recharging

www.marposs.com • Toll Free 1.888.MARPOSS Bluetooth® wireless technology The Bluetooth® word mark and logos are owned by the Bluetooth SIG, Inc. and any use of such marks by Marposs is under license. Other trademarks and trade names are those of their respective owners.

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QUALITY | January 2011

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I’ve Got It Made. ’A^SQWÈQOZZgRSaWU\SRT]`<2B ’7[^`]dSR^`]RcQbWdWbgZSaaR]e\bW[S ’@cUUSRRSaWU\PcWZbT]`bVS`WU]`a]TbVSX]P

Industrex Products

’4WSZR^`]dS\]\bVS[]abRS[O\RW\U<2BO^^ZWQObW]\a The Kodak Industrex HPX-1 is the first CR system designed specifically for the rigors of NDT applications. Industry leaders worldwide using the HPX-1 confirm it is fully capable of exceeding the demanding needs of the non-destructive testing industry. In the lab, the Industrex HPX-1 flexes its muscles through powerful imaging and high-resolution performance while in the field it’s rugged construction holds up to the harshest conditions.

Proven. Tough. Reliable. DIGITAL.

Carestream Health, Inc. Rochester, N.Y. 14608 © Carestream Health, Inc. 2010. Kodak and the Kodak trade dress are trademarks of Kodak used under license.

Want to find out more? www.hpx-1.com 1-888-777-2072

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PMA REPORT FORECASTS FEW ECONOMIC CHANGES IN COMING MONTHS CLEVELAND, OH—According to the November 2010 Precision Metalforming Association (PMA) Business Conditions Report, metalforming companies anticipate virtually unchanged business conditions during the next three months. Conducted monthly, the report is an economic indicator for manufacturing, sampling 137 metalforming companies in the United States and Canada. The November report shows that 20% of participants forecast an improvement in economic activity during the next three months—the same percentage reported in October—57% predict that activity will remain unchanged, compared to 54% last month—and 23% report that activity will decline, which is down from 26% in October. Metalforming companies also expect little change in incoming orders for the next three months. Twenty-five percent of participants predict an increase in orders—the same percentage as October—50% anticipate no change— compared to 45% the previous month—and 25% forecast a decrease in orders, down from 30% in October. However, average daily shipping levels dipped somewhat in November. Only 27% of participants report that shipping levels are above levels of three months earlier—down from 32% in October—45% report that shipping levels are the same as three months ago—compared to 49% in October—and 28% report a decrease in shipping levels, up from 19% in October.

Force Calibration Service

The uncertainty of the instrument calibrated is directly influenced by the measurement certainty of the calibration standard Morehouse force calibrations are performed using standards with the highest level of measurement certainty:










120,000 lbf Morehouse Dead Weight Machine

Dead Weights with accuracy of 0.002% of applied force used for calibrations through 120,000 lbf United States National Institute of Standards & Technology (NIST) calibrated standards Calibrations performed in our laboratory to 2,250,000 lbf in compression and 1,200,000 lbf in tension and equivalent kgf and Newtons Calibrations performed in accordance with the American Society for Testing and Materials (ASTM) E74, ISO 376, and other specifications Calibration for Proving Rings, Load Cells, Crane Scales, Force Gauges and other force measuring instruments ISO 17025 Accredited American Association of Laboratory Accreditation Calibration Cert 1398.01

2,250,000 lbf Morehouse Universal Calibrating Machine

Torque Calibrations accurate to 0.002% of applied torque to 2,000 N-m also available

MOREHOUSE FORCE & TORQUE CALIBRATION LABORATORIES

Phone: 717-843-0081 / Fax: 717-846-4193 / www.mhforce.com / e-mail: hzumbrun @ mhforce.com

INSTRUMENT COMPANY, INC. 1742 Sixth Avenue • York, PA USA

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QUALITY | January 2011

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The percentage of metalforming companies with a portion of their workforce on short time or layoff dipped to 15% in November from 17% in October. This number is at its lowest level since January 2008 when only 14% of companies had workers on short time or layoff. The monthly Business Conditions Report has been conducted by PMA since 1979.

CATERPILLAR TO ACQUIRE BUCYRUS INTERNATIONAL PEORIA, IL, and MILWAUKEE, WI—Caterpillar Inc. and Bucyrus International have entered into an agreement under which Caterpillar will acquire Bucyrus International in a transaction valued at approximately $8.6 billion. The acquisition is based on Caterpillar’s plan to expand its leadership in the mining equipment industry. Under the terms of the transaction, Bucyrus shareholders will receive $92 per share, $7.6 billion in aggregate consisting of all cash. The transaction represents an implied premium of 32% to Bucyrus’ share price. Caterpillar will fund the acquisition through a combination of cash from the balance sheet, debt and up to $2 billion in equity. The transaction is expected to close in mid-2011. Caterpillar intends to locate its mining business headquarters in South Milwaukee, WI, where Bucyrus headquarters are currently located, and maintain the Bucyrus brand for the principal Bucyrus legacy products. A driving motivation for the transaction is Caterpillar’s estimate of more than $400 million in annual synergies beginning in 2015 derived from the combined financial strength and complementary product offerings of the combined mining equipment businesses.

Repeatability

METHODS MACHINE TOOLS BECOMES NO. 1 SUPPLIER SUDBURY, MA—Methods Machine Tools Inc., a supplier of innovative machine tools, automation cells and machine tool accessories, has been recognized by Carl Zeiss Industrial Metrology as the number 1 sales volume partner in North America for the 2009/2010 Carl Zeiss fiscal year. Methods is responsible for sales of Zeiss Metrology products in the New England territory. Carl Zeiss Industrial Metrology (Maple Grove, MN) is a CNC coor-

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Nothing ensures repeatability better than comparing a part’s optical profile to a master.

starrett.com DO IT WITH PRECISION

January 2011 | QUALITY

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Helium Leak Testing

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PEOPLE NEWS

provides calibration services for leak standards and vacuum gauges.

 NSF International Strategic Registrations Ltd. (Ann Arbor, MI) has appointed William Niedzwiecki president and general manager. With experience in the manufacturing, service, aerospace, electronics and automotive industries, Niedzwiecki will play an integral role expanding NSF-ISR management system registration services both domestically and abroad.

» Accuracy confirmed by NIST » NIST traceable » All models and ranges of leak standards

 Mike Martire has joined Hayward Turnstiles (Milford, CT) as welding supervisor, bringing 17 years of supervisory and fabricating experience in the security and automotive field to the role. Martire’s main objective will be to develop and fabricate new products for Hayward. Hayward Turnstiles is a manufacturer and distributor of turnstiles, ADA gates and railing.

» All manufacturers of vacuum gauges » Recall schedule provided with order Complete helium mass spectrometer leak testing services—both in-house and field.

Mike Martire

 Kevin Strack has joined MegaPhase (Stroudsburg, PA) as managing director of business development. He brings three decades of experience in RF/microwave cable assemblies and signal processing components serving customers in the electronic warfare, phased array radar, misKevin Strack sile, space and communication arenas.

ALL LEAK TESTING IS ASNT CERTIFIED.

www.heliumleaktesting.com 800-423-1701

 Thomas Kessler will advance to executive vice president of global sales of Edmund Optics (Barrington, NJ), follow-

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PEOPLE NEWS CONTINUED ing the planned retirement of Allan Kreutzer at the end of January. Kessler has been responsible for all of Edmund Optics’ European sales and distribution operations as vice president, European operations, from his office in Karlsruhe, Germany. He will assume the additional responsibilities of managing the company’s Americas and Asian sales teams as the company continues to aggressively expand its sales growth and standard product offerings.

 Robert Agnes has been appointed senior vice president of sales and field marketing at X-Rite Inc. (Grand Rapids, MI). In his new role he will oversee all sales and field marketing activities for the Americas and EMEA regions. He also will have responsibility for the company’s global OEM and global digital supply chain organizations and serve on X-Rite’s senior leadership team.

dinate measuring machines multidimensional metrology solution provider with more than 90 years of industrial metrology experience. Methods Machine Tool Inc. has been a supplier of precision machine tools, automation cells and machine tool accessories for more than 50 years, providing installation, parts, service and training through a network of technology centers and dealers throughout North America and Mexico.

GM TO INVEST $163M, RETAIN 184 JOBS DETROIT, MI—General Motors (GM) announced a $163.2 million investment in its operations in Flint and Bay City, MI, and Defiance, OH, to support engine production for the Chevrolet Volt, Chevrolet Cruze and a new Chevrolet small car to be built in the United States. The investment will protect 184 jobs at the three sites. The announcement brings the total of new U.S. investment to more than $3.3 billion, and GM has created or retained more than 8,000 jobs in 21 U.S. plants since emerging from bankruptcy in July 2009. The investments include: • Flint Engine Operations: $138.3 million and 135 jobs • Bay City components: $12.7 million and eight jobs • Defiance castings: $12.2 million and 41 jobs

Conference April 11-13, 2011 | Charlotte, NC Don’t miss the 2011 Quality Conference and the chance to tour the Joe Gibbs Racing facility. The tour is limited to the first 25 registrants. For more information, or to register, visit www.qualitymagconference.com.

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January 2011 | QUALITY QLT01114Unit.indd 1

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FAC E OF QUALI T Y

B Y J IM L . SMI T H

The Quality Profession Continues to Evolve The profession is moving into new areas of responsibility and expertise.

Jim L. Smith has more than 45 years of industry experience in operations, engineering, research & development and quality management. You can reach Jim at [email protected].

W

hen looking back on more than four decades as a quality professional, it is fairly easy to see the evolutionary journey that took place during this period. During the first decade or so, the role was one of inspection. At that time, we were focused on preventing any manufacture or shipment of products that didn’t meet the stringent requirements of the customer. We viewed ourselves as the organization’s customer representative. We were ready to do whatever it took to protect the organization’s quality reputation while delivering our customer a quality product. We were more police officers of the manufacturing environment with a significant percentage of the organization’s quality initiatives concentrated on this effort. During the next decade, the quality role began to shift from police officer to correction. Quality personnel began to help manufacturing. We worked with manufacturing to solve problems so they could produce higher levels of quality product. Alliances and partnerships were formed between manufacturing and quality groups as team experiences were shared. Quality personnel became instructors to help the organization learn problem solving and team techniques. Assistance was provided to identify and solve problems. We began to focus more on business type measurements and the identification of quality costs. We ensured that products were shipped on time while minimizing errors. Focus was less on control and more on total quality management (TQM). The next decade saw quality organizations focused on prevention, particularly with the guidance of professional staff. We drove the resurgence of fundamentals such as statistical process control (SPC), process qualification and supplier certification initiatives. Concurrent engineering surfaced which resulted in quality professionals becoming involved in product development, design reviews and release procedures. We focused on redesigning and reengi-

Quality professionals have had to learn new skills and continue to reinvent themselves.

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QUALITY | January 2011

neering processes to ensure they were capable of producing quality product. The global effort to “get back to basics” resulted in the deployment of the ISO 9000 requirements as customers were demanding commonality and assurance of quality processes. Old, outdated quality manuals were dusted off and revised to meet the new standards. Documentation became more important than ever and quality professionals were needed to ensure compliance. Quality organizations focused on process assurance with the objective of preventing errors and reducing product costs. Six Sigma was on the horizon and quality professionals were at the forefront. Six Sigma rushed ahead of TQM. This change in focus, if not overall approach, excited management. During the first decade of the 21st century, the quality profession is changing again. The profession is moving into new areas of responsibility and expertise. The quality professional’s tool box, in addition to the recognized quality tools, now includes strategic planning, knowledge management, portfolio management and organizational change management. Quality professionals are now assisting organizational management by focusing on the development of firm foundations rather than propping up activities that result from poor decisions or actions. No longer are quality professionals relegated to policing manufacturing or preventing errors, but they are instead ensuring that maximum value is provided to every customer and stakeholder. To fulfill this role, quality professionals have had to learn new skills and continue to reinvent themselves. We not only need statisticians in our organizations, we need experienced managers and project managers. Today, an effective quality organization considers itself a value-added service. Organizations realize the role these professionals play in their survival and consider the development of their quality organization to be a significant competitive advantage. The quality profession will continue to evolve and have a positive impact on everything within an organization it contacts.

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B Y H IL L C OX

Certificates of Confusion It seems to be more about paperwork than what that paperwork means.

Hill Cox is president of Frank J. Cox Sales Ltd. (Brampton, Ontario, Canada). He may be reached at [email protected].

B

eing a simple guy, I’m easily dazzled by many things in life. For example, I’m thunderstruck when airline crew warn me to turn off my cell phone, computer, Etch A Sketch or similar devices in case they interfere with the aircraft’s electronics. What amazes me about this is the thought that the airline has spent a gazillion dollars to buy the latest f lying technology that could be rendered inoperative by some kid with an iPod that didn’t hear or heed the warning. Of course, it could be that the warning is a lie and what it’s really all about is making sure passengers pay attention to the demonstration on how to fasten a seat belt. I really shouldn’t be that surprised with all of this because I see a similar situation in the quality field. Here’s how it goes: A company hires the appropriate consultants to establish a quality system to whatever standard is in vogue in its industry. After spending all this money to keep the quality of the products it produces up to expectations, the process then becomes one of ensuring everyone in the organization follows the rules. It’s rather like a government producing a new, specifically vague law with laudable goals, if that’s possible. The details required to make it work are left to the civil servants to interpret and apply by creating regulations that even the politicians who voted in favor of the law rarely understand. On the quality side of things, to the uninitiated like me, it seems to be more about paperwork than what that paperwork means—if anything. We can end up with the whole system failing because one piece of paper is not what it implies or the holders of it assume what it means. The most used document that falls into this category is the certificate of compliance, which is used when whatever it certifies cannot be verified after the fact. It’s a promise by the issuer of it that a specified process was followed. Too many people assume it can be used in place

We can end up with the whole system failing because one piece of paper is not what it implies...

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QUALITY | January 2011

of a calibration report for a gage or instrument, and that is not the case. Why? The certificate of compliance is a promise that simply claims “we did it right.” No proof is provided. A calibration report offers data to prove the gage is correct— or not. The key reason why these worthless bits of paper are so popular is because they cost the gage buyer nothing. They are the result of cost cutting by gage buyers who do not want to pay the price to get a proper calibration report from their suppliers. You can’t blame suppliers of this type of equipment for the problem. They work on the basis that if the customer is happy with a useless piece of paper and that is all that stands between them and an order, it’s cheaper for them to provide the paper. When you look at the situation generically, the gage buyer wants a gage with a piece of paper that says it’s good. If the auditor accepts it, all is well. Whether the gage is good or bad doesn’t matter so much as having the paperwork to please the auditor. What amazes me in all of this is the acceptance of such junk paper by quality auditors. I can see it all now. The wheels come off something, there’s a crash and some folks don’t survive it. After great study it is determined that the bolt thingie was to blame. The manufacturer claims it couldn’t be the bolt thingie because it was passed by a gage. And they know the gage was good because they have a certificate of compliance that says so. The systems people may not be able to sort it out, but you can be sure a lawyer will spot the weasel words in one of these certificates. The reason for this is that it was probably a lawyer who wrote or reviewed the weasel words in the first place. Unfortunately, this would be a rather expensive way to find out, particularly if it was during a product liability court case. Insurance companies are getting more interested in these matters of late when product liability coverage is involved. Their auditors may turn out to be more stringent than quality auditors and lawyers combined.

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Q UAL I T Y 101

 CAD chart overlay measurement has become one of the most popular ways to inspect samples. Source: Nikon Metrology Inc.

It should come as no surprise that as computers play a larger role in the design and manufacturing process in industry, computer programs designed to facilitate inspection become more prevalent, as well. To that end, CAD chart overlay measurement has become one of the most popular ways to inspect samples, thanks to its ease of use and the faster throughput it offers.

WHY IT WORKS

CAD Overlay Inspection Basics As the need for manufactured part inspection becomes more critical, automated inspection plays an increasingly important role. BY M I CHA E L K I RE YE V

A

s the design for industrial manufactured parts becomes more complex and the requirements more stringent, the demand for faster, more accurate and highly automated inspection becomes more urgent. The necessity for tools that aid in finding quick and correct results to problems has become increasingly important. For example, the design of fuel injection systems for internal combustion engines in automobiles has become more complex in recent years. This is due to industry requirements to design and manufacture cars with increased

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QUALITY | January 2011

fuel mileage, reduced emissions and greater efficiency. This trend toward more complex design is not limited only to the automotive industry, but is becoming more prevalent in other industries, such as aerospace and consumer equipment. While chart overlay measurement using traditional optical comparators might remain a core component of how engineers pass or fail manufactured parts, there is now a highly automated and precise option gaining traction in the field: computer-aided design (CAD) chart overlay measurement.

The use of CAD has a long-standing history in architecture and engineering. CAD overlay allows engineers to study a sample much like a blueprint, translating a sample into an onscreen rendering and allowing the engineer to view it within its correct dimensions and with tolerance lines. Unlike an optical comparator, which optically projects the part profile on a frosted glass screen, utilizing a dedicated overlay chart set at a specific magnification, a vision measuring system has the ability to digitally overlay any CAD file chart at varying magnifications and tolerance levels. This means that an operator can essentially get a digital rendering of the CAD file and study it overlaid against the actual sample. Vision measuring systems also have options to easily output quantitative data for statistical process control, and to record digital images that can be shared and studied anywhere they are needed. CAD overlay is flexible and can be used in multiple ways. With a vision measuring system’s high-resolution optics, an engineer can zoom in for a closer look, and the CAD overlay also zooms in along with it. Alternatively, one can zoom out for a larger view and the chart also zooms out, all while maintaining the calibrated magnification scaling. Chart overlay measurement with a conventional optical comparator is limited to a fixed magnification because the overlay charts are designed for a specific magnification. The magnification can be changed on the optical comparator by changing the objective lens. However, the size of the chart will

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not match. Additionally, the sample size will be restricted by the screen size of the optical comparator. For example, if a 10X objective lens is used on a 20-inch screen, the maximum sample size that can be displayed would be 2 inches. If one wants to traverse the part, he can manually drive—or automatically position—the vision measuring system’s stage, and the CAD chart moves with the stage’s translation. The vision measuring system digitally coordinates the CAD chart, the live digital image magnification and the stage position to produce a coordinated e-CAD overlay anywhere on the part. With an optical comparator, one would need to move the stage and manually perform a best fit to the chart. This is typically done at low magnification, which limits visibility and translates to reduced accuracy. If one simply needs an image, click the “capture” button and the image, with the overlay, is easily saved to the PC. The only thing that is required is a CAD file with the tolerance zone depicted. While several top equipment manufacturers make vision measuring systems, the goal of all metrology software programs—as well as the equipment systems that use it—is to create something compatible across a wide variety of industries that can be both easily learned by the individual and shared across teams. This ensures that the output can be sent to anyone who is taking part in the testing process, ensuring quicker response times for evaluating problems and issues.

Solutions such as CAD overlay allow teams to solve manufacturing issues in real-time. Source: Nikon Metrology Inc.

• Inspect. At each location, the operator can provide information such as deviation data, time interval and the ability to choose pass or fail. After images are stored, engineers can easily inspect the feature areas using traditional imaging software programs, such as Microsoft Paint or Windows Picture Viewer. This ensures that images can be passed among multiple operators for inspection without adding new software to his computer. Many programs also allow for multiple images to be stitched together, so operators can get a complete portrait of how multiple parts fit together and can then view them on the screen. As a final option, the results and accompanying data sets also can be printed.

CAD OVERLAY IN THE FUTURE In today’s global workplace, solutions such as CAD overlay allow teams—no matter where the individual members are located—solve manufacturing issues in real-time, which saves countless hours of manpower. The automation of CAD overlay means that repetitive and time-consuming tasks are reduced. At the end of the day, this type of streamlining results in bottom-line savings, which—regardless of industry—is a highly desirable outcome. Michael Kireyev is an application specialist at Nikon Metrology (Brighton, MI). For more information, e-mail michael.kireyev@nikonmetrology. com, call (847) 428-0980 x223 or visit www.nikonmetrology.com.

Flexibility

HOW IT WORKS For engineers already working with advanced computer systems, the process of using CAD overlay should be a familiar one. Programming of the system is easy and powerful and can usually be completed in few steps. For example: • Create a part coordinate system— also known as the reference points— at the same location as it is on the CAD file. • Open the CAD file. • Set up the tolerance zone. • In the chart measurement window, denote deviations from nominal or tolerance zones.

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Place the KineScope over your part and view fine detail on your monitor at 40-140x. Flexible. Compact. Simple. Powerful.

