Rapid parts measurement

In today’s highly competitive manufacturing environment, many factors keep companies eye-to-eye or give one the edge. One of those is passion; the production of goods to the highest level of quality possible. However, quality control can be a costly endeavor that requires skilled inspectors, expensive machinery, and large time investments to inspect even a small product sample.
 

Reducing time, effort

Imagine walking up to a glass stage, placing a handful of parts in any orientation anywhere on the stage, and pressing a button. The Keyence IM Series Instant Measurement system has the ability to identify the part, pull up the correct program, and measure up to 100 dimensions per part on up to 100 parts on the stage at once. The system automatically adjusts the lighting and focus, and repositions the program to match each part on the stage. It recognizes the profile and reflective images of each part, compares it to pre-programmed tolerances, produces a pass or fail for each dimension, and saves the data locally or to a network. With one more button press, it prints out a full inspection report – all of this being accomplished in three seconds.

The Instant Measurement (IM) system was designed to do away with archaic measurement practices that were limitations of the technology of their time. By using existing technologies in new ways, the system provides customers with added value from standardizing difficult measurements to streamlining entire inspection processes. The IM Series is designed to be fast and easy to use, and can perform measurements that previously required a range of inspection systems – optical comparator, optical CMM, measuring microscope, hand caliper/micrometer, and GD&T profile and measurement systems.

The Instant Measurement system uses 24 internal lenses, four of which are telecentric lenses that provide the system with a 4" field of view. Telecentricity provides constant magnification (object size does not change) across a range of working distances, virtually eliminating perspective angle error. Object movement does not affect image magnification, allowing for highly accurate measurements in gaging applications. A specially designed lens housing allows for transport from location to location without the need for recalibration or the use of a granite slab, making the system equally functional in a quality lab or on a shop floor.

The IM system features a simple, intuitive interface. A video guide and a step-by-step walk-through accompany every tool. It also has pre-loaded macros that can handle complex and repetitive shapes (thread, pitch, slotted hole, etc.)
 

Traceability

Because of the aerospace industry’s tight tolerances and need for record keeping, the IM Series’ statistics and analysis functionality automates data management and traceability. Once a part is measured, the system will store the data locally or on a network. Users can later extract the data by lot number, part name, or time frame.
 

IM implementation

Newcomb Spring Corp., a producer of springs, stamped parts, and wire forms, has implemented the IM system for a wide variety of aerospace applications.

“Keyence has made a remarkable difference in how we conduct our quality checks,” says Dan Tetreault, general manager at Newcomb Spring of Connecticut. “Specifications for a number of different parts can be saved into the system, and recalled when needed. The operator simply calls up the order details, places the part on the Keyence System, hits a button, and the measurement starts. This really speeds up our QC processes and provides consistent results. We can even confirm that parts we make today match the dimensions of orders we fulfilled months ago. Keyence technology lets us be very efficient, reducing waste, and providing the highest levels of quality.”

Systems such as the IM Series have helped make advances in the speed and efficiency of metrology, helping reinvent quality control.

Keyence Corp. of America
www.instantmeasurement.com
 

About the author: Manny S. Lopez is technical marketing engineer – Instant Measurement at Keyence, and can be reached at 888.KEYENCE ext. 84448 or mlopez@keyence.com.