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Why Use a CT Scanner for an Industrial Job?
By Dean Solberg, President, Exact Metrology F
or the longest time, CT imaging technology was only available for use in medical settings. Over the last several years, it has found a new home in the world of manufacturing, and is opening up many opportunities never
before available. Computed tomography (CT), is now commonly found in var- ious industrial metrology settings, both in the lab and in the production line for product evaluation and packaging integrity assessment. The main advan- tage is that it allows the inspection of a part’s interior structure or a package’s closure functionality without causing any damage to the object itself. Industrial CT scanners make use of the same type of technology as CT
scanners in hospitals and doctors’ offices — taking multiple readings from var- ious angles and converting the CT grayscale images into voxel-based three-di- mensional point clouds. Once the CT scanner generates the point cloud, a spe- cialist can generate a CAD-to-part comparison map, construct a 3D model of the part, or reverse engineer the part to suit specific needs. In the packaging world, especially where pharmaceutical or personal
products are concerned, this ability is paramount. High-speed scanning in- line, for example, can examine the seals on pill bottles for airtight quality as- surance, while lab scanning can instantly compare a manufactured product to the CAD program in various ways. Industrial scanners offer a multitude of advantages. These include: ob-
taining internal structure of an object nondestructively; validating extremely accurate internal dimensions; allowing comparison to reference models; no shaded zones; compatibility with all shapes and sizes; no post-processing work; and extremely high-resolution imaging.
Common CT Uses Common uses of 3D and CT scanning in industrial metrology applica-
tions include a wide range of applications, from examining parts and replicat- ing them to verifying the authenticity of works of art. Reverse engineering is extremely useful when a job requires taking a
manufactured part that may not include original prints or design data and copying it. CT scanning can be used for non-contact measurement, capturing the geometry of objects. It can also be used for contact measurement, which is a method of collecting single points relative to each other. Digitizing or artic- ulating arms are used to capture localized or small amounts of information. For larger, more volumetric projects, optical solutions, such as laser trackers and photogrammetry units, are used. The technology is also applicable for long-range scanning, creating a 360° 3D snapshot of a structure, bridge, plot of land, entire factory, or process operation, with millimeter accuracy. These 3D imaging devices and long-range scanners serve a wide range of
industries, and help to ensure manufacturers that they are performing to the highest levels of testing and accuracy. Some of the diverse industries that use the technology include: manufacturing, for internal inspection of components and parts; power generation, for scanning complex, hard-to-reach or haz- ardous areas of nuclear power and other plants for pipe alignment, boiler in- tegrity and building stability; medical devices, including scanning implants and prosthetics; and automotive and aerospace, allowing engineers to virtual- ly test parts and machinery and to perform failure analysis.
Variety of Equipment There is a wide variety of industrial scanning equipment styles and sizes
available to suit different types of applications. Micro-units in tabletop styles for lab use up to full industrial-grade floor models for in-plant or in-process use, to portable measuring arms that can be used on the shop floor or out in the field are all available, usually from a manufacturer or a service organization, for one- time contract use, with optional rent or lease-to-buy arrangements. Many of Exact Metrology’s customers, having used the company’s servic-
es, subsequently purchase the equipment and training to add this high-end metrology to augment their inside CMM or test labs. In the case of larger pro- duction facilities, we often see metrology being integrated into the line for in- stant analysis of parts, whether molded, stamped, welded or otherwise fabri- cated, as well as for packaged goods. Typical CT scanners offer a wide range of measurement capabilities and
features. Sizes start with small desktop models which meet the most stringent demands and measure the smallest 3D detail from 0.25 µm. They can be equipped with different X-ray powers, from 160 kV for nanometer resolution through 225 kV, 320W, to the highest power of 300 kV, 320W. Larger scanners are available for extremely fast CT data acquisition on
workpieces up to 500 mm (19.7 in.) in diameter and 600 mm (23.6 in.) in height, and weighing up to 50 kg (110 lb). Typical functions performed on this type of system include 3D analysis of scanned turbine blades, automatic pour porosity volume analysis for aluminum casting, and 3D measurements with nominal-actual CAD comparisons of machined aluminum cylinder heads. The future of industrial scanning holds unlimited possibilities, especial-
ly when combined with 3D printing or other additive manufacturing methods. As improvements are made in technology and performance and costs contin- ue to decrease, the industrial scanning industry is preparing for explosive
growth in the next decade. Contact: Exact Metrology, Inc., 20515 Industry Avenue, Brookfield, WI
53045 % 262-533-0800 E-mail:
deans@exactmetrology.com Web:
www.exactmetrology.com r
August, 2017
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