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Q UA L I T Y I NNOVAT I ONS

 The ColorRanger provides quality inspection and grading based on both 3-D shape and color. Source: Sick

3-D Inspection in

Color The ColorRanger E combines color and 3-D in a single high-speed camera. BY K A RI O’ROURK E, MANAG I N G E D I TO R

A

t the Vision show in Stuttgart, Germany, last year, a jury consisting of machine vision experts choose the ColorRanger E from Sick AG (Waldkirch, Germany) as the winner of the prestigious Award for Applied Machine Vision, which recognizes outstanding products or processes. This multi-imaging solution combines color and three-dimensional (3-D) capabilities in one high-speed camera, eliminating the need for multiple cameras and reducing the overall cost of hardware and integration. The calibrated 3-D data provides measurements in real-world units such as millimeters, which alleviates much of the complexity of calibrating the system in the field. “The major advantage of the ColorRanger 3-D camera is the ability to simultaneously acquire high resolution 3-D height data along with redgreen-blue (RGB) color data with one camera,” says Jim Anderson, vision product manager, Sick. “The camera

uses a multiscan technique to get multiple images from one camera and at a high rate of speed. In the case of color and 3-D data, the ColorRanger can acquire it at a rate of 11,000 scans per second.” Depending on the application requirements, the multiscan technology offers different measurement configurations for 3-D shape, RGB color, monochrome, contrast and laser scatter with a light source for each component that provides the suitable light characteristics. When using the multiscan setup, the image quality of each measurement can be tuned independently with its own set of parameters. According to Anderson, the ColorRanger helps customers overcome many of the obstacles that normally face multicamera vision systems. Because all of the images are created from a single camera, the alignment of images and timing of the system becomes a more manageable task.

Also, the data is in a format that works with several leading machine vision software packages, making the analysis a procedure that operators and integrators will be familiar with even though they are now working with 3-D data as opposed to two-dimensional (2-D) grayscale. The concept for the ColorRanger was a result of listening to customers and taking a look at the industry need for a high-speed 3-D camera that also provides high-quality RGB color images. While there are other systems available in the 3-D scanning market, they incorporate multiple cameras that capture different data components, for example, a line scan color camera and a separate camera for 3-D laser triangulation. Anderson says that more components create more points of failure and add to the complexity and potentially the size of the overall scanning system. So far, the ColorRanger has been well-received and customers who have traditionally been using only 3-D systems are starting to look at how to incorporate the color data to enhance the functionality of their systems without major redesigns. Since the multiscan technology is flexible, the ColorRanger can be used in a variety of applications by editing the configuration file. Potential applications that use color imaging and 3-D include wood processing, quality assurance of electronic assemblies and fill and color verification in pharmaceutical production. For more information, contact: Sick 6900 W. 110th St. Minneapolis, MN 55438 (952) 829-4728 www.sickusa.com

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50 Y e ar s of Qualit y This is a picture of the venerable optical comparator from patent number 1,903,933, filed May 21, 1925. The fact that a modern comparator appears little different from one patented 85 years ago might raise several questions about their relevance. Source: Hexagon Metrology

make taking measurements easier for the operator. A good analogy for the principle behind an optical comparator is that it is somewhat similar to the old-school overhead projector. In fact, one can make a rudimentary comparator device with an actual overhead projector. First, place any two-dimensional part on the stage of any overhead projector and project the image onto a large piece of paper taped to a wall. The resulting shadow projected on the paper can be outlined with a pen. This pen outline becomes the reference to compare to any subsequent objects placed on the stage. If the parts do not match the drawing, they are not the same.

The Pros and Cons of

Optical Comparators BY BI L L FETTER AND G ARY H O B AR T

T

he illustration pictured here should appear familiar to anyone who has spent any time in a quality control lab or on a factory floor. This is a picture of the venerable optical comparator from patent number 1,903,933, filed May 21, 1925. The fact that a modern comparator appears little different from one patented 85 years ago might raise several questions about its relevance.

The reason comparators have not changed much in 85 years is that the fundamental technology behind an optical comparator is elegantly simple, and it simply works. Since the physics behind optics have not changed, the only possible improvements in comparator technology will revolve around the quality of the optics themselves and the features added to the comparator to

PROJECTION BASICS As a practical matter, we cannot really use an overhead projector to check parts. For one thing, if a projector is sitting on a cart, as most are, what happens if the cart is bumped or moved? The projection distance changes slightly, and as a result, the size of reference image on the wall is no longer accurate. The basic concept of an optical comparator for quality control use is to take that idea of the overhead projector and package it all up inside a box so that the optical distance between the part and the screen is fixed, known and can be calibrated. A part is affixed to a stage, a light source shines on it, and the resulting shadow image of the part is magnified with lenses and bounced by mirrors, to be projected on the back of a screen for

PAY NO ATTENTION TO THE MAN INSIDE THE COMPARATOR Gary Hobart recalls an encounter from many years ago when he was servicing a monster 60-inch screen comparator. To adjust the optics inside a comparator, one had to open up the enclosure and work on the mechanism inside. With a comparator this large, one had to physically climb inside the enclosure to

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QUALITY | January 2011

work on it. An unsuspecting quality inspector switched on the comparator to use it while Hobart was inside. The blinding light made Hobart scream and stand up, hitting his head on the roof of the enclosure, while the stunned inspector screamed a the sight of a shadowy figure of a man on the comparator screen.

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This optical comparator was manufactured by Jones & Lamson, (J&L, Springfield, VT). Optical comparators were developed by James Hartness, president of J&L, and Russell Porter, architect, engineer and astronomer who worked closely with Hartness. Source: American Precision Museum

magnified viewing, pretty much just like the overhead projector example. Based on the known magnification of the lenses, measurements of the part can be made directly off the screen, traditionally using a screen overlay or crosshairs as the reference point for projected points or edges. The operator centers a feature of interest on the crosshairs, records a point, then moves the image and records another point. It is a process of taking multiple points that allows features such as circles, slots, radii and edges to be constructed mathematically. Typically this is done via a microprocessorbased digital display. The size and magnification of the projected image on a comparator is dependent on the optics and screen size of the comparator itself—typical screen sizes range from 12 inches to 36 inches but ones up to 60 inches have been built. However, the larger the screen size, the larger the enclosure becomes because a greater distance is required to throw the image. A comparator with an enormous screen is basically a giant, mostly

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The advantage of a comparator is that it is straightforward to use for simple operations with relatively little training. Source: Hexagon Metrology

empty box used to inspect small parts, as explained in the sidebar, “Pay No Attention to the Man Inside the Comparator.”

STRAIGHTFORWARD, EASY-TO-USE The advantage of a comparator is that it is straightforward to use for simple operations with relatively little training. On the simplest comparator, an operator merely has to affix a part and move it with hand controls and observe the onscreen image. Advances in technology, such as computer displays that do the math automatically and remember all measured points, automatic triggering technologies and improvements in stage movement all have contributed to the venerable comparator continuing to serve a useful function in a quality lab. If one reason for the continuing popularity of comparators is their basic simplicity, this also is their downfall. As production parts become ever more complex, with more features to inspect to greater tolerances, with higher sampling rates or even 100% inspection, the advantages of the traditional comparator diminish significantly. The rise of vision-based inspection systems makes manual

comparator technology, even equipped with modern capabilities, seem quaint in comparison. This is particularly the case when the requirement is to inspect large quantities of parts at once, where the automation capabilities of a vision system make it the winner in speed and flexibility. Automatic moving stages, computer-aided design (CAD) programming capability, the ability to use multiple lighting techniques and 3-D inspection capabilities greatly surpass the limitations of traditional comparator technology. So why would anyone still choose a comparator? For many simple, nonrepetitive tasks on two-dimensional parts with clearly defined edges, the optical comparator is still a great tool to have in the toolbox. As with any applied technology, knowing the correct tool to use and when to use it is essential. Bill Fetter is the director of marketing for Hexagon Metrology Inc. (North Kingstown, RI) and Gary Hobart is a sales manager for Vision products. For more information, call (847) 214-5234, e-mail [email protected] or visit www.hexagonmetrology.us.

January 2011 | QUALITY

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QUA LIT Y M EA SU REM E N T

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Driving to the Finish M

oving gaging to the point of manufacture is the process engineer’s dream. It is what drives productivity on the shop floor, puts quality in the hands of the machinist and quickly weeds out process problems before they become catastrophic. This is not only true of dimensional hand tools and gaging, but of surface finish gages, as well. Different, but similar to dimensional tools, surface finish hand tools are more important than ever with today’s strict manufacturing requirements. There is a strong similarity between dimensional handheld gages and portable surface finish gages. With

The automotive industry has special needs that make Th dedicated surface finish gages a necessity. B Y G E O R G E S CH U E T Z dimensional handheld gages there are two classes: general purpose hand tools and dimensional gages that are more dedicated to a specific task. Each has a specific purpose. Hand tools, such as calipers and micrometers, are great for versatility and can provide good results for many departments, from incoming inspection to dimensional part inspection on low-volume runs. For best results they require a skilled operator and time to

ensure they are aligned properly and applied with the proper gaging force. But if making a high volume of parts with tight tolerances, and the machinist does not have the skills of a trained quality inspector, then dedicated dimensional gaging is the better choice. These gages are made for a specific dimension so they are faster, easier to use and produce results with better performance and gage repeatability and reproducibility (GR&R). With a

 Surface finish parameters can be applied to virtually any surface on the part, from inside a small bore, on a short land, around a hole, to an outside diameter between two walls or even on those side walls.

 The need for fast and reliable surface finish measurement has created a whole family of dedicated gages, designed to put the fast, reliable surface finish analysis in the hands of machinists at the point of manufacture.

TECH TIPS  With a dedicated gage, virtually any operator can easily inspect machined parts and make decisions about their quality.

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www.qualitymag.com

 Cylinder bores were probably the first feature to have dedicated gaging designed for measuring surface finish. Characteristics include bores of various sizes which can be relatively deep, some up to 8 inches. The prints may call out specific depths and locations for checks, and with up to 12 cylinders in some blocks and four in a vast majority of high volume applications, there are a lot of bores to measure. Source: Mahr Federal Inc.

dedicated gage, virtually any operator can easily inspect machined parts and make decisions about their quality. They can even collect the results for process analysis and control.

reliable results for many applications. Simply place the pocket-sized gage on the part so that its built-in rest pads locate it in place, press a button and the results pop up, ready to be compared to the requirements.

DEDICATED PORTABLE SURFACE FINISH GAGES But sometimes it is not that easy. Surface finish parameters can be applied to virtually any surface on the part, from inside a small bore, on a short

PORTABLE SURFACE FINISH GAGES Beginning some 25 years ago, portable surface finish gages—some small enough to fit in a shirt pocket— brought a new level of part control to the manufacturing floor. Bringing surface finish inspection out of the lab and onto the floor was important for several reasons. For the previous 50 years, part dimensional tolerances had been shrinking. As a result, surface finish and form irregularities were eating up an ever-increasing portion of overall dimensional tolerance, a trend which continues today. Also, it became clear that surface finish played an important role in the performance of the part. The unique characteristics of a surface could determine whether the paint stayed in place, lubrication held or leaked, or how much noise was produced when surfaces moved against each other. With proper locating and fixturing, these small portable surface finish gages could measure surface finish parameters easily and usually with the touch of a single button. Like dimensional hand tools, the general-purpose portable surface finish gage provides easy to use and

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For these requirements, a special template is made that sits on the part to be measured. The template can only sit on the part in one orientation and provides the operator with the locations to align the matching surface waviness gage. Source: Mahr Federal Inc.

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land, around a hole, to an outside diameter (OD) between two walls or even on those side walls. These all have to be measured at a high rate of speed and in a dirty manufacturing environment by a semi-skilled operator. Now, these parts could be taken to a special surface gaging station. They could be located in a position where the portable surface finish gage could access the part, and the gage placed

gently on the part with the operator taking time and care to locate the sensitive probe on the feature without damaging it so a measurement could be taken. But this process would take a lot of time. In the interim, many additional parts would have probably been made, and given the delicate nature of surface finish probes, a goodly inventory of broken probes produced, as well.

The engine block is by far the largest and perhaps the most complicated part of an engine. There are literally thousands of dimensional checks to be made on blocks, along with many critical surface finish and surface waviness call-outs.

Thus, as with the dedicated handheld dimensional gage, the need for fast and reliable surface finish measurement on such parts has created a whole family of dedicated gages, designed to put the fast, reliable surface finish analysis in the hands of machinists at the point of manufacture—often while the part is still fixtured in the machine tool.

Like dimensional hand tools, the general-purpose portable surface finish gage provides easy to use reliable results for many applications. Nowhere have these requirements become more aligned than in the automotive industry. Automotive has special needs that make dedicated surface finish gages a necessity. These include a high volume of parts, the need for fast and reliable measurements by machinists semi-skilled in dimensional measurement, and more and more

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made on blocks, along with many critical surface finish and surface waviness call-outs. These surfaces include cylinder and crankshaft bores, along with deck, pan rail and front faces. It is clear how the finish in these applications is critical. Cylinder bores need specific finishes to balance retaining oil and smooth axial movement, while decks and other mating faces need to be flat and smooth to provide good sealing.

Cylinder bores were probably the first feature to have dedicated gaging designed for measuring surface finish. Characteristics include bores of various sizes, which can be relatively deep, some up to 8 inches. The prints may call out specific depths and locations for checks, and with up to 12 cylinders in some blocks and four in a vast majority of high-volume applications, there are a lot of bores to measure.

requirements for surface finish checks to ensure part quality and eliminate the high cost of part recalls. For gaging purposes, automotive engine components can be classified by portability. There are parts that can be brought to a gage and those where the gage has to be brought to the part. Pistons, connecting rods, cam shafts and transmission gears, for example, are all small and easy to bring to a dedicated gaging station where an operator can quickly assess the required surface finish. Then there are components that are not that easy to move around, such as engine blocks, cylinder heads and crankshafts. Moving these from a machine to a work bench is hard enough, but trying to precisely align a portable surface finish gage onto a short land without damaging the sensitive probe is nearly impossible. Thus, the need for dedicated hand gages to assist the operator in making these important checks. Systems are available for each of these major components.

THE ENGINE BLOCK The engine block is by far the largest and perhaps the most complicated part of an engine. There are literally thousands of dimensional checks to be

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easy • accurate • automatic

Save Costs Reduce Scrap Avoid Unnecessary Repairs and Rework Air operated, the journal surface finish gage allows for setting the locking jaws to the approximate size, then with manual air actuation, the gage locks itself into position and releases the probe to contact the part. As with all these gages, the probe does not make contact unless the gage is fully locked into place. Source: Mahr Federal Inc.

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QUALITY | January 2011

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The main factors for use are ease in positioning and fixing the gage location and probe protection. The waviness hand gage does all of these. The template sets the proper location, mating pins ensure it is locked in place, and a mechanical transfer protects the probe until the gage is in location and placed on the fixture. Source: Mahr Federal Inc.

Therefore the gages need to be highly portable and easy for the operator to align and set to depth. The design also has to protect the sensitive probe so it does not get damaged when bringing the gage to the part. The dedicated portable surface finish bore gage is much like an expandable tri-bore gage. The tri-bore has a certain amount of size adjustment, but can be set to a specific size. This allows it to lock in place and helps provide repeatable readings with no operator inf luence. The indicating device also is protected by a transfer mechanism so there are no locating forces applied to it when the gage is placed onto the part. The surface finish cylinder bore gage borrows the same principles. To give it adjustability to lock into various sizes, interchangeable plates are used to achieve the right measuring range for the diameter. Setting the gage with the right set of blocks allows easy entry into the cylinder bore, and

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Micro•Vu

Just as important as the bearing and crank journals are the thrust faces they ride against. Another snap gage concept is used to position the surface finish probe here, and with the same thoughts in mind: easy to use, no operator influence and protected probe positioning. Source: Mahr Federal Inc.

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once in place, a manually controlled air cylinder expands the sizing blocks so they lock the gage into position. The clamping force is such that an operator can virtually pick up the block with the gage, although this should only be done by serious weight lifters. But the gage’s cylinder has another, even more critical function. When compressed with no air applied, it holds the sensitive surface finish probe in a retracted position. This means that during insertion the probe is protected inside the body of the gage. After the operator is satisfied with the gage location, he applies the air, locks the gage into position and the probe extends so he can make the surface test. When done, the air is released, the probe retracts and the gage becomes free, allowing easy removal by the operator. Other bores in the block are not as large as cylinder bores but also require shop floor surface measurement. Here another tack can be taken. Again borrowing from the world of precision dimensional hand gaging, a take-off on the fixed mechanical plug can be incorporated. With this type of gage, the mechanical body of the plug is made to measure a specific bore size. Thus it is fast, self centering, and there is no operator influence. The same concept can be used for a portable surface finish gage. In this case, a plug body, made close to the bore size being measured, incorporates a surface finish probe. But unlike a

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Other bores in the block are not as large as cylinder bores but also require shop floor surface measurement. Here another tack can be taken. Again borrowing from the world of precision dimensional hand gaging, a take-off on the fixed mechanical plug can be incorporated. Source: Mahr Federal Inc.

fixed mechanical plug, which always has its contacts touching the bore, the surface finish version retracts the probe until a mechanical transfer mechanism releases the probe when the plug is in its final measuring position. Also, like a snap gage or fixed body bore gage, masters are part of the gaging routine since they are comparative measurements. With surface gages, a reference standard is used to verify the system and probe performance. In this case, a holder for the reference specimen simulates the part and places the reference specimen at the proper location to easily perform calibration throughout the day.

THE HEAD Deck face surface finish and waviness is important because it prevents oil from leaking between the mating block and head surfaces. Often specific locations are called out on the part prints for surface checks. This concept is similar to building air tooling where the jets are set to specific locations and orientations to ensure that the operator measures the parts at the proper place every time. For these requirements, a special template is made that sits on the part to be measured. The template can only sit on the part in one orientation, and provides the operator with the locations to align the matching surface waviness gage. As with the cylinder bore gage, the main factors for use are ease in positioning and fixing the gage location, and probe protection. The waviness hand gage does all of these. The template sets the proper location, mating pins ensure it is locked in place, and a mechanical transfer protects the probe until the gage is in location and placed on the fixture.

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With this type of gage, the mechanical body of the plug is made to measure a specific bore size. Source: Mahr Federal Inc.

THE CRANKSHAFT Surface finish is critical on a crankshaft. Rotating at thousands of RPMs, and with bearing and crank surfaces and their end faces in metal-to-metal contact, there is tremendous potential for wear. Surface finish helps determine the life of these products. Looking to dimensional hand tools yet again, the variable snap gage is one of the most shop-worthy gages used in the

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QUALITY | January 2011

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Deck face surface finish and waviness is important because it prevents oil from leaking between the mating block and head surfaces. Often specific locations are called out on the part prints for surface checks. Source: Mahr Federal Inc.

precision manufacturing environment. It can be used over a long size range, but is set to the specific size being measured. A similar concept is used when measuring surface on crank journals. The surface finish gage has to be adjustable for various sizes, has to lock in place, and protect the probe. Air operated, the dedicated journal finish gage allows for setting the locking jaws to the approximate size, then

The variable snap gage is one of the most shop-worthy gages used in the precision manufacturing environment. with manual air actuation, the gage locks itself into position and releases the probe to contact the part. As with all these gages, the probe does not make contact unless the gage is fully locked into place. The key difference with this gage is that it has a traverse probe operation so that the probe moves horizontally along the crown of the part. Just as important as the bearing and crank journals are the thrust faces they ride against. Another snap gage concept is used to position the surface finish probe here, and with the same thoughts in mind: easy to use, no operator influence and protected probe positioning. Q George Schuetz is director, precision gages at Mahr Federal Inc. (Providence, RI). For more information, e-mail [email protected] or visit www.mahr.com.

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Data Leads to

Good Leak Test Decisions L

eak testing is an important and widely deployed nondestructive test methodology used by many manufacturers to assess the quality of fabricated parts. The fact is that nothing is 100% sealed; everything leaks, whether it is supposed to or not. The challenge for manufacturers is to determine whether the leakage is acceptable from product quality and regulatory compliance perspectives. The majority of leak testing systems that are available today focus primarily on determining a single value that characterizes whether the leak rate is

Through the adoption of new leak testing approaches that provide comprehensive data about the entire leak test cycle, manufacturers can get more out of their leak test. BY BRU C E TAK ASAK I

acceptable under internal standards and regulatory directives. While this traditional method may detect 80% of the typical defects, the other 20% will typically represent 80% of the after sale warranty cost impacts. Manufacturers also need to be able to determine the cause or origin of the

leak, which is not possible with just the leak rate figure. More data must be collected and then analyzed in order to determine the characteristics of the leak. Unfortunately, most systems are not set up to gather the necessary data, nor do they offer detailed analysis of the leak characteristics.

