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Presentation on the LaserTRACER and LaserTRACER-MT system of Etalon during the workshop Machine precision of Sirris on 15 October 2014
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'Ontdek machinenauwkeurigheid in de praktijk!
15/10/2014
© sirris 2007 | www.sirris.be | [email protected] | 2
Agenda
13h00 Welcome & agenda
13h10 Introduction Etalon
LaserTRACER & LaserTRACER-MT
15h15 Sirris / Advanced Manufacturing
15h45 Break
16h00 Demo of Lasertracer-MT at FehlmannVersa P825
Guided tour at Sirris Precision & Smart Factory Lab
17h00 Networking & drink
15.10.14
© sirris 2007 | www.sirris.be | [email protected] | 3
Agenda
13h00 Welcome & agenda
13h10 Introduction Etalon
LaserTRACER & LaserTRACER-MT
15h15 Sirris / Advanced Manufacturing
15h45 Break
16h00 Demo of Lasertracer-MT at FehlmannVersa P825
Guided tour at Sirris Precision & Smart Factory Lab
17h00 Networking & drink
15.10.14
© sirris 2007 | www.sirris.be | [email protected] | 4
Agenda
13h00 Welcome & agenda
13h10 Introduction Etalon
LaserTRACER & LaserTRACER-MT
15h15 Sirris / Advanced Manufacturing
15h45 Break
16h00 Demo of Lasertracer-MT at FehlmannVersa P825
Guided tour at Sirris Precision & Smart Factory Lab
17h00 Networking & drink
15.10.14
© sirris 2007 | www.sirris.be | [email protected] | 5
Agenda
13h00 Welcome & agenda
13h10 Introduction Etalon
LaserTRACER & LaserTRACER-MT
15h15 Sirris / Advanced Manufacturing
15h45 Break
16h00 Demo of Lasertracer-MT at FehlmannVersa P825
Guided tour at Sirris Precision & Smart Factory Lab
17h00 Networking & drink
15.10.14
© sirris 2007 | www.sirris.be | [email protected] | 6
Agenda
13h00 Welcome & agenda
13h10 Introduction Etalon
LaserTRACER & LaserTRACER-MT
15h15 Sirris / Advanced Manufacturing
15h45 Break
16h00 Demo of Lasertracer-MT at FehlmannVersa P825
Guided tour at Sirris Precision & Smart Factory Lab
17h00 Networking & drink
15.10.14
© sirris 2007 | www.sirris.be | [email protected] | 7
Agenda
13h00 Welcome & agenda
13h10 Introduction Etalon
LaserTRACER & LaserTRACER-MT
15h15 Sirris / Advanced Manufacturing
15h45 Break
16h00 Demo of Lasertracer-MT at FehlmannVersa P825
Guided tour at Sirris Precision & Smart Factory Lab
17h00 Networking & drink
15.10.14
Sirris “Driving industry by technology”
8© sirris | www.sirris.be | [email protected] |
Sirris – Collective center of the Belgian technology industry
Driving industry by technology
“We help large and smaller players
in Belgian technology industry
make the right technological choices and achieve sustainable
economic growth.”
9© sirris | www.sirris.be | [email protected] |
5 domains of technology
10© sirris | www.sirris.be | [email protected] |
METALS
COMPOSITES
PLASTICS & HYBRIDS
COATINGS
NANOMATERIALS
ECO-MECHATRONICS
SENSORIZED FUTURE
MODEL BASED DESIGN
FACTORIES OF FUTURE
WORLD CLASS TECHNOLOGIES
ADDITIVE MANUFACTURING
SOFTWARE ENGINEERING
CLOUD COMPUTING
DATA INNOVATION
High-tech infrastructure & 160 employees
11
on 7 sites close to industry
© sirris | www.sirris.be | [email protected] |
High-tech infrastructure
15.10.14 12© sirris | www.sirris.be | [email protected] |
Coating Deposition Additive Manufacturing Micro Precision
Microfabrication Robotics & Cobots Climatic Test Chamber
Research, develop and test your new applications on an industrial scale
13
The Sirris Application Labs
© sirris | www.sirris.be | [email protected] |
Inspiration for technology and innovation
14
� Stay informed?
Follow our blog! blog.sirris.be
� Find out more?
Consult our digital technology library, Techniline! techniline.sirris.be
� Invest in knowledge?
