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Metrology


on the measuring points, a measurement taken with a CMM probe would usually take between 10 and 20 minutes per crankshaft. “We initially saw just an opportunity to speed up inspection times,” says Bouet. “But full-field 3D scanning offers another benefit: a CMM inspection provides only a limited amount of data. These point-based measurements are enough for production control, but we could miss information on part geometry, which is particularly important during the ramp-up phase.” Forges de Courcelles uses the full-field scans for


statistical process control in production. In addition, the forge workers receive a 3D view, in colour, of their scanned parts and can spot deviations and material deficiencies that would have been missed in the past with the point-based CMM. “So we are speeding up the measuring process and making it more intelligible for the workers,” explains Bouet. At Forges de Courcelles, the ATOS ScanBox is


installed at three production stations in the crankshaft forging workshop. About 15 production workers regularly bring their parts to the measuring cell. The Kiosk Interface – a special user interface for simplified operation of the ATOS ScanBox with four modes of operation – makes it easier for them to inspect multiple parts at once, with 30 or more reference points.


acquisition in comparison with other well-known technologies such as 3D laser scanning.” In modern metrology, where processes are driven


and regulated by measuring data, you need to be able to trust the data produced by the measuring system. Forges de Courcelles therefore worked closely with GOM to adapt the system so that it met the criteria for accuracy, resolution and speed of data acquisition. GOM also helped adapt the standard ATOS ScanBox


5120 solution to the specific field of application required by Forges de Courcelles. To enable the company to measure three parts simultaneously, GOM worked with Forges de Courcelles to develop a fixture adapted to the forging environment, which guarantees optimum data acquisition while taking account of ergonomic aspects to keep the employees safe. The cell was adapted to allow for parts weighing up


to 35kg to be loaded on with a jib crane. The necessary safety and security measures were put in place to ensure the cell operated correctly. Throughout the process, collaboration between the teams at GOM and Forges de Courcelles was efficient, not just when installing the system but also during the training, familiarisation and post-installation support.


Full control via the soFtware


Hervé Maupied, an employee at Forges de Courcelles for 32 years (27 of them as a metrologist) and Franck Dorlet, who has also worked for the company for 19 years (three of them as a metrologist), are both user experts when it comes to GOM systems and software. They use the GOM Inspect Professional VMR


Franck Dorlet, metrologist “During the manufacturing process, we carry out


a dimensional check on three parts at regular intervals,” explains Schäfer. “This is to ensure the dimensional accuracy of the finished parts. The complete automation of our crankshaft production lines, including automated measurement, has greatly increased our production output. Previously, with the CMM, the measuring process was very time- consuming. We had to load up a crankshaft, take the measurement, unload it and then repeat the whole process twice over for the other two parts. This would take between 10 and 20 minutes per part. Thanks to the automated, high-speed ATOS ScanBox, which scans and inspects three parts simultaneously, we have significantly improved our response times in case of issues with parts or deviations from the standard parameters. It now takes us just 15 minutes to inspect three parts using the GOM system.” Bouet adds, “From the start, our aim was


to reduce our inspection times, but the reliability of the measurements is also essential in quality assurance. So we compared the GOM measurements with the measurements produced by our conventional systems beforehand. During this validation process, the GOM measurements proved to be reliable and accurate. We were also impressed with the quality of the measurement data and the speed of its


Instrumentation Monthly August 2020


software when programming offline and for assessing measurement data. The ATOS XL Professional VMR software is an essential part of the installed system. It processes the captured images and transforms them into meshes for the purposes of conducting the analysis. The forge workers who carry out the measurements do not need to be software experts. They use the self-explanatory Kiosk Interface. “GOM helped us to customise these modules


and now we have complete control and can work with them without external support,” say the two metrologists.


new company prospects


Forges de Courcelles generates most of its turnover in the automotive industry, an extremely competitive market. Pricing pressures in this sector, along with a pressure to maintain high productivity, have been intense for many years now. The company has grasped this and has taken the necessary steps to ensure it is continuously evolving. “Because of the 3D digitizer, our business is now


able to measure the entire surface of the parts we produce,” says Schäfer. “This opens up new prospects for improving products and processes. The measurement data is contributing to new confidential R&D projects.” “It is not only thanks to the support of the GOM


teams and the further training of the experts at Forges de Courcelles that this ambitious project was achieved,” he adds. “Above all, it is thanks to the commitment of employees at Forges de Courcelles that this standard measuring machine was transformed into a multi-functional unit.”


GOM www.gom.com ATOS ScAnBOx – SerieS 5


by GOM for efficient quality control in the production and manufacturing process. There are 11 models available for


T


different-sized parts and applications. While mechanical measuring systems capture data on a point or linear basis, optical 3D measuring systems provide full-field data on deviations between the actual 3D coordinates and the CAD data. The centerpiece of the automated measuring cell is the robot-guided ATOS 3D scanner. The ATOS ScanBox 5120 is able


to handle parts measuring up to two meters. This model is mainly used for mechanical components such as engines, transmissions and exhaust systems. The ATOS ScanBox 5120 has also performed well in molding, forging and stamping applications. The virtual measuring room


(VMR) acts both as the central control station and as the measurement planning software for all elements of the ATOS ScanBox 5120. The robot can be fully controlled through a clear and safe software interface. This means that users require no


specialist knowledge of robotics. The Kiosk Interface is a user


interface that simplifies operation of the measuring machine. It automatically handles the complete measurement and control workflow, as well as the display of pages of reports and exports. As human interaction is greatly reduced, high precision and data quality are guaranteed, and measurement parameters, data and the operating system are protected. Find out more about the ATOS


ScanBox: www.gom.com/metrology- systems/atos-scanbox/atos-scanbox- series-5.html


57


he ATOS ScanBox is an optical 3D measuring machine that was developed


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