TECH TIPS  Everything leaks. The challenge for manufacturers is to determine whether the leakage is acceptable from product quality and regulatory compliance perspectives.

 Optimizing an existing conventional system means that the test provides the best compromise between accurate defect detection and test time.

 One effective methodology that captures the complete characteristics of the leak is process signature verification.

 By implementing or upgrading to a system that decreases leak test cycle time, the manufacturer does not have to invest in additional stations or absorb the cost of maintaining and manning additional test stands.

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deviate from the standard. Why did one part pass and another fail? If a part has been shipped and is deemed defective after it is in use, yet it reached the desired endpoint of testing, where did it go wrong and why? What additional information about the leak characteristic is required in order to determine the root cause of the quality issue? In a perfect scenario, the manufacturer has complete visibility into

Leak testing is used in many industries, from engine assembly to medical device manufacturing. Source: Sciemetric Instruments

its manufacturing processes and can pinpoint specific variables that impact part quality as each part is tested. Most of the specialized leak testers on the market are focused on determining the leak rate through capture and analysis of a few precise moments of the test. But what if there were anomalies that took place at other points, due to noise or disturbances, for example, not captured by the test? Those defects

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Through the adoption of new leak testing approaches that provide comprehensive data about the entire leak test cycle, manufacturers can get more out of their leak test.

TAKING THE OLD STANDARDS TO A NEW LEVEL The efficacy of a manufacturer’s leak test is determined by a number of factors, including the condition of the test setup, how long the test cycle takes, how much information the test provides, whether all parts are being tested or if just a statistically representative sample is being collected, and whether manufacturers can determine from their test not only the leak rate, but the characteristics of the leak and what caused it. How well the test setup is working can greatly impact the results. Take, for example, pressure decay leak testing where the part being tested is filled with air or some alternative gas and then monitored as the gas leaks, measured in standard cubic centimeters per minute (sccm). If the reservoir was not filled to the correct pressure, the assumed pressure differential would be incorrect, rendering the test result inaccurate. Inaccuracies like this can be the result of a test system not functioning properly—for example, the inlet hose was crimped or damaged— resulting in a pass, but the part would not have been properly tested. The key determinant of a test’s overall effectiveness is how much information the test provides. With limited data, one has limited insight into results that

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would not be caught and faulty product could still make it to market. By capturing the full leak test pressure curve including fill, stabilization, decay and exhaust, manufacturers can recognize anomalies in a leak pattern and use that data to determine their cause. Optimization of the test setup is crucial to getting accurate results. Manufacturers are tasked with picking the right portion of the decay curve

to get a repeatable and consistent leak rate measurement and establishing the right limits to ensure an accurate and reliable test, with the shortest possible cycle time. Generally, the early part of the decay curve will show more variability and, therefore, will result in a less repeatable measurement, but waiting until later means a longer test. Balancing the two to come up with the best trade-off

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(A) The inside of a single channel leak test unit is connected to a control unit that measures, stores and analyzes the leak characteristic as shown in (B). Source: Sciemetric Instruments

between cycle time and repeatability is up to the manufacturer. Whether this test optimization is an iterative, timeconsuming process, or one that can be achieved in a software environment in a matter of a few days, is determined by the system itself, which will be explained in more detail.

INSIGHT AT EVERY STEP One effective methodology that captures the complete characteristics of the leak is process signature verification. Every manufacturing process produces a signature, a waveform that represents the characteristics of that process from start to finish. Any deviations from the norm, regardless of whether or not the part met the desired endpoint of the test, are readily identified and root causes easily determined by examining the process signatures. This approach is effective in most testing situations, with applications for myriad other tests such as weld, press fitting, crimping, torque, sound and vibration, and functional testing. Consider again the example of the incomplete fill cycle. This would only show up as a change in the shape of

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QUALITY | January 2011

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the fill pressure curve, which is not normally monitored. Furthermore, the shape of the fill curve can indicate where the problem is occurring. For example, the seals between the test station and the part being tested can become worn and start to leak in spurts, causing sudden, quick changes in pressure. In contrast, a blockage or poorly drilled opening in the part will change the slope of the fill curve but without the sudden changes described above. The complete manufacturing process is captured using both hardware and software components. Hardware on the production floor collects the process signature, then analyzes it to provide real-time pass or fail judgement, while simultaneously sending data to a database that stores the information. This capture and storage of comprehensive process data supports regulatory compliance, enables selective recalls (if required), and supports the optimization of test parameters in a modeled environment, among other benefits. Being able to store and re-analyze historical leak test data in software eliminates the need to optimize the test parameters using a live, iterative approach. The key to this approach is having a software package that uses the entire waveform, and not just single point values. The end result is a leak test that provides accurate and repeatable defect detection, while minimizing test time. Whether to optimize existing test systems or adopt a new one must be a well-examined decision. Manufacturers can be challenged by the need to meet increasing throughput requirements, particularly if their leak test stations are creating bottlenecks due to lengthy cycle times. Many feel that in order to accommodate their increasing volume, they need to either invest in additional test stations or improve the throughput of their existing leak test method. Optimizing an existing conventional system means that the test provides the best compromise between accurate defect detection (including avoiding false fails) and test time. The downside is that no matter how optimized the test cycle is the test still provides limited or no information for identifying root causes for leakages and may

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still miss some failure modes altogether. Also, it will take much longer to optimize the system without signature storage and analysis. By implementing or upgrading to a system that decreases leak test cycle time, the manufacturer does not have to invest in additional stations or absorb the cost of maintaining and manning additional test stands. Or, for the same amount of test stands, enjoy

a significant increase in productivity. An attractive return on investment for making the switch to a better method is quickly realized.

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January 2011 | QUALITY

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BALL GAGE INSTEAD OF A CYLINDRICAL PLUG GAGE. Save time with the self centering spherical surface of the ball gage. When measuring a large number of holes it can be 100 times faster. Put one or two flats on the ball and find any out-of-round holes. Measure how parallel the space is between two surfaces and or the size. You can get into inside diameters or inside spherical surfaces of rod end bearings.

This screenshot from an advanced leak tester shows the fill, stabilization decay regions of the curves. The blue rectangle indicates where the fill pressure is measured, while the green rectangle and green triangle illustrate where the leak rate is evaluated. Source: Sciemetric Instruments

Bend the stem to reach inaccessible

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confined areas, down in a hole, inside a cavity or in a buried feature which cannot be seen. Mount the ball on a wire for flexibility to go around corners in pipe and tubing, for example. Easily measure the width of grooves or the surfaces of spherical and toroidal features. Accurately

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pitch diameter of bearing races, threaded surfaces and of gears. Bal-tec Division Micro Surface Engr., Inc. 1550 E. Slauson Ave Los Angeles, CA 90011 323-582-7348 www.precisionballs.com

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QUALITY | January 2011

ities are integral to avoiding irreparable brand damage and millions of dollars in penalties and legal settlements. Manufacturers are wise to use test systems that provide them with the information necessary to rectify quality control issues before hundreds or even thousands of faulty products are produced. Effective systems can provide competitive advantage and support regulatory compliance. Manufacturers should be aware that without a system that provides comprehensive information about manufacturing processes that can readily determine what caused a problem, they can be faced with lengthy and expensive shut downs until the root cause is determined and rectified. In the case of industries with stringent regulatory considerations, such as the medical field, corrective actions required by regulatory bodies could result in significant losses. The are several benefits that arise from having more insight into a leak testing and having more leak test data at one’s disposal. With the complete leak test waveform available for analysis, it is possible to identify and diagnose failure modes that might otherwise go undetected, enabling the development of additional fea-

ture checks to minimize downstream failures. These can then be applied in real-time on the manufacturing f loor, instantly improving downstream yields. The data also can be uploaded to analytical software, where the impact of test parameter changes can be simulated in minutes. This allows for the rapid optimization of pass/fail criteria, minimizing commissioning times and ensuring maximum yields. Use of process signature technology that provides comprehensive data about the leak test offers manufacturers significant benefits that impact the bottom line. Investment in modern leak test technology delivers a quick ROI, supports compliance initiatives, improves productivity and ultimately, improves product quality. Q Bruce Takasaki is a product marketing manager for Sciemetric Instruments (Ottawa, Ontario, Canada). For more information, e-mail brucet@ sciemetric.com or visit www.sciemetric.com.

QUALITY ONLINE For more information on leak testing, visit www. qualitymag.com to read the following: • “Choose the Right Seal” • Quality 101: “Leak Testing: Calibration Matters” • “Trace Leaks with Hydrogen Gas”

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An advantage of using a laser in production test applications is the laser can be aimed in such a way that the normal act of mounting the part in the test fixture is all that is necessary to position the part to ready it for the vibration measurement. There is no need for expensive automatic robotic arms or manual attachment of the sensors. Source: Polytec Inc.

Laser Doppler

Vibrometers Rewrite the Book T

here are many ways to measure vibration, but when the item to be measured is very hot, very cold, small, easily damped, requires a large number of measurement points, is vibrating at ultrasonic frequencies or is physically inaccessible, collecting the data becomes much more challenging. Laser doppler vibrometers are extremely accurate and are an excellent tool to address any of these situations. The laser doppler vibrometer is increasingly finding its place in R&D labs, the finite element analysis (FEA) verification process, the quality control department, on the production floor and as a maintenance tool. Laser doppler vibrometers are accurate enough to be used as a calibration reference

Laser vibrometry is rewriting how today’s engineers measure vibration in the lab, on the production floor and in the field. B Y G R E G G PAL O MBO source, and with a frequency response range starting just above DC and with the ability to measure up to 1.2 GHz, they have a wide range of uses. Laser light does not have a resonant frequency so laser vibrometers have a flat response curve, and because they only touch the measured object with a light beam, it does not matter if the target object is hot, cold or easily damped. With a scanning vibrometer, hundreds or thousands of data points can be measured far quicker than using any

other method, and if the part is small, the laser can be routed through a lens (similar to a magnifying glass) or even through a microscope to measure on microscopic objects.

PRODUCTION TESTING In production testing the part under test must be easily indexed to the next part coming down the line. Wires and cables often become a maintenance issue particularly if they must move with each part change. Shocks to other

TECH TIPS  Single point industrial vibrometers are used in production testing because of their long life, accuracy and two-year calibration cycle, but mainly because they are easy to design into the test process, easy to install and easy to set up.  An advantage of using a laser in production test applications is the laser can be aimed in such a way that

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QUALITY | January 2011

the normal act of mounting the part in the test fixture is all that is necessary to position the part to ready it for the vibration measurement.  Laser vibrometers are portable, can measure from a safe distance and can measure directly on bearing housings or on a rotation shaft.

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Precision is Our Business.

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QUA LIT Y T EST & IN S P EC TI O N

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The scanning laser not only outputs highly detailed data that traditional strain gages cannot match, but it also can measure well above the maximum temperatures where strain gages fail. In this demonstration, 1,122 data points were placed on a test sample that is 1.5 inches high and 3∕8 inch wide, where the main area of interest was ¼ inch wide and ½ inch high. Measurements were taken at room temperature to prove the values matched strain gage values. The part was then heated to 850 C to collect the data desired. Source: Polytec Inc.

vibration sensors during mounting can result in damage to the sensor. The tradeoff between making a machine that can easily load and unload the parts for testing normally has an indirect relationship with how easily

Seeing the entire part move in high definition, as opposed to seeing just data or seeing a few points of interest, adds a whole new level of understanding to the data. Manufacturers of hard disk drives have been using this data to optimize the design of the cantilever arm that holds the read-write head. Source: Polytec Inc.

the sensor can be mounted. This is not true for laser vibrometers as they require no contact. Single point industrial vibrometers are used in production testing because of their long life, accuracy and two-

year calibration cycle, but mainly because they are easy to design into the test process, easy to install and easy to set up. An advantage of using a laser in production test applications is the laser

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can be aimed in such a way that the normal act of mounting the part in the test fixture is all that is necessary to position the part to ready it for the vibration measurement. There is no need for expensive automatic robotic arms, or manual attachment of the sensors. Lasers are the sensor of choice for this type of application because the only thing that touches the part is a light beam. If necessary, the laser can even be aimed through a window into a test chamber. This light beam can be aimed at a small target area that is in a confined space and it will still measure accurately. The laser’s ability to measure is not affected by the texture of a rough casting such as a turbocharger housing or engine block for a car, or by smooth surfaces such as an injection molded pump housing for a washing machine or a dishwasher. Measuring for excessive vibration on the production floor as a pass/fail stage is just one application. There are many products that require a specific vibration frequency and amplitude

for the product to work correctly, such as ultrasonic welders, vibrating razors, ultrasonic scent or medical dispersion systems, and vibrating surgical instruments. Vibration measurement can be added at any stage in the production line, without changing how the line operates, making it an advantage of using lasers in production environments.

FIELD MAINTENANCE ANALYSIS Predictive maintenance requires moving from one measurement data location to the next quickly and collecting valid data. If any of these data locations are in areas that would be dangerous to access when the machinery is operating, the solution traditionally involved installing multiple permanently mounted sensors. It does not take long for the price of the sensors, cables, switchboxes and labor to become a major expense. Laser vibrometers provide a solution because they are portable, can measure from a safe distance and can measure directly on bearing housings

or on a rotation shaft—something an accelerometer cannot do. The measuring principle of a laser doppler vibrometer dictates that it cannot measure shape; this comes in particularly handy when measuring on a rotating shaft. This means the shaft can have scratches, be out of round or even have rust on the measuring surface, and the laser will ignore these physical flaws in the shaft and will only measure the shaft motion.

R&D LABS Laboratory use of laser vibrometers normally involves a scanning vibrometer. The scanning vibrometer is essentially a single point vibrometer that utilizes galvanic mirrors to redirect the laser beam to different measurement locations. The scanning vibrometer allows a grid containing hundreds or thousands of measurement points to be placed on a part and then measured automatically, providing discrete data and visually modeled ODS images so the operator can quickly and easily see how the entire part moves.

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Because lasers do not touch the part, no dummy weights are needed; therefore, the part is measured in its real condition and no mass damping takes place. The time required to measure 6,000 points is now less than one man day, making high resolution measured data that looks like finite element models, now possible. Source: Polytec Inc.

Seeing the entire part move in high definition, as opposed to seeing just data or seeing a few points of interest, adds a whole new level of understanding to the data. Manufacturers of hard

disk drives have been using this data to optimize the design of the cantilever arm that holds the read-write head. Manufacturers of home appliances such as washers, dryers and dishwash-

ers use this data to make their products quieter. Companies that manufacture circuit boards use this data to improve the layout of their boards, particularly when these boards contain motion sensors or are experiencing wire bonds that are breaking. A 3-D scanning laser uses three lasers measuring at exactly the same point to measures in-plane as well as out-ofplane movement. The in-plane motion can be used to calculate dynamic stress and strain. This is helpful when trying to characterize the dynamic strain of high temperature alloys. The scanning laser not only outputs highly detailed data that traditional strain gages cannot match, but it also can measure well above the maximum temperatures where strain gages fail, for example, >800 C. The combination of these two advantages makes this a tool for measuring stress and strain on new alloy materials. In a demonstration of this capability, 1,122 data points were placed on a test sample that is 1.5 inches high and ⅜ inch wide, where the

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QUALITY | January 2011

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main area of interest was ¼ inch wide and ½ inch high. Measurements were taken at room temperature to prove the values matched strain gage values. The part was then heated to 850 C to collect the data desired.

FEA VERIFICATION FEA verification is simplified with the use of laser vibrometry. Because lasers do not touch the part, no dummy weights are needed; therefore, the part is measured in its real condition and no mass damping takes place. The time required to measure 6,000 points is now less than one man day, making high resolution measured data, which looks like finite element models, now possible. The combination of using the same sensor for every data point, not touching or altering the measured part, and the high resolution data, all combine for very high modal assurance criteria (MAC) values. In a blind comparison of a laser vibrometer vs. accelerometer to generate FEA verification data, approximately the same time was used to generate both sets of results. The measurement object was a right side engine cover from a motorcycle. The accelerometer measurements had MAC values of 0.64 and 0.41, and anything over 0.6 was considered a good MAC value. The scanning vibrometer had MAC values of 0.99, 0.96, 0.93, 0.89 and 0.80. In other FEA verification testing, laser vibrometry continued to show these high MAC values. These high MAC values mean that fewer iterations are needed to bring a part from concept to production. This equates to less time from concept to production and less cost. Finite element models can be accurate, almost to the point where some companies feel they can skip the verification stage. As the frequencies of interest increase, or the part complexity increases, the need for verification becomes more important. The use of bonding agents in manufacturing also has increased the need for FEA verification. These bonding agents can have different structural characteristics based on their thickness or their temperature, and failing to verify a model can result in making assumptions about that bond that may not be valid.

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During the past decade, dramatic improvements and innovations in the field of laser vibrometry have taken place. Laser vibrometers are becoming the sensor of choice on production machines and in the lab. Their accuracy, f lat response curves and dynamic range make them desirable as single point sensors, and their ability as scanning units to render high definition data and images

quickly is unequalled. In many ways the doppler laser vibrometer is rewriting how today’s engineers measure vibration. Q Gregg Palombo is territory manager at Polytec Inc. (Irvine, CA). For more information e-mail [email protected] or visit www.polytec.com.

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Figure 1: The sample matched two possible EVA values—15.24% and 18.21% —at a high level. The latter value placed the sample outside of the allowed variation, lowering the confidence of the operator in the method. Source: Thermo Fisher Scientific

Spectroscopy Simplified T

he main function of spectroscopy in quality assurance/quality control (QA/QC) laboratories is to determine if a product meets control specifications in relation to its identity, composition or purity. Due to the importance of product quality, each step of QA/QC testing is defined by strict standard operating procedures (SOPs). In today’s QC laboratory most of the responsibility for performance verification falls on the instrument and software itself, enabling operators to perform simple and accurate analyses

Advances in FT-IR spectrometers and software enable improved sample verification and increased confidence in QA/QC testing. B Y MI K E B R AD L E Y, PH .D., F E D E R I C O I Z Z I A AN D JE F FR EY H I R SC H , PH .D.

and to focus on handling the increasing number of samples entering QA/QC laboratories. Improvements in fouriertransform infrared (FT-IR) instrumentation and software now provide effective sample verification and complete confidence in instrument operation.

During each stage of the manufacturing process there are unique challenges to product quality. As a result, incoming raw material, in-process sample and outgoing products must be monitored and tested for QC purposes. In order to prevent supplier

TECH TIPS  The main function of spectroscopy in QA/QC laboratories is to determine if a product meets control specifications in relation to its identity, composition or purity.

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QUALITY | January 2011

 Many hardware features required to support system verification are now available preinstalled as standard components.

 System intelligence as applied to a spectrometer can be divided into four categories: scheduled maintenance, instrument status, performance verification and system suitability.

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quality issues from contaminating the current manufacturing process, it is important to devote substantial effort to goods-in or incoming raw material analysis. Mid-stream analysis, where a sample is analyzed during processing, enables process control where parameters such as starting material concentration, solubility or temperature may be adjusted to maximize output or retain quality. In terms of ensuring released product quality downstream, customer complaints are monitored using data from the QC laboratory. In laboratories that are not part of a manufacturing process but still regulated or subject to audits, such as forensics labs, questions over the performance of any instrument can be legitimately raised if there is no data showing its ongoing reliability. In order to mitigate risk it is important to establish credibility of the information provided by an FT-IR spectrometer. In the past, knowledge of all facets of spectrometer operation, from properly loading chart paper to final data interpretation, was required to obtain reliable answers creating a generation of expert users. QC laboratories have since evolved in terms of personnel, instrumentation and throughput. In order to meet the demands of a modern QA/QC lab, FT-IR spectrometers must include capabilities that shift the burden of proving the reliability of information away from the analyst, leaving them to concentrate on samples. In order to satisfy internal, regulatory and legal body requirements, there is a need for regular independent verifications of instruments with accurate record keeping. The pharmaceutical industry has a long history of being subject to stringent regulations, including the need for all drug-related data to be backed with instrument performance verification and validation. With the increasing involvement of the legal system, the food and beverage industry is moving toward the same model. Add-on software and hardware tools have made this process simpler, but there is a need for a set of routine tools fully-integrated with the spectrometer (hardware and software). This study details some of the most notable changes in FT-IR instrument design for the QA/QC lab including hardware, regulatory compliance and software.

