There’s no doubt about the benefits of 3D metrology for manufacturing processes: it makes metrology smarter than ever.
With the right solution, 3D metrology can not only improve measurement precision and accuracy, but also eliminate rework, reduce iterations and facilitate troubleshooting by providing rich data on defective products without having to physically disassemble the parts.
However, recent business challenges are forcing manufacturers to demand an end-to-end 3D metrology solution that is comprehensive, cost-effective and scalable.
Understand the current business challenges affecting 3D metrology
How to remain operational and profitable while standing the test of time is a major business challenge affecting most sectors, including 3D metrology. Some additional challenges are caused by uncontrollable external events, including:
- Control requirements for global metrological processes and associated costs
- Reductions in metrological workloads
- Reductions imposed on on-site personnel
- Increase in part-time or remote working
These challenges demand that advances in 3D metrology happen quickly, because it’s not enough to simply improve measurement equipment and software.
What’s needed is an approach that effectively exploits all available data, whatever its type, and makes it accessible to production staff, whenever and wherever it is available.
Overview of the ideal end-to-end 3D metrology process
Meeting the above challenges requires an innovative, comprehensive, scalable and cost-effective end-to-end 3D metrology process.
This would help manufacturers to :
- Reduce cost of ownership by eliminating metrological silos and inefficient workflows.
- Ensure consistency of measurement results.
- Increase workforce mobility by facilitating greater collaboration between teams and plants.
- Reduce staff training and licensing costs for multiple software applications.
- Increase production efficiency levels by automating certain functions.
Scalability is very important. Ideally, manufacturers should be able to select individual components or use the application as a whole, depending on their needs.
The components of an end-to-end 3D metrology process
A standardized end-to-end 3D metrology process would include the following four key components for staff to follow:
- Prepare: identify the features to be measured, the applicable inspection rules, the tools required for inspection and check that the digital chain is assured, in particular for automatic GD&T decoding included in the CAD model.
- Programming: create inspection programs in just a few clicks thanks to advanced simulation solutions, including automatic avoidance and trajectory optimization based on the digital twin concept. Understand how to use simulation software that recreates the workshop environment and covers all parts of a machine.
- Run: connect the measurement device and run the above program for highly accurate data capture, analysis and reporting.
- Manage: harness the power of digital collaborative solutions by connecting your preferred statistical software application for enhanced analysis and reporting.
Factors to consider when looking for the ideal end-to-end 3D metrology solution
The right end-to-end 3D metrology solution will be open and collaborative; it won’t disrupt existing processes, but will adapt and enhance them. Here are the elements to consider:
Does it mitigate risk?
The absence of a software solution, or the use of several software applications focused on different operational activities, can lead to significant risks, such as inaccurate measurements, misinterpretation of data, loss of critical data, and loss of time in creating manual reports, all of which affect and delay the production process.
A suitable end-to-end 3D metrology solution will eliminate all these risks by programming the entire CMM or robot using universal software, regardless of machine size, make or configuration. It will seamlessly recreate the shop floor environment, using a virtual representation to simulate the measurement workflow and detect any collision with a digital twin.
It will also generate error-free reports to analyze the project, machine performance or any manufacturing errors.
Does it improve the quality of the inspection process?
The ideal solution will leverage simulation technologies to enhance the quality of the inspection process. The CMM or robot can continue to monitor and measure, while metrologists program offline inspection tasks on complete simulated twins of their real environment and equipment.
An offline simulation program would work directly with native or neutral CAD files and automatically interpret geometric dimensioning and tolerancing (GD&T), delivering faster results.
Does this reduce part programming capacity?
The right solution will be a practical virtual measuring machine, driven by an intelligent algorithm integrated into the Inspection Path Planning (IPP) module.
It will calculate the best measurement trajectory with automatic head orientation and obstacle avoidance, and work on an optimized path, with a minimum of crossing points, smarter and faster, whether the probe is tactile or optical.
Does it encourage user adoption and collaboration?
If the end-to-end 3D metrology solution is universal, i.e. can be applied to any device, application and industry sector, it will be designed so that metrology professionals at all levels can easily use it to improve productivity and the quality of results.
It would take advantage of cloud computing technologies that enable data and reports to be stored in a centralized repository and made accessible to staff, regardless of time zone or location.
Industries are currently moving towards the use of such an end-to-end solution in their 3D metrology processes, heralding radical changes for the future.