Check out our calendar of upcoming events! www.sirris.be/agenda
© sirris | www.sirris.be | [email protected] |
Members of Sirris
15
2485 SMEs (<250 employees)
2500 companies
115 big companies (>250 employees)
© sirris | www.sirris.be | [email protected] |
International network
16© sirris | www.sirris.be | [email protected] |
Advanced Manufacturing
17© sirris | www.sirris.be | [email protected] |
METALS
COMPOSITES
PLASTICS & HYBRIDS
COATINGS
NANOMATERIALS
ECO-MECHATRONICS
SENSORIZED FUTURE
MODEL BASED DESIGN
FACTORIES OF FUTURE
WORLD CLASS TECHNOLOGIES
ADDITIVE MANUFACTURING
SOFTWARE ENGINEERING
CLOUD COMPUTING
DATA INNOVATION
Precision Manufacturing
18© sirris | www.sirris.be | [email protected] |
Precision manufacturingfor new and better products
19
“Over a period of 5 years
the product tolerances will decrease
by a factor 3 to 4
but the costs of production
will have to remain at the current level.”
© sirris | www.sirris.be | [email protected] |
Precision manufacturingInfrastructure
20© sirris | www.sirris.be | [email protected] |
15.10.14 21© sirris | www.sirris.be | [email protected] |
1. Fast prototyping of precision parts
2. Extreme low surface roughnesses
3. Finishing complex shaped parts in difficultmaterials
4. Surface details on large parts
5. Finishing brittle parts
6. Controlling deformations (tensions)
7. Garantee the precision on series
Precision manufacturingResearch topics
© sirris 2007 | www.sirris.be | [email protected] | 2215.10.14
Precision manufacturingMachine accuracy (topic 7)
© sirris 2007 | www.sirris.be | [email protected] | 2315.10.14
Precision manufacturingMachine accuracy - Direct
Ball bar
Commercial supplier
Renishaw www.renishaw.com
Axes that can be measured
Linear axes
Measuring trajectory
1) Circular trajectory (movement of linear axes); radius is limited by length of ball bar (extentable to max. radius = 600mm) 2) 3 planes (XY, YZ, ZX)
Advantages 1) Easy, well-known and quick test 2) All measured parameters are taken in one measurement
Disadvantages 1) Error diagnosis requires experience 2) Not possible to automate measurements
Machine-errors that can be measured
1) Statical errors of linear axes, like squareness 2) Dynamical errors (quadrant glitch, backlash, stick slip) (ISO 230-4) 3) Volumetric tests (measuring in 3 planes) 4) Diameter value of executed test
Machine-errors that cannot be measured
1) Measuring zone is limited by length of ball bar device (local errors); extendable to 600mm 2) Dimensions (except diameter value of executed test) 3) Errors related to rotary axes
KGM
Commercial supplier
Heidenhain www.heidenhain.de
Axes that can be measured
Linear axes
Measuring trajectory
Random 2D-trajectory in a flat plane (measuring zone is limited by dimensions of grid size)
Advantages 1) Possible to measure a random trajectory in a 2D-surface. 2) Very suitable for measuring dynamical errors on non-circular trajectories (e.g. square) to finetune servo parameters afterwards
Disadvantages 1) Grid plate is fragile 2) Experience is necessary for error diagnosis 3) More expensive than ballbar system
Machine-errors that can be measured
1) Depends on the trajectory that has been followed 2) All static errors of 2 linear axes can be measured (positioning error, straightness error, angular errors, perpendicularity errors) 3) Dynamic contour errors can be evaluated
Machine-errors that cannot be measured
1) Cannot be used for 3D-measurement of volumetric accuracy 2) Cannot be used for errors of rotary axes
Laser tracer
Commercial supplier
Etalon www.etalon-ag.com
Axes that can be measured
Linear axes Rotary axes
Measuring trajectory
Random 3D-trajectory in space
Advantages Possible to measure 3D tool center point for a random trajectory; this is a unique feature
Disadvantages 1) Time-consuming 2) System is not the cheapest among the others
Machine-errors that can be measured
All static errors of linear and rotary axes. Etalon software gives for each linear axis geometric errors (positioning error, straightness error, perpendicularity errors, …)
Machine-errors that cannot be measured
Dynamic errors
R-test
Commercial supplier
IBS Precision www.ibspe.com
Axes that can be measured
Rotary axes
Measuring trajectory
Circular trajectory with synchronous movement of both linear and rotary axes
Advantages 1) 3D-trajectory of sphere can be measured; more information can be gathered in shorter time (compared with ball bar) 2) Measurements can be automated
Disadvantages 1) Device is more fragile than ball bar system 2) Errors of linear axes should be small during R-test (difficult to separate errors coming from linear and rotary axes) 3) More expensive than ball bar system
Machine-errors that can be measured
1) Positioning and orientation errors of rotary axes 2) Motion errors of rotary axes
Machine-errors that cannot be measured
Errors of linear axes
© sirris 2007 | www.sirris.be | [email protected] | 2415.10.14
Precision manufacturingMachine accuracy - Indirect
© sirris 2007 | www.sirris.be | [email protected] | 2515.10.14
Precision manufacturingMachine accuracy - Indirect
15.10.14© sirris | www.sirris.be | [email protected] | 26
Precision manufacturingMachining of ceramics (topic 5)
Machining of ceramicsin hardened state
- State of art of current machiningtechnologies?- Problem: how toselect the best onefor your application?