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The QC lab environment is challenging for analytical instrumentation as the spectrometer may be exposed to noise, heavy machinery, solvent vapor or varying humidity levels. Vibrational tolerance is critical for spectrometer signal-tonoise and overall performance. Novel techniques are being applied to minimize the effects on spectral data resulting in significantly improved system performance. Advanced designs incorporate engineered base plates with specific support shapes and, in some cases, lighter materials to shift the spectrometer’s resonant frequency window away from interference with the spectral data. Other systematic improvements include vibration isolation and dynamic alignment for real-time optimization of signal. Systems also include advanced sealed and desiccated interiors or enhanced purge capabilities to slow the ingress of solvent and water vapors. Many hardware features required to support system verification are now available pre-installed, as standard components. This includes validation wheels for ASTM compliance

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a reminder at the proper interval so audits requirements can be met. When the specified reminder interval elapses, the operator is notified and the system performance verification icon turns yellow. This augments standard record keeping and provides a safeguard as laboratory personnel change over time. Instrument status indicators have been incorporated into spectrometer designs for several years, but their

capacity for communicating hardto-access system performance data continues to grow, providing operators with a real-time virtual heartbeat of their spectrometer. Modern spectrometer systems manage everything from basic checks such as power supply voltage to experimental concerns, such as interferogram size or excessive environmental interferences.

This is an example of modern, innate system intelligence. The green checks indicate all tests are passed and are current (note the inclusion of date information). Source: Thermo Fisher Scientific

or testing against various pharmacopeia standards. These wheels permit verification or validation of wavenumber accuracy (X axis) and the absorption response (Y axis).

SYSTEM STATUS As the technology inherent in optical systems continues to advance so does innate system intelligence. From washing machines to automobiles, systems can now give clues in realtime as to their operation based on factory specifications. Cars have automated tire pressure gages and airbag readiness indicators. The same principles can be applied to spectrometers where a powerful integration of hardware, firmware and software allows operators to quickly and easily understand potential system issues that may occur during the lifetime of the spectrometer. This frees the analyst from having to be an expert in all parts of spectrometer operation and allows him to concentrate on his main tasks. System intelligence as applied to a spectrometer can be divided into four categories: scheduled maintenance, instrument status, performance verification and system suitability. Together these innovative features help ensure confidence in data collected during normal operation. A visual alert informs the operator that some aspect of the spectrometer performance is not within the control specification. Incorporation of the system maintenance status into the overall system indicator is a critical feature for modern FT-IR instruments in the QA/QC lab. This allows the operator to set

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Performance verification routines provide regulatory or audit level detail on spectrometer performance, testing FT-IR systems against manufacturer-published specifications such as throughput and noise, as well as against standard methods including ASTM E1421-99 (2004). These tests can use automated, internal standard operating procedures to carry out the analysis, eliminating operator error and ensuring consistency. For QA/

QC labs that require a more significant level of validation compliance, more extensive packages are available including design qualification (DQ), installation qualification (IQ), operational qualification (OQ) and performance qualification (PQ). These packages comply with ASTM, US-FDA, Japanese Pharmacopeia and European Pharmacopeia guidelines and provide trend charting for long-term evaluation of system performance.

In order to accomplish measurements, standards are incorporated into and supported within the spectrometer beam path. These standards are traceable to national measurement bodies to comply with current regulations. For instance, NIST-traceable polystyrene SRM 1921a tests wave number accuracy on the X axis, and NIST-traceable NG11 glass measures photometric linearity on the Y axis. With these standards incorporated into the system’s automatic performance verification routine, multiple tests can run automatically to demonstrate that the system performs to specification. System suitability uses a sample to determine if the spectrometer is ready for a specific analysis. Whereas performance verification uses internal standard beam paths to verify system performance against established specifications, system suitability is a real-world test using a customer sample with a known performance profile. The system suitability test can be configured to meet specific sample types. System suitability can include tests for specified throughput, specific sample peaks that should be present and their absorbance values. More advanced algorithms include features like contamination analysis to test for the presence of material that might remain on an ATR crystal from a previous experiment. The key differentiation between performance verification and system suitability lies with sampling. Performance verification uses traceable standards to check the spectrometer (and only the spectrometer) against an established set of criteria (ASTM, FDA and JP). In contrast, system suitability uses the full system—spectrometer, sampling accessory and a customer supplied sample—to test against an internal audit or performance specification. Together, these ensure the spectrometer is audit-ready for operations today, in the operator’s lab, with the operator’s samples and accessories.

SOFTWARE DESIGN FOR ROUTINE USE Modern software packages allow QA/ QC operators to run analyses at the touch of a button for rapid sample or contaminant identification or in automated multiple-run workflows where there is a large queue of samples.

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Advanced tools with information about how a new spectrum compares with other samples also have emerged. Even spectra taken under different conditions can now be easily compared. This process can discriminate two similar materials based on spectroscopic differences arising from routine variations in content. Natural products (plant materials) are a good example of a material where some variation is expected depending on the natural conditions (soils and weather). Differentiating well-controlled process materials requires a higher level of discrimination power. Some quality algorithms may return multiple answers or use pass criteria that are too liberal. More stringent algorithms provide higher levels of discrimination, giving an even higher level of confidence.

analyst in the QA/QC laboratory can focus on the ever-growing number of samples being processed without needing to become an expert on every aspect of FT-IR systems operation, improving laboratory efficiencies and simplifying the process of complying with stringent regulatory requirements. Q Mike Bradley, Ph.D., is product manager, Federico Izzia is marketing manager and Jeffrey Hirsch,

Ph.D., is chief scientist at Thermo Fisher Scientific (Waltham, MA). For more information, call (608) 327-6764 or visit www.thermofisher.com.

QUALITY ONLINE For more information on spectroscopy, visit www. qualitymag.com to read the following: • Quality Innovations: “Analyzer ‘Sees’ the Light” • ”Solve Common Industrial Problems with Automated SEM Analyses” • Web Exclusive: “Alloy Identification”

DISCRIMINATION IN THE QC LAB Polymer blends of polyethylene and ethylene vinyl acetate (EVA) are used for making food packaging films and hot melt adhesives. The raw materials contain EVA at various concentrations in the polyethylene matrix. In Figure 1, a target value for the production line was set at 15% EVA, with a very tight control limit required. A simple database of spectra from samples with a range of EVA concentrations was obtained and saved without the need for processing or library creation. Material from the production line was then run through the algorithm using the low-discrimination algorithm. Turning on the high-sensitivity option provides the much more exacting result. Now, only the 15.24% match is within the allowed tolerance limit (0.98 match index) and the next closest is considerably lower. The algorithm stresses small differences, giving the QC lab a much higher level of confidence in the results. Further, this provides a semi-quantitative analysis of the sample without requiring regression or other fitting methods. This process works well for such a tightly controlled processing environment. New advancements in both FT-IR spectrometer hardware and software are shifting responsibility for instrument performance from the analyst to the instrument itself. Performance verification and system suitability tests inform operators when their spectrometer is ready to operate. As a result, the

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The Need for ISO 13485 I

n October 2010, Medtronic agreed to pay $268 million to settle U.S. lawsuits and claims related to its Sprint Fidelis family of defibrillation leads recalled three years ago due to faulty wires. In 2009, the company estimated that at least 13 people may have died because of the problem. Situations such as this emphasize why standards have been put in place, standards such as ISO 13485: 2003, that help medical device companies maintain quality assurance and manage risk. Medical devices such as pacemakers and diabetic pumps can save countless lives, but they also pose a huge threat to human life if proper safety and quality procedures are not followed. ISO 13485: 2003 solves two concerns for medical device manufacturers: • Supplying customers and end-users with safe medical products and superior patient outcomes • Complying with FDA regulations.

The increasing need for quality medical devices is matched by the need for compliance with ISO 13485: 2003. BY NI K K I WI L L E TT

According to the U.S. Department of Commerce’s International Trade Association, the medical devices industry is expected to grow to more than $285 billion by the end of 2012. Medical device manufacturers need quality management systems to ensure quality, standardize manufacturing and ensure that their devices are safe for the end-user. Many standards such as ISO 13485: 2003 have become the global standard for those who manufacture medical devices because they provide a proven guideline for maintaining assurance and managing risk. The EU device directives require medical device companies to employ a quality system consistent with this standard, and

Canada requires device manufacturers marketing their products in Canada to have a quality system certified to ISO 13485 or 13488. Adoption of the standard is still under consideration by the FDA. ISO 13485: 2003, “specifies requirements for a quality management system where an organization needs to demonstrate its ability to provide medical devices and related services that consistently meet customer requirements and regulatory requirements applicable to medical devices and related services.” The key word is consistently. Consistency helps to minimize errors. How can consistency be achieved? The short answer is through documen-

TECH TIPS  Medical device manufacturers need quality management systems to ensure quality, standardize manufacturing and ensure that their devices are safe for the end-user.

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 Consistency can be achieved through documentation of processes, incorporating quality control into every step of the production process and utilizing an automated quality management system.

 ISO 13485: 2003 shifts the importance from the role of quality inspection at the end of production to responsibility for quality control throughout every aspect of production and builds quality assurance procedures into the process itself.

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BALL BAR - DUMBELL tation of processes, incorporating quality control into every step of the production process and utilizing an automated quality management system. The primary objective of this international standard is “to facilitate harmonized medical device regulatory requirements for quality management systems.” The standard is based on eight quality management principles: customer focus, leadership, involvement of people, process approach, system approach to management, continual improvement, fact-based decision-making and mutually beneficial supplier relationships. Revised in 2003, ISO 13485: 2003 shifts the importance from the role of quality inspection at the end of production to responsibility for quality control throughout every aspect of production and builds quality assurance procedures into the process itself. The revised standard focuses on how well the organization assesses and manages risk, identification and traceability, and cleanliness of the work environment.

The bottom line? ISO 13485: 2003 is a tool that reassures consumers that any hazards to them with the medical devices they may come in contact with are being managed through a systematic approach to making the products safer for use. The key to this standard is a quality management system that builds the key themes of the standard into its processes from the very beginning. As a result, medical device manufacturers can realize better product quality, costeffectiveness and time to market. Q Nikki Willett is vice president of product marketing and regulatory affairs, Pilgrim Software Inc. (Tampa, FL). For more information, e-mail [email protected] or visit www.pilgrimsoftware.com.

QUALITY ONLINE For more information on ISO 13485, visit www. qualitymag.com to read the following: • “ISO 13485: Medical Devices and Risk Management” • “Understanding ISO 13485”

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CA SE ST U DI ES

 The Faro Gage is a portable CMM that was designed to enable machinists to speed through measurement challenges. Source: Faro Technologies Inc.

The Faro Gage is a portable CMM designed to enable machinists to speed through measurement challenges and produce the most accurate results. It allows measurements to be taken right on the shop floor, without the need for stopping production. The gage provides accuracy up to 0.0002 inch, and because it offers portability and quick setup, it reduces inspection time. Since the gage can automatically record measurements, inspection reports are easily generated.

Accuracy in Production

D

rawing on 30 years of design and manufacturing experience, Ansco (Cuyahoga Falls, OH) always turns a critical eye to the design and functionality of the parts it produces and actively seeks cost savings and efficiencies in its processes and finished products. It put this critical thinking to use when it was challenged with the machining of a cast iron housing that weighs approximately 750 pounds. This part was too large and cumbersome to be inspected by Ansco’s traditional bridge-type coordinate measuring machine (CMM). The cast iron housing had several large bored holes and ring grooves that had to be held to within a 0.001inch tolerance. There also were several drilled and tapped holes for various bolts and fittings. Although the bores

could easily be checked with dial bore gages, it was difficult to check the location and relation between features using conventional methods. The older technology could not accommodate the housing and all of its features, particularly with the features being on different sides. With an inspection requirement of 100% and full documentation on all 80 critical features, it was not practical to do a layout and check using conventional methods. These methods were not sufficient in terms of size, time or cost.

PORTABLE CMM TO THE RESCUE After seeing an on-site demonstration of the Faro (Lake Mary, FL) Gage, Ansco could easily see that the gage was the only tool that could do and meet its needs.

RETURN ON INVESTMENT A conventional layout and checkout would take more than an hour and a half using conventional technology. But with the Faro Gage, Ansco can set the part up on the table, check out all of the required features, and return it to the skid in less than 20 minutes. That is almost an 80% reduction of the standard work time, which equates to a real savings in time and productivity. Without this capability, Ansco would not be able to meet the delivery requirements for this project. “This project is now in its third year of production and we are still going strong,” said Wes Suladie, Ansco’s quality assurance manager. “We can honestly say that of all of the suppliers of machined components for the end product, Ansco was the only supplier that did not have one field reject. That’s because we were able to find the errors and correct them before they ever got to the customer and the Faro Gage was a big part of that success.” Faro Technologies Inc. (800) 736-0234 www.faro.com

BENEFITS  The Faro Gage provides accuracy up to 0.0002 inch.

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QUALITY | January 2011

 The A conventional layout and checkout would take more than an hour and a half using conventional technology, but with the Faro Gage, it takes less than 20 minutes.

 The gage allows measurements to be taken right on the shop floor, without the need of stopping production.

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CA SE ST U DI ES

 The PC-DMIS Planner allows the user to identify changes to an original part model or inspection plan. Source: Wilcox Associates

An Upgraded

Inspection Process

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he pressure is on in the automotive industry to generate more and better dimensional data for designing and building the next generation of automobiles and trucks. The sheet metal team at Chrysler’s Advanced Metrology Group (Belvidere, IL) is responding to this challenge. New inspection procedures and software to manage them have dramatically improved the team’s productivity during the past two years. For example, during the first four months of 2009, the team delivered approximately 200 coordinate measuring machine (CMM) programs for evaluating new Chrysler truck and passenger car designs,

including model launches scheduled for 2010 and 2011. Judging from the number of inspection programs that were written, sheet metal team leader Howard Casey believes his team was at least 40% more productive last year than they have been in previous years. As it becomes even more proficient with the new procedures and tools, he anticipates that its productivity could increase by as much as 60%.

E-TOOL AND INSPECTION PLANS The new approach evolved rapidly between 2007 and 2009 when Chrysler was making its transition to CATIA v5. Since this upgrade would require

substantial changes in the corporate design software anyway, it was a perfect opportunity to correct longstanding problems in the way design intent information is communicated to CMM programmers. Part designers need to communicate to the CMM programmers creating inspection routines which dimensions and tolerances to evaluate. There are many ways to do this, but each shares the same flaw: Designers may print out 2-D blueprints of the part, model and mark up the critical dimensions; they may jot down some notes in a text document or they may pass this information along via phone calls. In each case, the electronic link between manufacturing and the original design data is broken, and there is no assurance that the parameters used to inspect the parts are current. Chrysler knew there had to be a better way. So, as part of its upgrade to CATIA v5, it developed a module inside a software package called eTool that allows designers to embed their inspection plans in the CATIA file. This ensures that the link between design data and its inspection requirements is never broken. The inspection plans include datum definitions, feature measurement information and dimensional evaluation information. Chrysler’s next objective was to find software tools that would automatically transform these inspection plans into inspection programs for a range of CMMs used at several of its facilities. This would save a substantial amount of time and money. Hexagon’s software arm, Wilcox Associates (North Kingstown, RI), was already at work on this very problem.

BENEFITS  PC-DMIS allows operators to be 30% to 50% more productive, depending on the nature of the individual projects.

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 Design intent information is stored in the CATIA model so operators get exactly the same information regardless of location.

 Today there are far fewer steps involved in part validation procedures because of numerous checks and balances incorporated in the eTool and Change Manager software.

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Delivering New Perspective to Precision Manufacturing

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Bringing unprecedented measurement capability and performance to precision manufacturing industries, enabling faster ramp-up times, improved product quality, and increased productivity. Based on white light interferometry, NPFLEX offers many benefits beyond traditional contact measurement technologies, including 3D images, rapid data-rich acquisition, and greater insight into part performance and functionality.

For more information visit www.bruker.com, email [email protected], or call +1.520.741.1044/800.366.9956.

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CA SE ST U D IES

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It was developing a new, standalone product, PC-DMIS Planner, which would let designers embed inspection plans inside its computer-aided design (CAD) data so that it could be used by inspection system programmers to create programs. The tool set Wilcox was developing within PC-DMIS Planner was very close to what Chrysler had envisioned to round out its eTool software. It included a plan importer, a probe path optimization module, an auto clearance move insertion tool, and a Change Manager for keeping the inspection plan and the part program in sync. During the next two years, Chrysler and Wilcox worked together to incorporate these tools into the Chrysler software while Wilcox worked inde-

pendently to refine its own commercial product based on its experience with the Chrysler eTool system.

CLEAR COMMUNICATION Both Chrysler’s eTool and the commercial version of PC-DMIS Planner close the loop between design and inspection by providing tool designers and inspectors with special tools that allow for the clear communication of design intent along with the verification and incorporation of changes that occur during the product development process. This is accomplished by automating previously informal lines of communication between design and inspection personnel to establish bidirectional data flow between a CAD model and its related inspection part programs.

The design engineer can use PC-DMIS Planner to identify and embed information about critical characteristics in a planning file that is associated with the product’s CAD file. PC-DMIS Planner offers Direct CAD Interface to the CAD model in the original CAD database so updated planning files can be easily associated with updated CAD files. Bidirectional change management tools within PC-DMIS Planner allow the user to identify changes to an original part model or inspection plan, and provide fast and easy methods to update part programs based on the new information. Wilcox Associates (800) 218-7125 www.pcdms.com

VIDEO INSPECTION SYSTEMS “8700” Series with 4" x 8" or 4" x 12" Travel Stages

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Contact Sunny Coverly, today! Phone: (610) 932-8350 Fax: (248) 283-6587 [email protected]

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CMM First Article Inspection Reverse Engineering DCC Full Automation Capability Contract Inspection & Layout Non-Contact Video Inspection Vane & Blade Profile Analysis 2D & 3D Digitizing White Light & Laser Scanning 3D CAD Model Based Inspection CAD Solid Modeling Capability Studies Roundness Testing Fixture Calibration Surface Finish Analysis

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PRECISION PIN GAGES Used as masters to calibrate measuring equipment or check linearity of comparators, micrometers, and calipers. These “Tenth Step” gage sets have unlimited applications, such as quality control inspection, prototype work and production layout. Inspectors select from the range of pins to find the size of a hole or slot.

Meyer Gage Company Inc 230 Burnham Street • South Windsor, CT 06074 1-888-PIN-GAGE • www.meyergage.com

Styli and Accessories from Carl Zeiss • Large selection and great prices on M5, M3, and M2 styli and other popular accessories. • Over 500 products in stock and available for same-day shipping. • Find styli fast using new convenient search tools: shop by size, material, length, and sensor type.

www.zeissmetrology.com Carl Zeiss Industrial Metrology 6250 Sycamore Lane North Maple Grove, MN 55369 (800) 327-9735

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QUALITY | January 2011

First Article Inspection: Get DISCUS DISCUS will help you save 50% to 80% of your time complying with AS9102, PPAP, Part 820 You can balloon drawings/models and simultaneously create the corresponding inspection sheets. Customizable for various customer/internal formats. DISCUS Software Company 829 Bethel Rd Columbus, OH 43214 (614) 360-2424 www.DISCUSsoftware.com

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Custom Gage Applications • Fast and Accurate • Simplified Dimensional Control for in-process or post-process inspection of lengths, depths, diameters, position of slots or shoulders and angle of taper (male or female) • Mechanical or Electronic Indicators • Bench top or Hand Held • Quick Change and Interchangeable • Standard Gages or Customer Designs

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Low Cost, High Performance Machine Vision Cameras PixeLINK has released the PL-E530 series of machine vision cameras. • Available in 1.3, 3.0, or 5.0 MP • Aptina CMOS Sensor • Color or Monochrome Versions • 8 & 10-bit output • Rolling shutter • Simple and easy to use SDK for all cameras

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Dimensional Measuring System ProTable™ is a battery operated dimensional measuring system designed for use in a manufacturing environment. Measurements are displayed with a resolution of .001in., 01mm, or .001cm. Steel bearings, temperature and non-linear error compensation maintain an accuracy of ±.010 in. (±.003 optional) over the entire range. Standard models are available to measure up to 19.5 feet. Custom designs also available.

