In today's fast-paced manufacturing world, precision and efficiency are more important than ever. To meet these demands, innovative technologies like optical gauging systems are revolutionizing how manufacturers measure and maintain the quality of their products.
In this interview, Dr. Erik Novak, Vice President, and Kris Brown, Application Engineer from 4D Technology, speak to AZoOptics about the impact of optical gauges and how 3D Metrology can be used for precision inspection.
Could you explain the importance of optical gauging systems in modern manufacturing?
Dr. Erik Novak: Optical gauging devices are becoming increasingly important on the factory floor. They provide a faster and more reliable non-contact measurement mode than older methods.
In manufacturing, where precision is critical, having a device that can swiftly and correctly measure items without physical contact decreases the danger of damage while speeding up the entire process. This is especially important when dealing with complicated surfaces, as traditional approaches may struggle.
Image Credit: IM Imagery/Shutterstock.com
Could you tell us more about the 4D InSpec product range and how it works with other technologies?
Kris Brown: The 4D InSpec product portfolio consists of our flagship system, the 4D InSpec surface gauge, and our new 4D InSpec SR surface roughness system. The 4D InSpec, with micrometer-level resolution, is the first handheld, precision instrument for non-contact, 3D measurement of surface features and defects. The 4D InSpec SR is the industry’s first portable, precision instrument for 3D measurement of surface roughness, with nanometer-level resolution. All of our industrial systems are geared towards bringing the measurement to the part right on the shop floor rather than having to bring the part to a lab or outside of the production area.
The 4D InSpec product series is highly adaptable, particularly when combined with robots and automation. This enables automated measurements, which increases inspection throughput by up to 100X, and includes the ability to specify pass/fail criteria, flag any out-of-spec measurements and automatically remeasure the location, and allow operators to immediately see both an image of the feature of interest and easy-to-read statistics to qualify a part quickly and accurately.
Image Credit: 4D Technology Corporation
For example, we have previously demonstrated how the system could automatically measure various places on a gear tooth, with the 3D results for edge geometries, radius, and surface defects being directly entered into a database following each measurement. This level of automation speeds the workflow and reduces human error, making it a very useful tool for any shop floor.
What are the issues of surface roughness measurement, and how does the 4D InSpec product line address them?
Dr. Erik Novak: Surface roughness measurement is one of the more complex issues, particularly when working with the large variation of critical machined surfaces, which range from mirror-smooth to sandpaper-rough. The 4D InSpec SR product series is designed specifically to measure that entire range quickly and accurately.
Traditional measurement methods struggle to achieve the high sampling rates and large vertical ranges required for effective roughness measurement. To address this, we have implemented a system that is based on our patented polarization-employing optical technology and proprietary algorithms that enables measurement despite vibration and results in fast, areal roughness measurements with millions of data points.
This system enables us to attain high vertical resolution, even on extremely smooth surfaces. Our technology is also designed to be portable, making it suitable for usage on the shop floor or in more regulated settings.
The 4D InSpec SR quickly quantifies roughness on the shop floor.
Image Credit: 4D Technology Corporation
How does the 4D InSpec product line address real-world applications? Can you provide some examples?
Kris Brown: The 4D InSpec system was designed at the request of leading aerospace manufacturers to develop a way to measure surface defects with a handheld optical gauge with micrometer-level resolution. The 4D InSpec SR is an evolutionary product to expand the handheld capabilities into the nanometer-level surface roughness space. They both serve a wide range of applications that involve precision surfaces, including aerospace, aviation and automotive components and assemblies, MRO, engine components, gears, crank shafts, drive trains, turbines, and even medical devices.
One example is in aerospace blade manufacturing, where there are numerous dimensions that are critical to performance. The 4D InSpec measures features such as edge break, radius, and chamfer, and defects such as nicks, pits, scratches and corrosion. It measures interior and exterior areas of interest, as well as complex geometries and hard to reach locations.
We have also examined a silicon wafer, both its polished and unpolished sides. For example, the unpolished side was rough at about 660 nanometers, whereas the polished side was smooth at 14 nanometers. These real-world applications demonstrate the system's adaptability, whether working with aerospace components, silicon wafers, or other complex items.
It sounds like the 4D InSpec product range is incredibly versatile. What makes it suitable for various industrial settings?