15.10.14
Demonstrator
© sirris | www.sirris.be | [email protected] | 27
ZrO2-TiN 60/40 disks of Ø 40mm and height
UAG
ELID-Grinding
Die sinking EDM
Micro-EDM
Micromilling
Precision manufacturingMachining of ceramics
15.10.14
Precision gear
• (Hardened) Steel (200-400 HV)
• Dimensional tolerances up to +/- 7 �m
• Roughness: <0.8 �m Ra for milled area
• Diameter: 82,8 mm
• Depth: 41,5 mm
© sirris | www.sirris.be | [email protected] | 28
Gear-making technologies•Disc milling (moduul frezen)•Gear shapers (afwikkel frezen)•Gear hobbing•Finishing (grinding)
Prototyping?Dedicated tools!
Precision manufacturingCase gear (topic 1)
15.10.14© sirris | www.sirris.be | [email protected] | 29
Precision manufacturingTechnologies
Precision milling
Wire EDM
SLM
© sirris 2007 | www.sirris.be | [email protected] | 3015.10.14
Code Ra (µm) Rz (µm) Ra (µm) Rz (µm)
brown 0,021 0,15 0,017 0,14
0,025 0,14 0,013 0,12
0,022 0,17 0,014 0,17
blue 0,094 0,58 0,056 0,31
0,082 0,46 0,05 0,29
0,085 0,51 0,048 0,26
grey 0,099 0,07 0,43
0,097 0,73 (0,303) (1,72)
0,089 0,59 0,074 0,47
red 0,106 0,73 0,048 0,37
0,052 0,39 0,051 0,33
0,078 0,56 0,045 0,3
PCD
parallel milling direction perpendicular on milling direction
MCD
MCD
PCD
Precision manufacturingMirror milling (topic 2)
Smart Production
31© sirris | www.sirris.be | [email protected] |
32© sirris | www.sirris.be | [email protected] |
Automated Loading Human Robot Interaction Measuring in production
Incremental Forming Sheet Metal Cell
Smart productionInfrastructure
33© sirris | www.sirris.be | [email protected] |
Human Robot Interaction
Smart productionBaxter, the collaborative robot (cobot)
New generation collaborative robot (Cobot)
Safe human-robot cooperation
Easy to use
34
Smart productionBaxter, the collaborative robot (cobot)
35
Smart productionMeasuring in production
Measuring in production
36
Smart productionSignature analysis
� Control of an automated production process (cutting process)
� Autonomous control of cutting process
� Based on an acoustic signal
� Comparing with a reference signal (= good process)
� Alarm if there is a problem (tool wear, tool breakage)
15-10-2014© Sirris | www.sirris.be | [email protected] | 37
Smart productionISF Examples
� Incremental sheetmetal forming
� Innovative and flexibel processing technique
� Big variety of geometries possible
� No need for expensive tooling
15-10-2014© Sirris | www.sirris.be | [email protected] | 38
Smart productionISF
15-10-2014© Sirris | www.sirris.be | [email protected] | 39
Services
� Shared capacity
� Prototypes
� Process optimization
� Case studies
� Participation of companies in research projects(user groups)
© sirris 2007 | www.sirris.be | [email protected] | 40
Guided tour at Sirris Precision & Smart Factory Lab
� 5-axis precision milling machine Fehlmann P825 Versa
� Smart pick glasses
� Automatic measuring cell Kogame-Safety Eye
� Signature analysis
� Baxter robot
15.10.14
http://www.sirris.be
#sirris - @sirris_be
http://www.linkedin.com/company/sirris
http://blog.sirris.be & http//techniline.sirris.be
© sirris | www.sirris.be | [email protected] |