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FREE SPC eBook A complimentary electronic version of The Book of Statistical Process Control is now available from Zontec. The 200+ page publication helps demystify SPC methods, techniques and calculations for the non-statistician. Each chapter is complete with examples, charts, tables and diagrams that can be adapted to any quality operation. Request your copy (a $34.95 value) at the Zontec web site or call (866) 955-0088 today.

www.zontec-spc.com

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Stop looking. We have what you need! Any bulb. Any purpose. Replacement lamps for all makes of optical comparators, microscopes, inspection equipment, fiber-optic light sources and other precision instruments. Fluorescent, incandescent, LEDs, mercury arc, metal halide, miniatures, quartz halogen, xenon, and miniatures. Sockets and lamp holders for all lamp types.

Bulbworks, Inc. 1-800-334-2852 973-584-7171 www.bulbworks.com

Dimensional Layouts and Statistical Process Control Whether you need to reduce your inspection backlog, require a check of first-article production parts, or audit incoming parts – we can help. We are an accredited lab to ISO/ IEC 17025-2005. We inspect a variety of parts including automotive and medical devices. You can count on Siemers Inspection Service for quick and accurate turnaround on your Dimensional inspection needs.

Siemers Inspection Service, Inc. 713 W. Prairie St. Vicksburg, Michigan 49097 269-649-4434 www.siemersinspection.com email: [email protected]

January 2011 | QUALITY

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QUALITY

PRODUCTS QUALITY CONTROL AUTOMATION

FINITE ELEMENT ANALYSIS AND MULTIPHYSICS SIMULATION Abaqus6.10-EF is a unified Finite Element Analysis and multiphysics product suite. It has improved support for substructure modeling capabilities; Abaqus users can now more easily create a substructure of a distinct region in their product, import it into an assembly, recover the results during an analysis and reuse the substructures in future models. Support for 3-D pressure penetration loading can now be used with any contact formulation, and users can now predict crack growth due to low-cycle fatigue, and predict the durability and damage tolerance of composite structures with complex failure mechanisms. SIMULIA • (401) 276-4400 • WWW.SIMULIA.COM

InspectionXpert First-Article SP2.4 automates quality control inspection processes by ballooning computer-aided design (CAD) drawings and creating quality inspection forms such as AS 9102 and PPAP forms. This version has improved optical character recognition, new operator support options and an improved online activation process. It works with PDF and TIFF file formats to capture inspection characteristics. EXTENSIBLE CAD TECHNOLOGIES (800) 379-0322 WWW.EXTENSIBLECAD.COM

MINIATURE INFRARED SENSOR The thermoMETER CSlaser is a miniature infrared sensor with an integrated controller. It has a two-beam laser aiming feature, which marks the spot size at any distance. The controller is not necessary with this model because it is already integrated into the sensor. Objects of 0.5 millimeter can be measured at a distance of 150 millimeters from the sensor. It has a scalable 4 to 20mA two-wire analogue output and an alarm output. MICRO-EPSILON (919) 787-9707 WWW.MICRO-EPSILON.DE

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DATA TRANSLATOR TOOL The CADfeature 10.0 is a feature-based design data translator tool. The software works with computer-aided design (CAD) systems to preserve design intent, control remastering, heal workflows and protect intellectual property. The latest release includes drawing support and associability for commercial CAD systems, as well as new 64-bit processor support. ELYSIUM INC. (248) 799-9800 WWW.ELYSIUMINC.COM

www.qualitymag.com

VERTICAL TRANSLATION STAGE The VTS300 vertical translation stage can position loads up to 450 kilograms with ±25 micrometer accuracy in applications requiring a compact footprint with travel from 50 to 200 millimeters. Applications range from step and settle placement to high force generation. Multiple units can be combined for lift and tip/tilt motion. It has a high-stiffness aluminum-alloy base and table and pre-loaded angular contact ball bearings that support the 0.1 inch/rev lead-screw. AEROTECH INC. (412) 963-7470 WWW.AEROTECH.COM

SPEED DATA ACQUISITION SYSTEMS The PCIe data acquisition products are built on the technology of their AD83,000 series product line. The AD81500 series of data acquisition systems deliver uninterrupted signal processing over two channels at a rate of 1.5 gigasamples per second, each with 8-bits of resolution and an aggregate rate of up to 3 gigabytes-per-second. The products have data acquisition capabilities in signals intelligence, surveillance, missile testing and radar. ULTRAVIEW (925) 253-2960 WWW.ULTRAVIEWCORP.COM

FIREBALL ADAPTER The Fireball Adapter USB digital linear measurement interface for linear variable differential transformers (LVDTs) and half-bridge transducers converts analog gaging probes to digital gaging probes. It provides plug-and-play digital measurement probe USB connectivity. It promises longer-range linearity, no need for regular calibration and use of a single master rather than Min and Max masters. ALBION DEVICES INC. (858) 792-9585 WWW.ALBIONDEVICES.COM

www.qualitymag.com

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CD-SEM METROLOGY TOOL The E3630 is an SEM-based critical dimension measurement system for next-generation photomasks and patterned media. It has 30% improved linewidth repeatability, an objective lens and low-vibration platform

NE

and has 30% higher linewidth repeatability compared to its predecessor. It is designed for measuring the critical dimension of the miniature-sized patterns on photomasks for extreme ultraviolet and nanoimprint lithography. The tool can be used for pho-

tomask development and manufacturing evaluation at the 22 nanometer and 16 nanometer production nodes. ADVANTEST CORP. (212) 850-6670 WWW.ADVANTEST.COM

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Leak Detection Solutions Since 1960

Mahr Federal Hand Tools The New REFERENCE for Digital Calipers

HLT specializes in helium mass spectrometer leak testing services. Leak testing is an essential aspect of quality requirements in fabrication of new parts, systems and processes. We create solutions for design and product engineers. » » » » » »

New REFERENCE system means the zero position needs to be set only once

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HLT’s experienced staff utilizes a vast library of procedures and specifications. We provide consultation for implementing leak testing processes into comprehensive quality assurance programs.

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Mahr Federal - let us demonstrate our complete line of dimensional gages. Contact Mahr Federal Inc., Providence, RI Phone: 800-343-2050, Fax: 401-784-3246 or E-mail: [email protected], Internet: www.mahr.com

Practical experience of 50 years in business guarantees an answer to your leak testing requirements.

(800) 423-1701 www.heliumleaktesting.com E-mail: [email protected]

QLT01114HELI_2.indd 1

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QUALITY MANAGEMENT SOFTWARE ProFicient is available as a hosted, ondemand application as an alternative to the client-server version of ProFicient SPC, which is quality management system software. This model creates a central quality hub for real-time SPC from the shop floor as well as comparative analysis across lines, sites and suppliers. The scheduler alerts operators to upcoming scheduled quality checks and allows users to implement a sampling workflow. If a quality check is missed or reveals process irregularities, the system adjusts workflow requirements in conjunction with changes in the process state and notifies relevant parties. INFINITY QS (800) 772-7978 WWW.INFINITYQS.COM

LASER SCAN MICROMETER The Triton 331 has a 30 millimeter measurement window and measures 12,000

measurements per second. The higher scan rate enables detection of shorterlength flaws and accurate measurement of hexagonal or other product shapes that incur oscillation, and measurement of nonconstant diameter products, such as corrugated tubing. It links to a PC running Total Vu software. LASERLINC (888) 707-4852 WWW.LASERLINC.COM

• A fast, accurate, portable gauge for testing aluminum brass, copper and steel. 3-D METROLOGY INSTRUMENT The Talysurf Optics 3-D has part diameters up to 200 millimeters and repeatability can be typically lower than 50 nanometers. Its measurements on optics range from less than 2 millimeter diameter parts with high numerical apertures up to parts of 200 millimeters in diameter with 20 millimeters of sag. This allows the instrument to measure optics used in a range of applications, including Blu-ray DVD optics, cell-phone and digital camera lenses, IR imaging optics, laser diode/LED collimation optics and fiberoptic coupling components. TAYLOR HOBSON +44 (0)116 276 3771 WWW.TAYLOR-HOBSON.COM

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• Test a variety of shapers, extrusions, tubing and flat stock. • Models available to test thickness up to one inch.

WEBSTER INSTRUMENT, INC. 11856 Mississippi Avenue Los Angeles, California 90025 EST. 1932

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Tel. 800-394-3541 • Fax 310-478-1365 January 2011 | QUALITY

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DATA ANALYSIS AND REPORTING SOFTWARE The GDM-3D Version 7.0 is interoperable with 3-DCS tolerance analysis software and includes numerous enhancements. This version has built-in computer-aided design (CAD) translation that allows users to work with CAD file formats including CATIA V4, CATIA V5, ProEngineer, UG-NX, Parasolid, Solidworks and JT. This version also has visual improvements and cleaner, more streamlined images. DCS (248) 269-9777 WWW.3DCS.COM

detectors are used in the automotive, RAC, aerospace and medical markets. ALCATEL VACUUM PRODUCTS (781) 331-4200 WWW.SENSISTORUSA.COM

DIMENSIONAL MEASUREMENT SYSTEM The SmartScope Apex Micro precision dimensional measurement system is a floor model fixed optics system with a digi-

tal camera and digital zoom. It has a feather probe micro-probe with a 0.005-inch stylus and a TTL laser for detailed highresolution micro-measuring. It also has a high-precision rotary air bearing indexer. It has multiple system illumination sources, including white LED light, coaxial white surface light and a green LED back light. OPTICAL GAGING PRODUCTS (585) 544-0400 WWW.OGPNET.COM

ANSYS 13.0 is the newest release of the engineering simulation technology suite designed to optimize product development processes. The technology has an electromagnetic transient solver that produces higher-fidelity results in dynamic simulation environments, includes different engineering specialties to exchange data and develop real-world simulations and multiphysics simulations can be accomplished more quickly and efficiently than previous versions. ANSYS (724) 746-3304 WWW.ANSYS.COM

SENSOR SYSTEM DDU4 is designed for tool monitoring in drilling and tapping operations and also as a sensor for torque and feed force when used in combination with the tool monitoring system CTM. It also can be used to determine quality characteristics of the produced threads already in the production process. The sensor is designed as a cylindrical rotor based on the application of strain gauge technology and is attached to the shaft of a tool holder. ARTIS SYSTEMS INC. (248) 370-0404 WWW.ARTIS-SYSTEMS.COM

HYDROGEN LEAK DETECTOR The ASH 2000 is a redesign of the H2000 hydrogen leak detector and promises faster and easier testing than its predecessor. Its probe has pass and reject indication lamps, site illumination LEDs and a button for the summation of individual leaks for a global picture. The

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©2010 Thermo Fisher Scientific Inc. All rights reserved.

ENGINEERING SIMULATION TECHNOLOGY

Eliminate the guesswork – verify metal alloys for manufacturing quality assurance. Now you don’t have to risk your business and its reputation on the accuracy of your suppliers’ material. Our easy-to-use Thermo Scientific Niton XRF analyzers are the leading tools available today for rapid, nondestructive positive material identification (PMI) and alloy composition analysis to: t
Validate incoming alloy material t
Recover lost material traceability t
Verify proper weld dilution More than 25,000 Thermo Scientific Niton XRF analyzers are in use daily worldwide. For more information on our analyzers, please visit www.thermoscientific.com/niton or contact us at +1 978-670-7460.

The all-new Thermo Scientific Niton XL2 GOLDD and Niton XL3t GOLDD+ join our family of handheld XRF analyzers. Speed, accuracy, value – the advantage is yours.

Moving science forward

January 2011 | QUALITY

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| An advanced state-of-the-art palm sized metal hardness tester

Q UALI T Y PRO D U C T S

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ANALYTICAL SOFTWARE

Key Features High accuracy: ±0.3% @ HL=800 / Repeatability: ±2HL Two-in-one probe can be used as D or DL Bluetooth communication to PC & micro-printer Wide operating environment: -40°C~+60°C Friendly display style: Normal or flip Re-calibration allowed by user

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QualityWorX is analytical software with a Web reporting interface that provides real-time access to centralized manufacturing data. It automates the storage, archiving, retrieval, analysis and reporting of manufacturing data on the plant floor. It enables collection and analysis of production data to demonstrate proof of compliance for parts made and determines trends to identify production improvements. This version includes a reporting function that makes manufacturing data available across the network through a Web browser. SCIEMETRIC INSTRUMENTS (877) 581-0112 WWW.SCIEMETRIC.COM

SENSOR MONITORING SYSTEM The sensor system DDU4 is designed for tool monitoring in drilling and tapping operations. This system can be used as a stand-alone system for the purpose of monitoring for tool breakage and also as a sensor for torque and feed force when used in combination with the tool monitoring system CTM. In addition, the CTM system also can be used to determine quality characteristics of the produced threads already the production process. ARTIS GMBH +49 (0) 5194 950-0 WWW.ARTIS.DE

COATING THICKNESS GAGES

Simple. Durable. Accurate. I I I I

Wireless Technology

Tough probes, robust housing, and two year warranty Automatic Ferrous/Non-Ferrous substrate recognition Free Certificate of Calibration traceable to NIST Fully interchangeable probes for a variety of applications

1-800-448-3835 www.defelsko.com 40 Years of Quality

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QUALITY | January 2011

DeFelsko Corporation • Ogdensburg, New York Phone: +1 ( 315 ) 393-4450 • [email protected]

www.qualitymag.com

HEIGHT GAGES The Master Height line of height gages comes in 450, 600 and 1,000 millimeters and in two error ranges: the Magna, with magnetic scales and the Ultra, with glass scales. The line has a soft-touch keyboard, swivel adjustment and USB and RS232 ports for data transfer to PC or printer, motorized and manual movements with rapid jog, air bearing cushion with built-in air pump, multiple reference points, optional printer attachment, millimeter/ inch conversion feature, SPC capabilities, 1,000-step memory and 2-D capabilities. SUBURBAN TOOL INC. (888) 647-8665 WWW.SUBTOOL.COM

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IMAGING AND ANALYSIS SOFTWARE The MountainsMap 6 software provides modular surface imaging and analysis solutions dedicated to instrument families including confocal microscopes, white light interferometers, scanning probe microscopes and 2-D and 3-D profilometers. There also is a universal solution for sites with instruments belonging to more than one family. It has the ISO 25178 standard on 3-D areal surface texture. Its native 64-bit code uses multicore processors. DIGITAL SURF +33 (0) 38150 4800 WWW.DIGITALSURF.COM

METAL LASER-SINTERING EQUIPMENT

Relaunch – 795 & 796 Electronic Micrometers

Value

Prices reduced by more than 25%

Line expanded with ranges to 4"/100mm

The EOSINT M 280 is direct metal laser-sintering equipment that can manufacture at up to twice the speed of the previous equipment. The system has an optional 400-watt fiber laser, a larger vertical build chamber, capability of running either nitrogen or argon atmospheres in the chamber and part property profiles for standardized part manufacture. EOS +49 89 893 36-0 WWW.EOS.INFO

Exceptional Value. Unsurpassed Quality. Starrett Precision.

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January 2011 | QUALITY

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Introduction to Precision Ultrasonic Thickness Gages and Applications February 23, 2011 | 2pm EST This webinar provides a basic introduction to the theory and practice of ultrasonic thickness gaging, for both newcomers and more experienced users who would like a review. It covers basic ultrasonic theory, how ultrasonic gages work, and how they are used in contact or immersion mode. The webinar highlights the benefits of precision thickness gages using single element transducers, and discusses a number of common and specific gage applications. Applications that will be described include nondestructive measurements on engineering materials such as metal, plastic, fiberglass, and rubber. The webinar will also cover some innovative instrument features and software options that can be applied to measurements on multilayer materials, very thick or very thin materials.

This webinar will feature: • Discussion on the Theory of Ultrasonic Precision Thickness Gaging • Measurement Modes including advantages and disadvantages • Live application demonstration on several applications

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Gillian Campbell Editor Quality Magazine

Steve LaBreck Senior Product Manager Thickness Gages Olympus NDT

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QUA LIT Y P RO D U CTS

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MICROSCOPY LASER

DATA TRANSFER SOFTWARE

The Mai Tai DeepSee laser laser is designed for multiphoton microscopy and provides 350 nanometers in useable tuning range with more than 2.5 watts of average power. It has automated dispersion compensation and allows for the maximum fluorescence signals to be observed. It uses a regenerative mode locking technique to maintain reliability. It allows hands-free, dropout free wavelength tuning and collection of excitation profiles. It includes real-time monitoring of the laser system and helps maintain beam position, average power and wavelength. NEWPORT CORP. (949) 863-3144 WWW.NEWPORT.COM

The TranSend II utility software transfers data between data collectors, statistical process control applications, analytical software and common spreadsheets. It includes routines that automatically generate reports in both standard and Web-based formats. It provides automatic data harvesting, automatic spec limit and configuration updates to data collectors. A data collector operator can automatical-

ly upload data from all setups and update all setup parameters by connecting a cable to the data collector and clicking on a start button. When any of the names or labels used to identify a characteristic are called up, the data structure provides a reference to all the other names or labels associated with that characteristic. ASI DATAMYTE (763) 553-1040 WWW.ASIDATAMYTE.COM

VIBRATION TEST SYSTEM The DSX-12000 electrodynamic vibration test system has a 16-inch diameter magnesium armature able to produce acceleration levels up to 120 G-force. It has shock performance for low-frequency and high displacement tests with heavy product payloads. Its optical sensors center the armature during travel and have vibration test solutions for applications including automotive shock, squeak and rattle testing, military transportation testing, aerospace vibration test requirements and stress screening applications. THERMOTRON (616) 392-1491 WWW.THERMOTRON.COM

METROTOM. We call it a CMM with an x-ray sensor.

STATISTICAL ANALYISIS SYSTEM QI Macros is a statistical analyisis system that recognizes the data operators have selected the most likely statistical tools and runs them while describing the statistics in layman’s terms. The software works in Excel 2000-2010. It performs mathematical equations and draws the statistical process control graphics. It has more than 30 charts and more than 90 Six-Sigma-based templates. QI MACROS (888) 468-1537 WWW.QIMACROS.COM

www.qualitymag.com

Metrotomography, the fusion of metrology and tomography, lets you non-destructively validate difficult interior and exterior GD&T dimensions. Both the METROTOM 800 and 1500 are traceable, calibrated gages. These systems are ideally suited in R&D, mold setup and ongoing quality control. They can also be used for assembly verification, void analysis, wall thickness analysis and reverse engineering. www.zeiss.com/METROTOM

Carl Zeiss Industrial Metrology (800) 327-9735 www.zeiss.com/metrology

Styli & Accessories ð Same Day Shipping ð ZEISS Components ð Dedicated Service ð M2-M5 In Stock

January 2011 | QUALITY

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WIRELESS HANDWHEEL FOR MACHINE TOOLS The HR 550 FS handwheel is a cordless electronic wireless handwheel for use on machine tools. It enables remote control datum setting and probing with free and unrestricted movement around the machine. Used with the iTNC 530 530 control, it communicates with its base through a 2.4 gigahertz ISM radio band. The handwheel has an emergency stop button and permissive buttons. If the machine operator moves out of range, it reacts with a vibration alarm. HEIDENHAIN CORP. (847) 490-1191 WWW.HEIDENHAIN.US

GAS FLOW TECHNOLOGY MicroPulse technology is a solid state means of producing small, short pulses of various gases. It has a miniature heat exchanger and precision temperature control that can be fitted into process control circuits without adding volume. The operator can pre-set flow direction, volume-flow or mass-flow pulses in a range of pressures. Accuracy and repeatability of 0.1% can be achieved over extended periods of fully-automatic operation. INTERTECH DEVELOPMENT CO. (847) 679-3377 WWW.INTERTECHDEVELOPMENT.COM

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76

QUALITY | January 2011

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OPTICAL COMPARATORS VisionGauge digital optical comparators can digitally compare a part to its computer-aided design (CAD) data--data which can be archived and documented electronically. The comparators have the capabilities of an optical comparator, video coordinate measurement machine, machine vision and vision system. They produce measurements in both manual and fully automated

modes and have machine vision tools to carry out pattern matching, color verification and defect detection. A high-resolution imaging system features detailed inspection of subjective properties, such as surface finish verification, digital image collection, annotation and electronic distribution. METHODS MACHINE TOOLS INC. (978) 443-5388 WWW.METHODSMACHINE.COM

3-D OPTICAL SURFACE PROFILER The ContourGT-K0 is a noncontact, 3-D optical surface profiler that delivers capacity and throughput increases over comparable systems on surface measurements and analyses. It has dual-LED illumination, Vision64 operation and analysis software, and a modular user interface to deliver customization capabilities for production, quality assurance and quality control, and R&D precision machining and manufacturing applications. VEECO INSTRUMENTS INC. (516) 677-0200 WWW.VEECO.COM

AS9100 Training & Registration QMI - SAI Global is North America's leading AS9100 registrar, offering premiere training courses and world class registration audits. Curious about the new Revision C updates to AS9100? Download our FREE aerospace white paper today! www.qmi-saiglobal.com/aeroWP Interested in AS9100 Training? Details regarding the IAQG Aerospace Auditor Transition Training Course are becoming available. All Aerospace Auditors and Aerospace Experienced Auditors (AA/AEA) will need to complete this course.