Dr. Erik Novak: Our system's versatility comes from its ability to work with various surfaces and its tolerance to external conditions such as vibration. One of its distinguishing properties is vibration immunity, which is critical in industrial contexts where absolute stability is not always feasible.
The system can be installed on a robotic arm, enabling automatic and exact measurements across various orientations and surfaces. This is especially useful in aerospace and automotive manufacturing industries, where components have complex geometries and tight tolerance requirements.
Chamfers and edge radii, traditionally difficult measurements, are quickly detected and quantified with the 4D InSpec.
Image Credit: 4D Technology Corporation
Can you explain your system's automation capabilities and how they benefit the measurement process?
Kris Brown: Automation is a notable element of our system. The 4Di InSpec automated metrology system (AMS) can automatically measure several places on a gear tooth or any precision machined surface. The automation interface, created by one of our integration partners, logs all measurement results to a pass/fail database based on user-defined nominal tolerances and can automatically re-measure failed spots to verify accuracy. This capacity is especially useful in high-volume manufacturing environments, where consistency and speed are essential.
The automated 4Di InSpec AMS has measured hundreds of typical engine call-out measurements in minutes – hundreds of times faster than manual inspection. In MRO the technology has demonstrated the ability to reduce scrap and rework by up to 40% on engine components.
With such high precision, how do you keep the system user-friendly for shop floor operators?
Kris Brown: We designed the 4D InSpec product line with operators in mind. The software interface is straightforward, allowing for simple setup and operation. Despite its complex functionality, the system is easy to operate.
For example, swapping between multiple measurement sites on a part is very easy. You can effortlessly change the focus, start the measurement, and see the results in real time. The system includes an autofocus feature, making it even more user-friendly. When looking for defects like pits and scratches, the software has an automatic feature analysis that finds defects based on user-defined criteria.
How does the 4D InSpec product line handle complex surfaces, such as those with high incidence angles or extremely fine features?
Dr. Erik Novak: The technology is extremely adaptable, especially under challenging conditions. Surfaces with high incidence angles, say up to 40 to 60 degrees can be measured as long as they are not mirror-smooth, due to the sensitivity of our camera and algorithms. Lateral resolution for our roughness measurements is about 1 micrometer, and for large defects or geometries is about 10 micrometers, so fine features are readily measurable.
The 4D InSpec automatically detects and quantifies pits, dings, scratches and other defects based on user-defined thresholds.
Image Credit: 4D Technology Corporation
In terms of dependability, how does your system maintain accuracy and consistency across various measurements?
Dr. Erik Novak: Reliability is crucial in metrology, and we have worked hard to ensure the 4D InSpec product portfolio produces consistent findings. Our proprietary optical configuration and polarization algorithms create a strong framework for minimizing measurement errors.
We have also conducted rigorous testing to assure system-to-system correlation, which means that the results from one system will match those from another, ensuring stability across several contexts.
What are the primary advantages of using optical gauging systems like yours in manufacturing?
Dr. Erik Novak: The primary benefits are numerous. First and foremost, the ability to acquire results quickly is a game changer. Optical gauging devices provide a near-instant response, reducing downtime and increasing shop floor efficiency.
In addition, the accuracy and reliability of these technologies result in increased yields and customer satisfaction. By lowering measurement uncertainty, producers may confidently develop higher-quality items.
Because the system is simple to use, more operators may interact with it, optimizing the production process even further. Overall, the goal is to provide a tool that improves precision and fits easily into existing workflows, making it an invaluable asset to any manufacturing organization.
About Dr. Erik Novak
Dr. Erik Novak is Vice President and General Manager at 4D Technology, where he was worked since 2013. He has been developing instrumentation for precision metrology for more than 24 years in applications such as semiconductor, optics, aerospace, automotive, photovoltaics, and medical devices. Erik has received seven international product awards, holds over a dozen patents, and has more than sixty publications and book chapters related to surface measurement and industrial process control.
About Kris Brown
Kris Brown is a 4D Technology Application Engineer with extensive experience with products and applications used in the Aerospace, Automotive, and Energy industries. Skilled in assembly and troubleshooting of optical systems in addition to on-site demonstration and operator training. Kris received a Bachelor of Science in Optical Engineering from the University of Arizona.
This information has been sourced, reviewed and adapted from materials provided by 4D Technology Corporation.
For more information on this source, please visit 4D Technology Corporation.
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