Adopting next-gen metrology in the machine shop

Laser scanners for machine tools can quickly capture the complete surface data for a part while it is still clamped, bringing new levels of speed, precision and flexibility to machine tool inspection

Automated wall thickness measurements on the machine tool with ultrasonic probes replace time-consuming manual measurements with external devices, without the need to move heavy and large parts to dedicated measurement spaces, ultimately resulting in significantly faster inspections and enhanced data capture

Moving towards a future where production processes will be heavily automated, Hexagon prepares its customers for the upcoming revolution. This is evident in solutions like Best-Fit alignments or HxGN NC Server, which are setting the new standard – automated probing on machine tools.

Hexagon’s shift of metrology towards the machine shop

Reimagining the classical form of metrology to an even more efficient system has always been a goal of Hexagon. While manufacturing keeps relying on certified measurements on measuring machines as per the ISO 10360 standard, Hexagon also transposes metrology right into the heart of machine tools. Various sensor technologies capture and measure all kinds of specifications and pieces.

While Hexagon ensures measurements are captured with accuracy and reliability, it is how they utilise the data that’s rather ingenious. The results are statistically evaluated to discover the unexplored potentials in the production process while simultaneously resolving bottlenecks like process time on CMMs, part transports and personnel shortages.

Mainstream role of machine tool probes in the past were limited to simple probing tasks, such as defining the raw part’s position before machining. For more precise measurements, the utility of other devices, such as coordinate measuring machines, became inevitable. To make the best use of all devices and at the same time remove bottlenecks, Hexagon’s goal is to perform detailed measurements also directly on the machine tool with advanced measurement technologies like ultrasonic measurements, laser scanning and highly accurate probes. In essence, these technologies facilitate on-machine inspection processes, which streamlines quality control procedures significantly.

Hexagon accompanies these technologies with dedicated calibration and verification devices that monitor the geometric condition of the machine tool to derive correction values. This ensures the measurement process capability and reduces dependency on external measurement devices. The combined use of advanced technology and calibration methods not only maximises the potential of CMMs but also reduces the process times, while considerably minimising the demand of highly skilled operators.

Hexagon’s machine tool measurement products

Hexagon has established itself in machine tool measurement solutions, boasting a wide range of innovative tools that enhance production efficiency and accuracy in the industry. 

Machine calibration and optimisation 
Hexagon provides system solutions for the accurate and comprehensive geometric analysis, monitoring and accuracy improvement of machine tools, measuring machines, robots and structures with the ETALON machine calibration and optimisation range.

Tactile workpiece measurement systems
Accurately measuring workpieces is pivotal in any machining operation. Hexagon’s tactile workpiece measurement systems utilise radio or infrared transmission to record individual points on the workpiece. This data helps in determining the part’s position in the clamping and inspecting its dimensions and quality.

Tactile and optical tool measurement
Constant production quality can be ensured through accurate tool data. Tactile and laser tool setters monitor tool wear or breakage. Hexagon’s tool measurement solution automatically feeds this precise data into the control’s tool table, enabling a highly reliable and accurate machining process.

Innovative, application-based sensor solution
Keeping customer needs at the forefront, Hexagon develops innovative sensor solutions:

Ultrasonic probe for wall thickness measurement
The RWP20.50-G-UTP ultrasonic touch probe simplifies the process of measuring the wall thickness of larger parts. Unlike manually measuring wall thickness, which generates machine downtime and a lot of manual effort, the RWP20.50-G-UTP ultrasonic touch probe automates the process using ultrasound technology on the machine tool.

Solutions like the ETALON X-AX LASERBAR for the geometric analysis, monitoring and accuracy improvement of machine tools help to improve the overall quality of produced parts

 

Touch probes are standard on almost every CNC production machine, and Hexagon’s portfolio of probes with radio or infrared transmission benefit from many unique capabilites, such as the combination with other technologies, exchangable measuring units and more

Temperature probe
Monitoring part temperature during the machining process has profound benefits. Hexagon’s temperature probe, which measures the temperature automatically, allows for adjustments to the machining parameters during production based on the temperature readings, thus avoiding potential quality issues due to thermal changes.

Machine tool laser scanner
Hexagon’s m&h LS-R-4.8 is a wireless laser scanner that transmits data via radio to the machine control and measuring software. By capturing and analysing a complete, data-rich image of a part while still clamped, it enhances precision and accelerates machine tool inspection, while minimising the need for external measurement devices.

State-of-the-art machine tool measurement software
Hexagon’s suite of software products caters to diverse measurement needs. From performing quick setups and verifying critical dimensions in process to conducting complex quality analyses, it all becomes a streamlined affair.

HxGN NC Measure: Simplifying the inspection of a wide range of parts directly on the machine tool.

3D Form Inspect: Enables logging ruled geometries and forms on all sides and axes on the machine tool.

HxGN NC Gage: PTB-certified algorithms grant high precision to machines and performance.

HxGN NC Server: Connecting machine tools with the power of PC-DMIS measurement software, it enables the execution of CMM-like operations directly on the machine tool and facilitates active monitoring of measurements across multiple machine tools.

In essence, Hexagon’s innovations transform machine shops into highly efficient production units. With thoughtful, productive leaps in every stage of machining processes, right from measurement to quality control, Hexagon stands at the forefront of leading a new age in the realm of machine tool measurement. 

Hexagon’s versatile measurement probes and sensors turn every CNC machine to a multisensor device, adding advanced capabilities and applications to the shop floor and removing QA bottlenecks

With advanced products and solutions that transcend the limits of current processes to offer in-depth real-time measurement, calibration and verification, Hexagon isn’t merely offering tools for quality and efficiency. They are reimagining processes, redesigning methods and recreating systems to form a future where machine tool measurement is integral to the machine shop, making the pursuit of precision less a process and more a standard.