LED MICROMETER The Adcole LED Micrometer Sensor for the Model 1200 Crankshaft Gage provides ±3 micrometer accuracy, ±1 micrometer repeatability and 0.25 micrometer resolution to validate that parts have been rolled to the proper depth. Capable of measuring fillet undercut depth at a 35 degree roll angle, journal straightness and radial distance or journal shoulder to journal, it creates chart reports depicting any problem areas. ADCOLE CORP. (508) 485-9100 WWW.ADCOLE.COM

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Email us at [email protected] to be put on our advance notification list so you know right away when the course is available for sign-up.

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A DV E RT I SI NG I NDEX ADVERTISER

PAGE

Automated Precision Inc.

1050 IL Route 83, Suite 200 Bensenville, IL 60106-1096

36

www.apisensor.com

Bal-tec Division, Micro Surface Engr. Inc.

42, 57

www.precisionballs.com

Bruker Nano

11, 61

www.handheldxrf.com

Carestream

13, 59

www.carestreamhealth.com

Carl Zeiss

37, 75

www.zeiss.com/metrotom

Certified Comparator Products

47, 73

www.certifiedcomparator.com

Cybermetrics Corp.

BC

www.cybermetrics.com

Dalsa

33

www.dalsa.com/gige.vs1

DeFelsko

Group Publisher Darrell Dal Pozzo (630) 694-4342 [email protected]

REGIONAL MARKETING

Deltronic Corp. Easy-Metric Edmund Optics

Central and Southeast Bill DeYoe 109 Willow Springs Trail Mt. Holly, NC 28120 Phone: (704) 822-6434 FAX: (704) 822-6834 [email protected]

Classified Ad Sales/ Reprints/Trade Shows Sunny Coverly 116 Cooper Ln. Oxford, PA 19363 Phone: (610) 932-8350 FAX: (248) 283-6587 [email protected]

www.deltronic.com

12, 36

www.easymetric.com

21

www.edmundoptics.com

49

www.gradientlens.com

16, 68

www.heliumleaktesting.com

5, 45

www.hommel-etamic.com

Hoto

16

www.hotoinstruments.com/esl-ned.com

Imada

48

www.imada.com

Intertech

29

www.intertechdevelopment.com

Ledford Gage Lab

46

www.ledfordgage.com

Mahr Federal Inc.

1, 47, 51, 68

www.mahr.com

Mark-10 Corp.

7

www.mark-10.com

Marposs Corp.

12, 76

www.marposs.com

70

www.mdmwest.com

Meyer Gage

52

www.meyergage.com

Micro-Vu Corp.

34

www.microvu.com

IFC, 43

www.mitutoyo.com

Morehouse Instrument Co. Inc.

14

www.mhforce.com

Olympus/Innov-X

53

www.innovx.com

39, 55

www.ogpnet.com

MDM West

Mitutoyo America Corp.

Origin Technologies Corp.

32

www.origintech.com

PQ Systems

54

www.pqsystems.com

Precitec Inc.

30, 31

www.precitec.com

3

www.qioptiq.com

QMI-SAI Global

35, 77

www.qmi-saiglobal.com

Ram Optical Instrumentation

16, 48

www.ramoptical.com

9, 62

www.stindustries.com

67, 68

www.scienscope.com

72

www.sadt.com.cn

15, 23, 57, 73

www.starrett.com

Qioptiq Linos Inc.

S-T Industries Inc. Scienscope International Sino Age Development

INSIDE SALES

www.defelsko.com

25

Helium Leak Testing

Optical Gaging Products Inc.

Midwest, Southwest, West and Northwest Buck Bicek 1050 IL Route 83 Suite 200 Bensenville, IL 60106 Phone: (630) 971-0904 FAX: (630) 227-0204 [email protected]

10, 72

Gradient Lens Corp. Hommel-Etamic America

New England and Mid-Atlantic Barbara Grim 1288 Centerton Rd. Pittsgrove, NJ 08318 Phone: (856) 358-4800 FAX: (856) 358-0900 [email protected]

WEB SITE

Starrett Te-Co Thermo Niton United Testing Verisurf Webster Instrument Inc. Western Gage Corp. Yxlon International

14, 67

www.te-co.com

71

www.thermoscientific.com/niton

17

www.unitedtesting.com

40, 41

www.verisurf.com

69

www.webstertesters.com

15, 76

www.westerngage.com

19

www.yxlon.com

This index is provided as a reader service. The publisher assumes no liability for errors or omissions.

QUALITY (ISSN 0360-9936) is published 13 times annually, monthly except semi monthly in November, by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $178.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $216.00 USD (includes GST & postage); all other countries: $228.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: QUALITY, P.O. Box 2145, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to QUALITY, P.O. Box 2145, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

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Continental Breakfast and Registration Welcome Address, Darrell Dal Pozzo, Quality Magazine KEYNOTE: The GD&T Measurement Conundrum, Jim Salsbury, Mitutoyo America Corporation Quality Plant of the Year Award Presentation Morning Break TRACK 1 TRACK 2 Developing a Risk-Based Calibration Program Industrial CT Scanning Harry Spinks, Boston Scientific Stephanie Masse, Jesse Garant & Associates How to Calibrate Any Machine Tool X-Ray Micro CT: The Rules and When to Break Them David Maxham, Automated Precision Inc. Dr. David Bate & Jim Clark, Nikon Metrology Inc. Luncheon PCMM Certification Progress X-Ray Computed Tomography for 3D Inspection Alan Metzel, Nothrop Grumman Jeff Bibee, Werth Inc. CMM Based Surface Profilometry of Macro Quality Control of Metal Alloys and Welds Using Handheld X-ray and Micro-Parts Fluorescence (XRF) Shane Woody, InSituTec Jeff Walker, Thermo Fisher Scientific Afternoon Break Verifying the Accuracy of CMMs Between Calibrations Can Smart Automated Weld Inspection Turn A Cost Into A Profit? Rick Richardson, QA Productivity Systems Jeffrey Noruk, Servo Robot Corp. Would Statistical Process Control Work for Me? Advances in Eddy Current Verification of Heat Treat Processes Rick Sloop, InfinityQS International Joe Jessop, Criterion NDT Networking Reception

5:00pm-6:30pm Wednesday, April 13, 2011 7:30am- 8:30am Continental Breakfast and Registration 8:30am-8:45am Opening Remarks, Darrell Dal Pozzo, Quality Magazine 8:45am-9:30am KEYNOTE: No-Compromise Leadership – A Higher Standard of Leadership Thinking and Behavior Neil Ducoff, No-Compromise Leadership 9:30am-10:15am Quality Professional of the Year Award Winner 10:15am-10:45am Morning Break TRACK 1 TRACK 2 10:45am-11:30am Hand Gages and Metrology Challenges for Smart Cameras and Technology Gains Driving its Adoption Manufacturing in the 21st Century Ron Pulicari, Cognex Paulo Pereira, Caterpillar Inc. 11:30am-12:15pm Pat Nugent, Mahr Federal Optical Measuring Technologies for Air Quality and Regulatory Compliance James Drago, Garlock Sealing Tech. 12:15pm-1:30pm Luncheon 1:30pm-2:15pm Non-Contact Metrology: Eliminating the Cycle Time, Inspection Applications of Acoustic Pulse Reflectometry (APR) Data Density & Price Trade-Off Dr. Noam Amir, AcousticEye Paul Joss, Perceptron 2:15pm-3:00pm Total Quality Management is NOT Total! Accuracy, Efficiency, and other Technology Advancements for Walter McGee, Raytheon Space & Airborne Systems Common and Complex Coating Thickness Measurement Applications Paul Lomax, Fischer Technology 3:00pm-3:30pm Afternoon Break 3:30pm-4:15pm KEYNOTE: Beyond Quality – A Roadmap for Innovation, Praveen Gupta, Accelper Consulting 4:15pm-4:30pm Closing Remarks, Darrell Dal Pozzo, Quality Magazine

January 2011

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VISION & SENSORS

TA B L E O F C O N T E N T S

January 2011 18VS

DEPARTMENTS 3VS Editor’s Note Technology Drives Growth 4VS Industry News 6VS Integration Corner

Machine Vision: Back to Basics 8VS Machine Vision 101

Image Processing Broken Down 20VS Case Studies • Sensing with Robotics • Vision Sensors Improve

Wheel Fastener Productivity 25VS Advertising Index THERMAL IMAGING

12VS SEEING HEAT WITH IR Infrared cameras improve quality assurance, process monitoring and control in industrial applications. LIGHTING

16VS GAIN CONTROL OF LIGHTING Unless light is controlled, it is impossible for a vision system to perform reliably.

IN THE NEXT ISSUE GigE Interface Industrial Machine Vision Software CCD vs. CMOS ABOUT THE COVER January 2011

www.visionsensorsmag.com

SMART CAMERAS

18VS SMART CAMERAS GO MOBILE A smart camera that uses mobile computing technology has a number of advantages.

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p. 20VS

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p. 16VS

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C Cameras and power ssensors enable tthis robot to detect what it touches with w hhumanlike sensitivity. SSource: Allied Vision TTechnologies

VISIT VISION & SENSORS ONLINE AT

www.visionsensorsmag.com Vision Blogs by Ned Lecky, John Nagle and Norman Axelrod

2VS

VISION & SENSORS | January 2011

www.visionsensorsmag.com

VISION & SENSORS

FROM THE EDITOR

Technology Drives Growth Welcome to 2011! With the New Year comes new beginnings and a chance to set new resolutions and, in my case, finally use that dusty gym pass that hasn’t seen the light of day for months (real original, I know). While it’s a time to start off fresh, it also is important to look back and reflect on the things we want to change. Perhaps quality procedures in your plant need some fine-tuning or you need to take steps toward improving your manufacturing process. Maybe you’d like to invest in more technology or update your equipment. When looking back on last year, I was glad—as I’m sure most of you are—that things were not as bleak as 2009 and that we saw some momentum in the market. Quarterly reports from the Automated Imaging Association (AIA) show that starting in the first quarter of 2010, sales increased by 34.4% compared to results from the same quarter the previous year. This was the beginning of what some would say is a recovery. While this is encouraging, experts say the industry isn’t completely back to prerecession numbers. “Despite the impressive growth we are experiencing now, the fact that our industry has not yet returned to the turnover levels of 2008 should not be overlooked. If we have predicted the situation correctly, it will be 2012 at the earliest before we are back on top,” says Dr. Olaf Munkelt, chairman of the board of German Engineering Federation (VDMA)

Machine Vision, speaking at the Vision 2010 press lunch last year in Stuttgart, Germany. However, a strong indicator that the market is picking up is the number of companies that exhibited at the Vision 2010 show. Some 323 companies purchased exhibition space, up from 293 in 2009, and there were 6,200 attendees, while the previous year there were only 5,700 visitors due in part to the economic climate. The final report showed that 83% of visitors came with specific investment and purchasing intentions, while 60% surveyed said that they looked to invest within the first half of 2011. What’s partially driving this growth is the spur in new technologies across all machine vision markets as the need for it continues to grow in existing industries, as well as branching out to new ones—biometrics, advanced traffic management, laboratory automation, medical imaging, high-end surveillance and the solar market. On top of that, there is a significant technological shift to threedimensional (3-D) camera technology and improved standardization.

One company that has jumped on the 3-D technology wave is Sick AG (Waldkirch, Germany). They were presented with the prestigious Vision Award for Applied Machine Vision for their ColorRanger E color camera. This multi-imaging solution combines color and 3-D capabilities in one high-speed camera, eliminating the need for multiple cameras and reducing the overall cost of hardware and integration. The calibrated 3-D data provides measurements in real-world units such as millimeters, which alleviates much of the complexity of calibrating the system in the field. The jury members selected the winner from a total of 28 submissions. Other technologies exhibited included recent advancements in cameras, such as smart, line scan, high-speed and infrared. Also, attendees were able to check out the latest in frame grabbers, software tools, lighting and optics. With the New Year comes new prospects. Mark your calendar for the upcoming Quality Conference in Charlotte, NC, April 11-13. The Quality Conference will provide an exclusive behind-the-scenes tour of the Joe Gibbs Racing facility and show attendees how cars are built from the ground up and prepared for each race track. For more information, visit www. qualitymagconference.com.

Kari O’Rourke, Managing Editor

Vision & Sensors Editorial Advisory Board David Dechow Aptura Machine Vision Solutions

www.visionsensorsmag.com

Ned Lecky Lecky Integration

Perry West Automated Vision Systems Inc.

January 2011 | VISION & SENSORS

3VS

VISION & SENSORS

NEWS

Vision 2010

Shows Strength of Industry Recovery STUTTGART, GERMANY—After the largest economic crisis in 60 years, Vision 2010 is now benefiting from a sharp upturn in the economy, mainly in Germany. The willingness of the industry to invest is currently exceeding even the most confident expectations of economic forecasters. Many exhibitors are reporting a marked improvement in orders booked. According to the VDMA Machine Vision (German Engineering Federation for Machine Vision), many companies report increasing orders from user industries, including machinery and plant engineering, the plastics and rubber industry, robotics and the electronics industry. For the first time more than 300 exhibitors have registered. Last year the number was 293; this year it is 323 exhibitors. At the same time, the amount of international exhibitors has grown from 42% to 44% in 2010. An accompanying program provides multiple perspectives on machine vision applications and solutions. Twenty-seven countries were represented, including the United States (32 exhibitors), Japan (14), Great Britain (13), the Netherlands and Switzerland (10 exhibitors each). The exhibitors showcased machine vision and identification components, including smart, matrix and line scan camera systems, high-speed and infrared cameras, vision sensors, frame grabbers, software tools and libraries, lighting, objectives and optical filters, as well as accessories and application solutions and services for complete systems.

VISION AWARD GOES TO SICK WALDKIRCH, GERMANY— The Vision Award—the Award for Applied Machine Vision—was presented to Sick for the 3-D color camera ColorRanger. The jury included Dieter-Josef Walter, Daimler AG; Don Braggins, Machine Vision System Consultancy; Hermann Tropf, Vision Tools, and Martin Wäny from Awaiba Lda. The jury members chose from a total of 28 submissions.

NAVITAR AWARDED CONTRACT FOR ASSEMBLY TO BE USED BY NAVY ROCHESTER, NY—Navitar Inc., a manufacturer of precision optical and electro-optic systems, was recently awarded a contract with the Defense Supply Center in Columbus, OH, (DSCC) for a multi-element lens assembly to be used by the Naval Air Warfare Center Aircraft Division (NAVAIR). The lens assembly requested by the DSCC has been approved for use in the Aircraft Launch and Recovery Equipment of U.S. Navy aircraft carriers, specifically within the optical landing system. The origins of the lens assembly lie with Buhl Optical, an optics

4VS

company previously based in Pittsburgh, PA, that was acquired by Navitar in 1997. Buhl fi rst manufactured the lens assembly for the Navy in 1989. Navitar engineers worked with NAVAIR to make slight modifications and improvements to the specifications and updated the lens design to meet today’s standards.

LUMENERA SHIPS 125,000TH DIGITAL CAMERA OTTOWA, ONTARIO, CANADA—Lumenera Corp., a manufacturer and developer of high-performance digital cameras and custom imaging solutions for scientific, industrial and surveillance markets, has sold 125,000 digital cameras since its inception in 2002. To date, more than 1,250 camera variants have been designed, including USB, Ethernet, GigE, custom and OEM solutions.

PHYSICAL OPTICS CELEBRATES 25TH YEAR TORRANCE, CT—Physical Optics Corp. (POC), a system integration company for military, aerospace,

VISION & SENSORS | January 2011

homeland security and avionics markets, marks its 25th year in business serving advanced technology communities. POC, founded in 1985 by Dr. Joanna Jannson and Dr. Tomasz Jannson, began as an R&D company focused on holographic technology and laser optics. POC serves the private sector in applied technologies, electro-optic systems, information technology, avionics, wireless communication, software and advanced sensor systems. The privately-held company has grown in revenue and personnel each consecutive year as a self-funded, employee-owned business. This year’s consolidated revenues have topped $45 million and the company now employs 225 people. POC holds 91 U.S. patents and has introduced 100 new products to worldwide markets since the company’s inception. During the past 12 months, POC has created 16 new, high level technical jobs.

EDMUND OPTICS INCREASES FOCUS ON TAIWAN SINGAPORE—Edmund Optics (EO), the premier provider of optical components, continues its expansion across Asia with the opening of an office in Taichung City and appointment of Mr. Johnson Chang to lead its Taiwan Sales operations. “We are extremely pleased to welcome Johnson Chang to our Asia Sales team. This is an exciting time for us as we continue to see rapid growth in the demand for our products across the region, especially in Taiwan,” commented Vincent Thong, director, Asia Sales. “Chang’s knowledge and experience in vision integration systems and imaging lenses adds tremendous strength to our Asian team.” In his role as Sales Manager, Johnson Chang will spearhead further development of EO’s Taiwan presence. Chang joins EO after having worked in precision optics for more than 12 years at one of Taiwan’s most established lens manufacturing businesses.

www.visionsensorsmag.com

Rock it

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VISION & SENSORS

I N T E G R AT I O N C O R N E R

Machine Vision:

thermore, the more sensor types that are added to a system, the flakier the system often will become. However, by going back to the basics, we were able to create a simple solution. We took the demo PROGRAMMERS ARE MAKING USE OF TOOLS THAT HAVE BEEN programs supplied by each vendor AROUND FOR DECADES. By Ned Lecky for his own camera interface and wrapped each one of these into its own thread. A thread is a lightweight process that coexists with many other threads as part of the same application. They run independent of one another, each waiting, in the appropriate way, for an image from the desired camera. By adopting this approach, we were able to rapidly create independent camera interface The UI-1008XS from IDS is a programs based on the 8-megapixel color camera that camera vendors’ own weighs only 12 grams and fits in a volume less than a code—a safe and risk1-inch cube. Source: Imaging averse approach that Development Systems (IDS) is almost certain to speed deployment. It turns out that modern multicore processors and big 64-bit operMy company spends its days building and deploying ating systems—including Linux and 7—can actually manage machine vision applications for factory automation, Windows all of the memory and library interOEM machinery, transportation and security applications actions required to support armies requiring faster, accurate, real-time image analysis. Some of threads for cameras with very effort. The threads are autoof these applications involve 10-camera simultaneous little matically distributed across all of the processor cores to allow for true simultaneous execution, making use Our application, however, also acquisition, mixed line scan and area of all of the hardware that is availrequired more standard machine scan cameras and combinations of able for processing. vision cameras with GigE interfaces, other specialty cameras. In our typical applications, each and needed the option of adding Not long ago, we discovered an camera has its own grab thread, Camera Link or analog cameras to application for a camera from Imagwaiting patiently for the next support some legacy hardware preing Development Systems (IDS) image. In addition, each camera has installed on older machines. Some called the UI-1008XS. This 8-megaa processing thread that analyzes of the cameras required could only pixel color camera weighs only 12 the data most recently received be purchased from other camera grams, fits in a volume less than from its camera. vendors including Basler, Dalsa, Pixa 1-inch cube—including built-in Finally, we add multiple acceleLink and Point Grey. auto-focus lens—and has trigger erator threads for hard operations, Putting such an integrated imagcapability and a USB 2.0 interface such as OCR, a processor-intensive ing solution together in the past was that powers the camera, as well as activity that benefits from the subnearly impossible due to the lack of provides data connectivity. At less division of the image into separate imaging software that could support than $500, it is a capable addition regions to allow parallelizing of the these types of devices simultaneously. to many a machine vision system. character recognition tasks. To this day, none of the off-the-shelf We have used these for general Tricky programming? Sure. But imaging software packages are likely inspection, optical character recogreally, this is all just back to basics to handle such a mix of sensors seamnition (OCR) and security applicafor programmers, making use of lessly and at high performance. Furtions with great success.

Back to the Basics

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VISION & SENSORS | January 2011

www.visionsensorsmag.com

tools that have been available for decades. The camera-specific interface code, often a real bear to write and debug, can be extracted from the vendors’ own example programs, often in just a few hours. Image processing and feature extraction is designed by the machine vision expert and can be performed by the expert’s tool or library of choice. The thread boundaries even ease the chore of using different libraries with different cameras using a custom OCR library, for example, on one camera, while using a general-purpose machine vision library on all of the others. Ned Lecky, Ph.D., is the owner of Lecky Integration (Little Falls, NY). For more information, call (518) 258-5874, e-mail ned.lecky@ lecky.com or visit www.lecky.com or his blog at www.visionsensorsmag.com.

www.visionsensorsmag.com

Shown here is a programming screen capture in Windows 7. Source: Lecky Integration

January 2011 | VISION & SENSORS

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VISION & SENSORS

M A C H I N E V I S I O N 10 1

Image Processing

cameras. OIP is routinely done with handheld cameras using a suitable color filter, polarizing filter, numerical aperture, lighting angle or sensing direction. Appropriately used, DETERMINE WHEN TO APPLY DIGITAL VS. OPTICAL IMAGE these all can increase the signal-toPROCESSING TECHNIQUES. By Dr. Norman N. Axelrod noise ratio or optical contrast by altering the light before the light strikes the photosensitive surface. In vision systems, OIP enhances the optical signal before the light reaches an electronic camera or photodetector, before electronic or digital signal processing, and before control decisions. OIP uses variations in the light, due to changes in materials, structure and processing, to improve signal-to-noise or optical contrast. It produces signals from critical features only and suppresses background images. This has the An integrated circuit on silicon without (right) and with (left) optical image processing before any digital obvious virtues processing is shown here. The defect can be easily of improving the detected in the area marked on left: the image intensity of the integrated circuit features has been significantly imaging and posreduced so that there is a large signal-to-noise ratio sibly simplifying between the light intensity from the defect compared software and with the light intensity from the circuit features. The high signal-to-noise ratio permits detection with hardware. It also reduced resolution. Source: Norman N. Axelrod Associates is fast. Simple applications of more complex optical pheIn a vision system, light is collected from an object nomena also are common to increase and made incident onto an array of photosensors in a the signal-to-noise ratio. Some of these provide outstanding results video camera, for example, a charged-coupled device without even forming an image. (CCD) or complementary metal-oxide semiconductor For example, to gage a small diameter cylindrical object such as a wire or fiber, the diffraction pattern of a laser beam from very small radii (CMOS), or a scanned analog phoassociated with it that represents the object will provide simple informatosensor surface in a video camera. intensity of light incident onto it. tion to gage the diameter. Even more All of the information from the Image processing is typically remarkably, the smaller the diameter object, contained in the light intensithought of as the digital image proof the object is, the more spread out ty variations, is in the light incident cessing (DIP), by a computer, of an the diffraction pattern will be and onto the photosensors. image in order to enhance the image the more accurate the measurement Not only is information from the or to extract information of interwith no image will be. feature of interest contained in the est. This DIP is done by a computer Optical spatial filtering—or 2-D light, but also light from possible after the light has been incident onto optical fourier transforms—has been other sources—reflected and scatthe camera’s photosensitive surface. used to eliminate background when tered light, room and sunlight—that Optical image processing (OIP) is the geometry of the defects is differwill interfere with the digital image done on the light before the light ent from that of the background. processing of the photodetected sigstrikes the photosensitive surface. This has been used in defect nals. The smallest area of the phodetection on complex integrated tosensing surface that is accessible OPTICAL IMAGE PROCESSING circuits (on both photomasks and by the computer is a pixel. Each The simplest tools of OIP are familon silicon wafers) when the circuit illuminated pixel provides a number iar to all operators of still and video

Broken Down

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VISION & SENSORS | January 2011

www.visionsensorsmag.com

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VISION & SENSORS

M A C H I N E V I S I O N 10 1

USEFUL FEATURES FOR IMAGE PROCESSING Features

Possible Applications • Area: Small vs. large • Shape: Regular, irregular, directional • Texture differences and texture axes • Optical properties of different materials (UV, visible, IR) • Processing changes in materials • Asymmetries in stresses as with extrusion • Suppressed reflections as with polarized sunglasses • Non-uniform stresses from pressure, temperature, etc.

Source: Norman N. Axelrod Associates

COMPARISON OF O.I.P. AND D.I.P. Optical Image Processing

Digital Image Processing

• Processing BEFORE light incident onto photo-sensor

• Processing AFTER light incident onto photo-sensor

• Higher S/N, reliability, speed

• More complex programs

• Photodetected OIP uses DIP

• D.I.P. programs available

images consist of straight edges. Since the optical fourier transform is the same as the Fraunhofer diffraction pattern, the straight edges provide a diffraction pattern perpendicular to the edges along and near the X and Y axis (perpendicular to the Y and X edges as with a single slit). The use of an opaque cross in the plane of the diffraction pattern results in the reformed image showing only the image of the irregularly shaped defects. A seemingly remarkable feat is the use of optical spatial filtering to optically filter the image of a 2-D rectangular grid of perpendicular (vertical and horizontal) identical lines. The final image after filtering and reimaging contains only vertical or horizontal lines, depending on the optical filter orientation used. The filter, in the diffraction (or transform) plane, contains only a vertical or horizontal slit oriented perpendiculalry to the lines reimaged.

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OIP is preferable to DIP if it can significantly improve the amount of information from the objects of interest (the signal) and/or decrease the amount of information from objects or sources that do not contain information on features of interest (the noise).

DIGITAL IMAGE PROCESSING DIP is done by computer after the light has been incident onto the camera’s photosensitive surface. After the light has been incident onto an array of photosensors (or photodiodes) as with a CCD or CMOS camera, all of the information is now contained in an array of numbers: each number corresponds to the intensity of the light that was incident onto that photodiode. So how can one get information from an array of numbers? A simple example is that of locating the edges of the image of a vertical wire. The numbers corresponding to the areas outside the wire will ideally be zero

VISION & SENSORS | January 2011

(black). The numbers corresponding to the areas inside the wire will ideally be 255 (white) Note that with a common 8-bit binary-intensity scale: 28 = 256 so that there are 256 levels from 0 to 255 including zero. To detect the location of an edge of a vertical wire, the computer looks at the numbers representing pixel intensities in the image along a horizontal line through the wire. The computer then subtracts adjacent numbers. The difference of all adjacent numbers on the line inside the wire is zero. The difference of all adjacent numbers on the line outside the wire is zero. The difference of adjacent numbers on the horizontal line, when one number is from inside the wire and one number is outside the wire, will be 255. That is the location of the edge. This method takes the mathematical derivative along the line, point by point. If the edge is not completely sharp, then the same approach will still work but there will be more non-zero differences between adjacent numbers. This new array can be used to systematically compute the location of the edge. The image processing that is used to detect a defect depends strongly on the properties of the defect and of the background behind the defect. The simplest case is where the intensity of the defect is very high (say 156) and the intensity of the background is very low (say 34). Then, the computer can use a simple thresholding function: if the pixel intensity was initially greater than a chosen value of 60, then set all pixels to 255 (white); if the pixel intensity was initially less than 60, then set all pixels to 0 (black). This eliminates background signals. The resulting all-white pixels would then represent defects. If the intensity of the defect is initially in the middle of the intensity numbers from the background, then the simple threshold operation by itself will not work. OIP often can be used to obtain high optical contrast between defects and background.

www.visionsensorsmag.com

For example, use of near-infrared pass filters—eliminating visible light—for defects on sutures to sew up surgery on an eye has been used to change the signal-to-noise ratio from about 1 to about 7. The signal-to-noise ratio of 7 provided much more reliability against possible interferences than the signalto-noise ratio of 1. This simple threshold method depends on either the natural high optical contrast between defect and background, or the high optical contrast obtained by use of optical methods. However, if the signal is smaller than the background noise optical signal (and the background is repeatable), then defect signals can be detected by subtracting a defectfree image from an image with a defect. For example, this method

has been used to detect defects on magnetic memory disks for computers where the background signal is from repeatable scattered light from the disk. OIP can be applied to information containing light before the light is incident onto the photosensitive surface of the video camera. DIP is then necessarily used to determine action for diagnostics, detection, recognition, gaging and other functions. DIP is applied to the numericalintensity pattern recorded by the photodiode array of the video camera. This can be used without OIP for diagnostics, detection, recognition, gaging and other functions.

systems. For more information, call (212) 7416302, www.axelrodassociates..com or e-mail [email protected].

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VISION & SENSORS

THERMAL IMAGING

Seeing Heat with IR INFRARED CAMERAS IMPROVE QUALITY ASSURANCE, PROCESS MONITORING AND CONTROL IN INDUSTRIAL APPLICATIONS. By Kari O’Rourke, Managing Editor

targets. These quantitative measurements can be used in a variety of monitoring and control applications in industrial and manufacturing environments. Essentially, if you need to see what a target or product looks like from a heat or temperature perspective, a thermography camera for automation is a valuable and efficient option. Compared to a spot radiometer, which is limited to a single spot reading and requires precise aiming at the point being measured, thermography cameras produce thousands of temperature measurement points.

Q: Who is using thermal imaging? A: Thermal imaging has a wide and growing number of valuLike visible light cameras, thermographic able applications: military, cameras and their associated software security, predictive maintecan recognize the size, shape and relative location of target objects. Source: Flir Inc. nance, building diagnostics, law enforcement, search and rescue, medical, science, research development (R&D), maritime Manufacturing engineers are constantly looking for and navigation, automation and condisolutions to improve production quality in their auto- tion monitoring. Consumer-based cameras also are mated processes. By using infrared cameras in autobeing designed and manufactured mated systems, there is the opportunity to improve for recreational boaters, outdoors process monitoring and control, quality assurance, enthusiasts and for automobile thermal night vision applications. For automation, infrared variations across an object or scene. asset management and machine conmachine vision is being used in a Some IR cameras are designed only dition monitoring. Jason Styron, busivariety of manufacturing environfor qualitative uses, providing relaness development manager, Flir Inc. ments, including food production, tive temperature differences. These (North Billerica, MA) addresses the iron and steel works, automobile are used in IR cameras for law key components of thermography. component manufacturing and enforcement, maritime thermal night testing, critical vessel monitoring vision navigation, in automobiles Q: What is thermal imaging? and predictive maintenance for and for monitoring applications A: Thermal imaging sees heat within mechanical equipment and electriwhere thermal images are interpretthe infrared (IR) spectrum—radiation cal systems within those environed based on temperature contrast. not detectable by the human eye, ments, among other uses. But cameras designed for therdigital (visible light) video or still mography application not only capcameras. An IR camera can convert Q: How do thermal cameras work? ture thermal images of objects, they the radiation it detects into a visual A: In many ways, thermal cameras also provide accurate noncontact image that depicts temperature operate similarly to digital video temperature measurements of those

tech tips

 An IR camera can convert the radiation it detects into a visual image that depicts temperature variations across an object or scene.

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 While the digital camera relies on a CCD detector to see light within the visible spectrum, an IR camera uses a resistive detector.

VISION & SENSORS | January 2011

 With GigEVision protocol, a near real-time IR vision system can be created in which almost all of the CPU time can be dedicated to processing images.

www.visionsensorsmag.com

and still cameras. While the digital camera relies on a charged-couple device (CCD) detector to see light within the visible spectrum, an IR camera uses a resistive detector. Each pixel on a thermal camera is a resistor, allowing the pixels to be sensitive to heat instead of light, which is how they pick up temperature differences and radiation within the infrared spectrum. A variety of components and features determine the sophistication, image detail and level of functionality of thermal imaging cameras. The camera’s centerpiece is its infrared detector. Resolution, thermal sensitivity, lenses and other features contribute to what makes a particular IR camera appropriate for a specific application and/or environment. Some are handheld models with viewfinders and liquid crystal display (LCD) screens, while others are fixed mounted (or mounted on pan/tilt devices) and operated by remote control. Lenses determine the field of view and clarity relative to distance from the object. The resolution affects the number of pixels and spot measurements. Finally, the detector sensitivity determines the range of temperature differences that the camera can capture to create the thermal image, the detail within that image and the data that complements it.

A generalized IR machine vision system and its communications network. Source: Flir Inc.

1 Computer, PLC and/or transaction manager server

5 Wireless access points

2 CAT-6 Ethernet cable with RJ45 connectors

Q: How is thermal imaging applied to machine vision applications in automation? A: It may sound cliché, but it is true: thermal imaging provides a whole new set of eyes in industrial, manufacturing and automation applications—environments where the ability to see and measure temperature differences provides critical data that helps monitor and improve quality assurance, uniformity and safety, among other benefits. Because of their combined imaging and temperature measurement capabilities, IR cameras can be cost-effective for noncontact obser-

www.visionsensorsmag.com

3 Industrial Ethernet switches with fiber optic ports 4 Fiber optic cable

6 CAT-6 Ethernet cable with RJ45 connectors. Powering the camera using PoE (Power over Ethernet) 7 Industrial Ethernet switch 8 ThermoVision A320 cameras monitoring a process or other target objects

Shown here is production testing of car seat heater elements. Source: Flir Inc.

January 2011 | VISION & SENSORS

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VISION & SENSORS

THERMAL IMAGING

the environment/conditions that the camera would need to withstand and how the camera needs to interface to other software, hardware and systems. In simple examples, if a customer needs to monitor a warehouse to prevent fires, machine vision would not be an appropriate solution where a smart camera would. If the customer needed to identify an anomaly in a manufacturing process, then machine vision IR cameras would be the best route. IR image of a circuit board indicates three spot temperature readings. Image colors correspond to the temperature scale on the right. Source: Flir Inc.

vation. Like visible light cameras, thermographic cameras and their associated software can recognize the size, shape and relative location of target objects. The electronics in newer IR cameras provide fast signal processing that allows high video frame rates to capture relatively fast-moving parts on a production line. Their analog-todigital (A/D) converters combine short integration times with 14- to 16-bit resolution, which is essential for properly characterizing moving targets or objects that change temperature rapidly. Q: How are signal and image processing techniques used to solve machine vision applications involving thermography? A: With GigEVision protocol, a near real-time IR vision system can be created in which almost all of the computer central processing unit (CPU) time can be dedicated to processing images. Making sure the IR camera also is GenICam compliant makes it easier for developers to integrate cameras in their IR vision systems. Common tasks associated with IR cameras in machine vision systems include configuration settings, command and control, image processing and appending temperature measurement results to the image data stream. In addition, the

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camera’s digital I/O can be used to control other hardware, as well as triggering and synchronization functions that go with real-time data acquisition. GigEVision makes hardware independence possible, while GenICam creates software independence. In a system with IR cameras compliant in both and connected to a GigE network, virtually any application program can command a camera to send a 60 hertz (Hz) stream of images without losing important data. The information can then be processed for alarm functions, trend analysis and statistical process control. GigEVision and GenICam compliant cameras make it easier for thirdparty developers to integrate cameras into vision systems with a broad array of functions and includes the ability to define complex pass/fail decisions, control digital I/O, and communicate with serial or Ethernet devices, such as programmable logic controllers (PLCs), personal computers (PCs) and human machine interfaces (HMIs). Q: How should customers go about choosing a thermal camera? A: The most efficient path is for the customer to consult with their representative who can customize the best recommendation based on what the customer needs to accomplish,

VISION & SENSORS | January 2011

Q: What types of applications are ideal for industrial thermography? A: Applications ideal for industrial thermography include: • Noncontact diagnosis of mechanical equipment/motors • Electric utility equipment monitoring • Gas leak monitoring • Boiler and furnace inspection with through-flame cameras • Part production and assembly lines • Building inspection and energy auditing • Slag monitoring and ladle inspection • Casting, soldering and welding of metals and plastics • Product packaging • Nondestructive testing • R&D, prototyping and production in the electronics industry Q: What are the advantages of using thermal imaging? A: Some advantages of using thermal imaging include: • Nondestructive testing • Noncontact temperature measurement/analysis • Improved quality and uniformity • Reductions in wasted materials during manufacturing • Maximum uptime • Predictive and preventative maintenance • Improved safety in the work environment. V&S Jason Styron is business development manager at Flir Inc. (North Billerica, MA). For more information, call (866) 477-3687, e-mail info@flir. com or visit www.flir.com/thermography.

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VISION & SENSORS

LIGHTING

Gain Control on

Lighting

trolled, it is essentially impossible for a vision system to perform reliably.

BEST PRACTICES

Light is the most critical tool for creating adequate contrast for a successful and reliable machine vision application. Quite simply, contrast is the delta between the light levels on the feature of interest and every other feaUNLESS LIGHT IS CONTROLLED, IT IS IMPOSSIBLE FOR A VISION ture visible to the imager. The total SYSTEM TO PERFORM RELIABLY. By Jeff Schmitz scope of the area seen by the imager, or field of view, is divided between the feature of interest and the background of these features. Illumination, or lumen levels, from the feature of interest are differentiated from all other elements of a field of view. In the case of front lighting— lighting from the top—the lumen level on features of interest is maximized. In the case of backlighting, the light level is minimized or completely blocked. Choices for lights to create and amplify contrast are nearly infinite. Lights are available in difLighting is the first tool fering photon producers, for building a stable consuch as halogen, incandestrast foundation for vision systems. Source: PPT Vision cent, light-emitting diode (LED), and also differing shapes—spot, area blocks—or evenly illuminated backlights, for When machine operators are polled about the most example, linear, diffused, reflective challenging aspect of applying vision systems, the over- domes, coaxial, and all in differing colors or wavelengths. To cut whelming majority have a single word answer: lighting. through the cacophony of options, What makes lighting such a critical component when the best advice is to backlight the application, if possible. applying a vision sensor? Backlighting entails placing a light opposite the smart camera to maximize contrast. This results Each pixel’s light level—in the The heart of a machine vision in creating a silhouette. Opaque 300,000 to 5 million pixels typically application is light. Essentially an objects are dark, whereas more present in a machine vision system— image processor, the digital imager translucent or empty air spaces in is processed in a machine vision used in both machine vision and conthe rest of the field of view are conalgorithm. The only other pixel data sumer digital cameras is a light coltrastingly bright. This is the most is its X-Y address—its location—on lector. Each tiny imager component, ideal method of applying machine the image processor grid. picture element or pixel is a microvision for opaque object presence, Unless light—both applied light scopic light measurement sensor. shape and measurement. and ambient light noise—are con-

tech tips

 Light is the most critical tool for creating adequate contrast for a successful and reliable machine vision application.

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 When backlighting for gaging a part, it becomes critical to collimate the backlight as it shines on the part, silhouetting the part from the camera.

VISION & SENSORS | January 2011

 Maximized contrast is a requirement for all successful vision system applications.

www.visionsensorsmag.com

Sophisticated image filtering algorithms, such as edge enhancement, Gaussian, meridian, average and binary filtering, light leveling, morphing and erosion controls, maximizes contrast for marginal contrast images. Source: PPT Vision

When backlighting a part for gaging it becomes critical to collimate the backlight as it shines on the part, silhouetting the part from the camera. Incoherent light will wrap around the silhouetted part, distorting its measurement. Collimation can be achieved with a collimating filter on the surface of the light, or more simply by increasing the distance between the light, the part and the camera. When deploying either method, its cost is less lumens from the light shining on the camera and being blocked by the part, lessening contrast. However, the contrast from this method has such a significant margin that the light loss from increasing the distance of or filtering the backlight greatly benefits both the accuracy and repeatability of the measurement without compromising required contrast. Often backlighting is not feasible because the mechanical space to fit the part between the camera and light is unavailable, or the feature of interest is on the surface of an opaque background. Then the art of optimal lighting for creating contrast becomes more complex. Significant arrays of lighting options become available for surface lighting an object. To build adequate lighting with top or low angle surface lighting requires experimentation— often very time-consuming trials— with the part, the camera and various lighting options. Shortening this time-extensive experimentation is to see if a ring light surrounding or an

www.visionsensorsmag.com

area light closely adjacent to the camera creates adequate contrast levels. The simplest way of selecting front or dark angle lights is to contract a professional vision integrator. After the lighting method is determined, a critical practice is to make the controlled light used to create contrast in the application free of light noise from ambient factory light. The best ways to eliminate ambient light from affecting robust contrast include: • Mechanically shroud the part being inspected and its lighting— build a chamber isolating the application from outside light. • Build a cave for the vision application for the vision application is at most ideal for the vision system design engineer, but often is not practical on the factory floor. • Use high-powered lights for the application. Flood the inspection with many photons so that ambient lighting has very little effect on the strong contrast levels created for the application. • Progressing LED brightness levels are making this achievement more and more achievable every year. • Use infrared light and filters to optically shroud the application from visible light. Most commonly, this is done with infrared light wavelengths and matching wavelength infrared band-pass lens filters.

SMARTER VISION ALGORITHMS Sometimes, light-engineered contrast seems too minimal for an application to succeed. Contrast, even

with optimal lighting, is imperfect and not perfectly consistent. This is where smart camera image preprocessing tools come into play. Software delivers scores of tools for extrapolating better contrast. Sophisticated image filtering algorithms, such as edge enhancement, Gaussian, meridian, average and binary filtering, light leveling, morphing and erosion controls, maximizes contrast for marginal contrast images. Image geometry tools use image sampling, line-profiling and other algorithms to further interpolate data from images with less-thanideal contrast. Lighting is the first tool for building a stable contrast foundation for vision systems. Image filtering and geometry are the next steps for robust contrast and reliable vision sensing. Controlled light creates contrast. Maximized contrast is a requirement for all successful vision system applications. The brighter LEDs continually being developed make contrast control better and better. V&S Jeff Schmitz is smart camera marketing director at PPT Vision (Bloomington, MN). For more information, call (952) 996-9500, e-mail info@ pptvision.com or visit www.pptvision.com.

VISION & SENSORS ONLINE For more information on lighting, visit www.visionsensorsmag.com for the following: • “Fiber Optics: Beyond Simple Light Pipes” • “Lights, Camera and Special Effects” • “Sensors See the Light”

January 2011 | VISION & SENSORS

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VISION & SENSORS

SMART CAMER AS

Smart Cameras

Go Mobile A SMART CAMERA THAT USES MOBILE COMPUTING TECHNOLOGY HAS A NUMBER OF ADVANTAGES. By Ben Dawson A smart camera combines a digital camera, processing, software and communications in a small package. Source: Dalsa Corp.

Smart cameras combine a digital camera, processing, software and communications in a small package. They are an excellent choice for a machine vision system to do tasks such as gaging or visually detecting part defects. Currently, there are several types of machine vision systems that are commonly used for quality control.

THREE TYPES OF MACHINE VISION SYSTEMS A vision sensor is appropriate for simple vision tasks, such as detecting when a part is present. Vendors such as Banner, Omron and Keyence offer a variety of sensors that

tech tips  Smart cameras are appropriate for the many machine vision tasks that require two- or three-dimensional imaging and have moderate computation and speed requirements.

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measure things such as International Commission on Illumination (CIE) color or depth at a point on an object. Sensors make one type of measurements at one or a few points. They require little or no programming so are easy to setup. Most machine vision tasks require multiple measurements on two- or three-dimensional images and so require significantly more intelligence

 Easy-to-use software is required for rapid and successful development of a machine vision application.

VISION & SENSORS | January 2011

than a simple sensor. These tasks are typically solved by a combination of vision processing functions and therefore require some programming. Machine vision tasks that are difficult, fast or require significant computational power are best done by a PC-based machine vision system. An example of a difficult task is detecting low-contrast defects such as scratches, bubbles, discolorations, burn marks or contamination. These types of defects are poorly defined so extensive computation is required to detect them. Smart cameras are appropriate for the many machine vision tasks that require two- or three-dimensional imaging and have moderate computation and speed requirements. Dimensional gaging, verifying a part’s outline, barcode or optical character recognition (OCR), defect detection and locating parts (perhaps to guide a robot), are examples of tasks that can be done quickly and inexpensively by a smart camera. Some vendors call their smart cameras “sensors” perhaps to emphasize that they have limited programmability and thus should be easy-to-use. An example of a smart camera often called a sensor is a dedicated barcode reader.

RIDING THE MOBILE COMPUTING CURVE Most smart cameras use a digital signal processor (DSP) for their intelligence. Some smart cameras also use processing elements similar to that in advanced cell phones or other mobile computing devices. These processing elements include a standard central processing unit (CPU), hardware image processors and a capable DSP. A smart camera that uses mobile computing technology has a

 The convergence of smart mobile devices and machine vision allows small, fast and inexpensive machine vision systems that are perfect for many machine vision tasks.

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number of advantages. per week for automoFirst, the demand for tive, aerospace and other smarter mobile devices industries. Defective with ever-better features parts cause expensive drives increases in proreturns and hurt customcessor performance. The er relations. Using smart smart camera can ride cameras, Prime is doing the mobile computing 100% quality inspection performance curve for with nearly zero part increased speed or to defect escapes. take on more demanding One Prime facility manvision applications. ufactures mostly screw Second, the inclusion machined parts—parts of a standard CPU means with grooved patterns familiar operating syssuch as threaded anchor tems and machine vision bolts. Critical dimensions software can be used. for these parts include the If more performance minimum and maximum is needed, it is easy to dimensions of the threads. PC-based machine vision systems and smart cameras require programming migrate to a PC-based To measure these dimenbecause they are general-purpose tools. Source: Dalsa Corp. system running the same sions, the parts are fed by machine vision software. a vibratory feeder into slots Third, mobile computing devices on an index wheel. The wheel turns on the part to be measured. There is are very low power and fit into to position the part in front of the no programming in the usual sense. small packages. smart camera and a caliper tool meaVision operations are presented in Some smart phone applications sures the thread dimensions. familiar terms, rather than the terms have a machine vision compoDefective parts are manually of machine vision algorithms. For nent. For example, one can get an removed from the product stream. example, the caliper tool is presentappplication for a smart phone It might seem odd to have automated as if it was a mechanical gage so that reads a bar code which coned the handling and visual inspecthere is no need to understand subnects to reviews of that product. tion of the parts but not defect pixel edge detection algorithms. Also, some cell phone cameras sorting, but the defect New smart cameras locate faces in an image to set rate is low and Prime are designed to be the color balance and exposure. examines defective servers on an Ethernet However, industrial machine parts to correct the network and have no vision requires hardware and softproduction process. way to display images ware not found in a smart phone. Once again, easy-tothemselves. Instead, Besides, who would want to washuse software for the images are sent over down their smart phone? smart camera was the Ethernet to a clithe key to getting this ent PC. Here a techni- Parts from a vibratory bowl go into an index wheel that rotates inspection task built. cian can set up and IT’S THE SOFTWARE to show the part to the smart camera for dimensioning. Note The convergence of program the smart PC-based machine vision systems protective enclosure around smart mobile devices camera from the client the and smart cameras require prothe smart camera’s lens. Source: and machine vision PC and then log off of Prime Engineering gramming because they are generalallows small, fast the smart camera and purpose tools. If the programming and inexpensive machine vision let it run independently. Results takes too much time, the need and systems that are perfect for many are reported over Ethernet using money for a machine vision project machine vision tasks. How about standard industrial protocols or evaporates. Easy-to-use software is having the smart camera e-mail or via digital input/output lines from therefore required for rapid and suctweet your smart phone when there the camera. One client PC can cessful development of a machine is a problem? V&S manage many smart cameras. vision application. Modern machine vision software allows you to program your vision A WORKING EXAMPLE Ben Dawson is director of strategic developapplication graphically—pointPrime Engineered Components ment at Dalsa Corp. (Billerica, MA). For more and-click to select a tool, such as a (Watertown, CT) manufactures information, call (978) 670-2002, e-mail ben. caliper, and then position that tool 800,000 precision-turned parts [email protected] or visit www.dalsa.com.

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January 2011 | VISION & SENSORS

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VISION & SENSORS

CASE STUDY

Sensing with Robotics

on many simple, unrefi ned tasks which previously had to be done by humans. The pi4_workerbot has been conceived to learn new Cameras and power sensors enable tasks or to change from one job this robot to detect what it touchto another with little retraining, es with humanlike sensitivity. Source: Allied Vision Technologies much like a human colleague. Even though the pi4_workerbot is no humanoid robot, it does possess certain similarities to humans: its size—just less than 2 meters—and proportions approximate those of a human so that it needs about as much space as a person. Like a human, it has two highly movable arms, a head and eyes. It has no legs, precluding independent movement, but instead stands with full steering technology on a rolling platform, allowing it to be easily moved from one workstation to the next. The pi4_workerbot does require a power supply at its new workstation; otherwise, it brings everything else along. Thanks to cameras and power sensors being built into its arms, the pi4_workerbot can see and feel what it grasps and manipulates. Thus, it is equipped to take on sensitive joining Robots are nothing new in industrial assembly. For tasks and to self-monitor the quality example, everyone has heard of the heavy yet highly pre- of its own work.

cise one-armed soldering or painting robots of the auto industry. Such systems take over laborious and repetitive tasks, raising production quality and productivity. Still, most industrial robots have the disadvantage of being very capital-intensive and reprogrammable only with great effort. For that reason, they are only profitable when used for large serial-capacity production, and they are not particularly known for their flexibility. The trend of today’s fast-moving economy, however, lies more along the lines of shorter product life cycles, greater product variety and

benefits  Allied Vision Technologies’ sensors and functions can be switched in and out of the robot system with ease.

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SUPERHUMAN POWERS

faster adaptation to new market requirements. More flexibility is the Holy Grail of industrial production. Pi4_robotics GmbH (Berlin, Germany), a robotics and imaging specialist, has developed within the framework of the EU-aided research project Assembly System Integrated Project (PiSA), a new type of robot that brings human flexibility to industrial automation. The so-called pi4_workerbot is a compact robot that can take

One feature of the pi4_workerbot is its extensive configuration of industrial imaging technology. Depending on the execution and formulation of tasks, it makes use of up to three digital cameras. For applications requiring spatial perception of the workspace, an optional time-of-fl ight camera is mounted in the middle of the head. For inspection tasks, two additional digital cameras from Allied Vision Technologies (AVT) with different illumination units can be attached to the head. The cameras in question are area scan cameras with FireWire IEEE

 The FireWire interface’s integrated power supply allows for an operator-friendly plug-and-play functionality.

 Thanks to cameras and power sensors being built into its arms, the pi4_workerbot can see and feel what it grasps and manipulates.

VISION & SENSORS | January 2011

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1394 interface, such as the little AVT Guppy or the high-performance AVT Stingray. The importance of easily integrated cameras cannot be understated. AVT’s FireWire digital cameras’ versatile selections of sensors and functions fulfill this need because they can be switched in and out of the robot system with ease. The FireWire interface’s integrated power supply is particularly convenient and easy to switch out, allowing for a operator-friendly plug-and-play functionality. The pi4_ workerbot is not fixed to a particular interface, however. For example, digital cameras with Gigabit Ethernet interface also can be integrated.

ABLE TO LEARN Crucial to the pi4_workerbot’s flexibility is its intelligent software. Pi4_control is a software solution that combines imaging with machine control. Thus, inspection tasks can be programmed particu-

larly easily and efficiently, such as having the robot grasp objects and move them within the camera’s field of view to achieve optimal test quality. pi4_robotics and Allied Vision Technologies demonstrated the pi4_ workerbot application at the Vision 2010 show in Stuttgart, where the robot inspected chrome-plated Peugeot emblems for an automotive component supplier. The chromeplated surface generates mirroring effects and light reflections that pose a challenge for testing with machine imaging. Moreover, the complex, angular form of the lion on the emblem requires that the part be turned to capture every edge and surface. Exactly as a human would, the pi4_workerbot holds the product in front of its camera eye and moves it to search for surface defects from all sides. The pi4_control software coordinates not only the machine controls and the imaging, but excels as well with an particularly simple

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operator surface, thanks to which the pi4_workerbot can be reprogrammed to a new task quickly and without complication, even by trained personnel without extensive robot programming experience. The pi4_workerbot’s potential range of applications is vast. For example, it can execute assembly, testing or packaging tasks that could not have been automated before and were handled by unskilled workers. Thanks to the pi4_workerbot, such personnel-intensive tasks that for cost reasons would have previously been outsourced to low-wage countries can be kept on location in higher wage countries. Alternately, for workstations that place workers in peril—such as those involving the manipulation of chemicals or laser beams—the pi4_workerbot offers an interesting alternative. Allied Vision Technologies GmbH (604) 875-8855 ext. 123 www.alliedvisiontec.com

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VISION & SENSORS

CASE STUDY

Vision Sensors Improve

to locate the edge of the part. Then he picked a brightness tool to look for the light reflecting off the threads. He then set up the vision sensor to interface with the programmable logic controller (PLC) that operates the assembly machine. The PLC provides a static output that indicates when a fi xture is in position with two new parts. When the vision sensor Cognex Checker 101 vision sensors receives this signal, it captures are looking down at a 45-degree an image and inspects the part. angle about 5 inches from the two parts in the inspection station The vision sensor then sends an of the assembly machine. Source: output to the PLC indicating Maclean Vehicle Systems that the part is either good or bad. Based on the inspection results, the PLC determines whether to send the part to the pass or fail bin. Most recently, MVS has standardized new applications on the Cognex Checker 232 vision sensor that One of Maclean Vehicle Systems’ (MVS; Royal Oak, provides high resolution and a wide MI) many automotive fastener products is stainless field of view to inspect small features up to 1,600 parts per minute. steel capped wheel nuts. The nuts are assembled on The ability of the vision sensor to an index machine that processes two parts simultane- determine the position of the part ously at each station. The fasteners must be inspected to and evaluate the brightness of the entire opening of the nut, as opposed to an individual point evaluated by a traditional sensor, has eliminated and pick tools off a menu that inspect verify the nuts are properly threadincorrect pass/fail decisions. The the critical features of the part.” ed. MVS previously performed this elimination of sorting costs quickly Konieczke mounted two Cognex fastener inspection with an eddy paid for the new vision sensor. The Checker 101 vision sensors looking current sensor whose accuracy was vision sensor also has increased down at a 45-degree angle about less than desirable, at times resulting confidence that not a single bad part 5 inches from the two parts in the in expensive over-sort. will be shipped to the customer. inspection station of the assembly “We looked at a number of differ“The latest generation of vision machine. The parts are presented to ent vision sensors,” says TJ Koniecsensors is much more reliable and the inspection station in a fi xture zke, manufacturing controls engineer accurate while being just as easy to and held in position by a springfor MVS. “Some were sensitive, set up and operate and not much loaded keeper, so there is some variintimidating and had a high learning more expensive than traditional senability in the height at which they curve like the vision systems that we sors,” Konieczke concludes. are positioned. have used in the past. We selected Konieczke set up the vision senCognex Checker vision sensors sor by dragging inspection tools and because they are very easy to program Cognex Corp. dropping them onto the features and operate. We simply put them in One Vision Drive that he wanted to inspect. First, he place, connect a PC to the USB port, Natick, MA 01760 addressed the variable placement of train them on the part to be inspected (508) 650-3000 the part by using an edge finder tool www.cognex.com

Wheel Fastener Productivity

benefits  The ability of the vision sensor to determine the position of the part and evaluate the brightness of the entire opening of the nut as opposed to an individual point evaluated by a traditional sensor has eliminated incorrect pass/fail decisions.

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VISION & SENSORS | January 2011

 The elimination of sorting costs quickly paid for the new vision sensor.  The vision sensor also has increased confidence that not a single bad part will be shipped to the customer.

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VISION & SENSORS

PRODUCTS

HIGH-SPEED CAMERA The Phantom v341 is a high-speed camera tailored to military, scientific, research and range applications. It has a light sensitivity rating of 4000 ISO and a 4-megapixel, 35-millimeter format sensor. It has 1 microsecond shutter speeds and a global electronic shutter. It has range data input and a 2560 by 1600 pixel complimentary metal-oxide semiconductor (CMOS) sensor. Vision Research (866) 450-7426 www.visionresearch.com

SAFETY CABLES Breakaway safety cables are designed to protect technicians and their equipment from being pulled into rotating machinery during route-based vibration monitoring. The safety cables disconnect in the event that a sensor or analyzer cable becomes accidentally entangled when collecting data. They are designed to interface directly with handheld data collectors and to withstand harsh industrial environments. They have EMI/RFI shielding and multiple connector configurations including 2-pin MIL style, BNC plugs or jacks that are compatible with most major data collector manufacturers. IMI Sensors (800) 959-4464 www.imi-sensors.com

LINE SCAN CAMERAS The uEye 1.3-megapixel line scan cameras with complementary metaloxide semiconductor (CMOS) have global shutter readout, high sensitivity and high color fidelity. The CMOS technology includes a fast line scan mode to camera models UI-1240 and UI-5240. The technology will then read it out with a rate of up to 64 kilohertz. In the USB version, the e2v sensor reads out with a line rate of 20 kilohertz. The models with GigE interface. IDS Imaging Development Systems Inc. (781) 787-0048 www.ids-imaging.com

CCD CAMERA

SWV TECHNOLOGY Super Wide View (SWV) is a technology for thin-film-transistor liquid crystal displays (TFT-LCDs). It is designed to solve the color shifting problems inherent in traditional twisted nematic (TN) and vertical alignment (VA) type displays and provides a viewing angle of greater than 170 degrees.

The VA-29MC-M4 is a 29 million pixel, 12-bit charged-coupled device (CCD) digital camera. It has an electronic shutter and four frame-persecond readout speed in a 35-millimeter optical format. It measures 68 by 68 by 83 millimeters and weighs 460 grams. It has a programmable lookup table, flat-field correction, exposure control and many more features make it easy to use. Vieworks +82-70-7011-6161 www.vieworks.com

Optrex America Inc. (734) 416-8500 www.optrex.com

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January 2011 | VISION & SENSORS

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VISION & SENSORS

PRODUCTS

FIXED FOCAL LENGTH LENSES

CCD SENSORS

Compact fixed focal length lenses provide transmission out to 1,000 nanometers and are designed for factory automation, inspection or qualification applications that require near infrared (NIR) or visible and near-infrared reflectance (VIS-NIR) performance. The lenses take into consideration the working distances and requirements of factory automation and inspection. They have large maximum apertures and a broadband anti-reflective coating.

Charged-coupled device (CCD) sensors for the AviivA 2 camera range extends from 512 pixels up to 4096 pixels, with Camera Link and GigE Vision interfaces. They have 68 dB dynamic range, responsitivity of 164 DN/(nJ/cm2) at minimum gain, and can be operated through a camera link interface at a pixel rate of 80-megahertz using 2 taps or at a pixel rate of 160-megahertz using 4 taps. A GigE Vision interface is also available with advanced generalpurpose input/output (GPIO) and features the fastest line rates on the market at a given number of pixels per line.

Edmund Optics (856) 573-6250 www.edmundoptics.com.tw

e2v (800) 342-5338 www.e2v.com

EMBEDDED VISION SYSTEM The high-resolution M-390 smart cameras is a single system with four independently operating cameras running distinct inspection, guidance or identification programs. Operators can mix and match camera resolutions for all points of inspection. It can differentiate parts, locate defects and gage features on four sides of a part. It has an optional right angle view and operators can perform up to four separate inspections with one vision processor. PPT Vision (919) 341-5425 www.pptvision.com

STROBE SPOTLIGHT

INDUSTRIAL VISION SOFTWARE

The ODS30 OverDrive Prox light is a strobe-only spotlight in a 30-millimeter sensor housing that includes an integrated strobe driver for light-emitting diode (LED) light control. Its driver monitors the strobe operation. The light has SafeStrobe technology, which applies safe working parameters to ensure the LEDs are not damaged.

Scorpion Basic is a product in the Scorpion Vision Software family; an independent and open software tool for industrial vision. The rapid machine vision framework speeds up the development by a factor of 10 compared to a standard library approach. The software is designed for robot vision, robot inspection and in identification systems.

Smart Vision Lights (231) 722-1199 www.smartvisionlights.com

Scorpion Vision Software +47 2315 8700 www.scorpionvision.com

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VISION & SENSORS | January 2011

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VISION & SENSORS

AD INDE X

ADVERTISER

PAGE

PHONE

WEB ADDRESS

Allied Vision Technologies

5, BC

(877) USA-1394

www.alliedvisiontec.com

Cincinnati Automation Ltd.

11

(859) 371-5070

www.cincinnatiautomation.com

Dalsa

9

Edmund Optics

1

(856) 547-3488

www.edmundoptics.com

Matrox Imaging

IFC

(800) 804-6243

matroximaging.com/mil

7

(613) 247-1211

www.pixelink.com

Pixelink

www.dalsa.com/boa/vs1

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Value packed

The Manta is a perfect balance of quality and affordability. Because reducing cost required more than just trimming a little fat, we developed a new, optimized platform featuring a compact cast housing, single board architecture, and our enhanced GigE Vision interface. Which means you don’t have to settle for anything less than a grade-A quality Sony ICX CCD sensor for images up to 5 megapixels, and up to 88 fps. If your application calls for a rugged, low cost camera, serve up the Manta. Learn more at www.AlliedVisionTec.com/ValuePacked

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