InfiniteFocus is a highly accurate, fast and flexible optical 3D surface measurement system that combines dimensional metrology and surface roughness measurement in one system. Users achieve traceable measurement results in a high repeatability and a vertical resolution of up to 10nm. The robust measurement principle of Focus Variation in combination with a vibration-isolating hardware enables the form and roughness measurement of also large and heavy components. All axes of InfiniteFocus are equipped with highly accurate encoders ensuring precise stage movement. With an automation interface, InfiniteFocus is also applied for fully automatic measurement in production.
InfiniteFocusSL is a cost efficient optical 3D measurement system for easy, fast and traceable measurement of form and finish on micro structured surfaces. Users measure both form and roughness of components with only one system. In addition, color images with high contrast and depth of focus are achieved. The long working distance of up to 33mm in combination with its measurement field of 50mm x 50mm allows a wide range of applications. Measurements are achieved in seconds and features, such as a coaxial laser for quick and easy focusing, further increase usability. With an automation interface, InfiniteFocusSL is also applied for fully automatic measurement in production.
IF-SensorR25 is a solid optical 3D measurement instrument for automated form and roughness measurement in production. The optical measurement sensor is integrated into a production line and delivers high resolution, repeatable and traceable results when measuring surface characteristics in the μm or sub-μm range. Therefore, the IF-SensorR25 is a platform that enables the use of the same measurement process both in-line and in ameasurement laboratory. Standardized interfaces (e.g. QDAS) support an easy and quick integration into production allowing comparable measurements. In combination with a collaborative 6-axis robot, IF-SensorR25 is used as a collaborative system – “Cobot” – for flexible quality assurance and the measurement of microstructures on large components.
PortableRL is a mobile 3D measurement system for quality assurance of micro structured surfaces. Users verify measurement fields of up to (mm) 50x50x26. The system is applied for both curved and flat components. A battery pack allows a flexible use and mobile positioning, enabling the use of the system wherever needed. A large vertical scanning range allows the measurement of various geometry types and forms. Amongst others, fields of use are platen inspection, asphalt measurement, quality assurance of turbine or rotor blades, 3D measurement of steel and body parts.
IF-Profiler is a handheld 3D roughness measurement system for high resolution measurement of surface finish. Users measure roughness of flat and curved components with only one system. Measurements are performed both profile based (ISO 4287) and areal based (ISO 25178). The lightweight IF-Profiler consists of a 3D measurement sensor and a robust, at the same time handy framework. The ergonomic design combines ease of use and required mechanical rigidity. Traceable and repeatable measurements are achieved in a min. measurement time of three seconds.
The EdgeMaster is an optical 3D measurement device for automatic tool measurement on the shop floor. Cutting edges of inserts, drills, millers and other round tools are measured regardless of type, size, material or surface finish. Users measure radii >2μm as well as rake, wedge and clearance angle of tools. Different types, including both waterfall and trumpet, are precisely measured. Traceable and repeatable results are delivered in high vertical resolution even at vibrations, variations in temperature and ambient light. In addition to chipping measurement, the high vertical resolution also enables traceable roughness measurement on the rake face.
The EdgeMasterX originates from the Alicona product line for optical, automatic tool measurement in high resolution. It is a fully automated cutting edge measurement system for quality assurance of drills, millers and other round tools to be applied in production. Specifically, the EdgeMasterX enables 3D measurement of multiple cutting edges. When utilized in combination with a motorized rotation unit, users benefit from the measurement of multiple tool edges, even chamfered edges, in one single measurement run. Deviations from a CAD file or reference geometry are indicated through a traffic light system. Measurements are initiated by a single button solution allowing for measurements to be performed without any further user interaction.
The EdgeMasterHOB is one of Alicona´s optical tool measurement systems and a market-specific adaption of the optical cutting edge measurement system EdgeMaster. Like all Alicona tool measurement systems, the EdgeMasterHOB is used for automated quality assurance. The hob measuring device is particularly applied in e.g. regrinding centers. A working distance of 33mm allows effortless measurement of cutting edges even in areas that are hard to access. Users measure, amongst other features, chipping and edge defects, chamfer as well as edge roundness at the tooth flank, tooth root and tooth tip.
µCMM, the first purely optical CMM machine, is used to measure extremely tight tolerances in high accuracy. Users combine advantages from tactile coordinate measuring technology and optical surface measuring technology and measure the dimension, position, shape and roughness of components with only one sensor. The optical CMM offers high geometric accuracy of several optical 3D measurements in relation to each other, enabling the measurement of small surface details on large components and precisely determining the position of these individual measurements in relation to each other. The spectrum of measurable surfaces includes all common industrial materials and composites such as plastics, PCD, CFRP, ceramics, chrome, silicon. Simple operation is implemented by single-button solutions, automation and ergonomic control elements such as a specially designed controller. Air-bearing axes with linear drive enable wear-free use and highly accurate, fast measurements.
EUni:Tr:ODS,MPE = (0.8 + L/600) μm
EUniZ:St:ODS,MPE = (0.15 + L/50) µm
MeX is a stand alone software package that turns any SEM with digital imaging into a true surface metrology device. Using stereoscopic images the software automatically retrieves 3D information and presents a highly accurate, robust and dense 3D dataset which is then used to perform traceable metrology examination. The results are obtained irrespective of the SEM magnification providing metrology at macro and micro levels. No additional hardware is necessary to run MeX and it can be used with any SEM. Due to the unique AutoCalibration routine the calibration data is automatically refined. Thereby only MeX enables traceable 3D measurements at any magnification in the SEM.
Alicona Cobots combine a collaborative 6-axis robot and a robust optical 3D measurement sensor to deliver traceable and repeatable high-resolution measurements, even in production. They require no prior knowledge of metrology and make handling, programming, and executing measurement series easy. This is made possible by intuitive hand-guided controls for the teach-in of measurement series, automatic measurement evaluation, and a no-enclosures safety concept. As a result, Cobots are ideal for verifying the surface state and dimensional accuracy of work pieces in existing production environments. The following real-world examples demonstrate the advantages and capabilities of two new Alicona Cobots. The DiscCobot is used to automatically verify the edges of turbine discs and the highly flexible Tool-Cobot allows users to measure large tools directly in the machine tool.
Avoiding sharp edges on turbine disks
The DiscCobot is used for the quality assurance of turbine discs weighing up to 120 kg. By verifying minimal radii, it prevents sharp edges that can, in the worst case, compromise aircraft safety. Operating and programming the Cobot is easy and intuitive. The robot arm, with its attached measuring sensor, is easily and conveniently manipulated by the operator to reach the desired surface position. Two handles with an integrated joystick are mounted on the sensor, making the robot arm easy to move. A smartphone app displays the live view for manual, precise positioning and measurement. Using connected automation software, any series of measurements can be defined at several positions, which the operator then starts with the press of a button. Control and measurement are fully automated, and upon completion the worker receives a measurement report with OK or Not OK details.
Designed for measuring large tools, the Tool- Cobot is an innovative addition to Alicona’s range of optical edge measuring devices. It is used, in the quality assurance of drills, millers etc. with shanks of up to 1 m in length. In addition, hobs and broaching tools are measured. The ToolCobot features an HSK interface for easy tool fitting and can be adjusted vertically and horizontally thanks to its flexible axes, ensuring ergonomic operation. The system is also mounted on wheels for added mobility, meaning the Cobot can easily be moved to wherever it is needed. No more re-clamping components or work pieces from the tool machine to measure them—the ToolCobot inspects them directly in the machine. This way, defects and tolerance deviations are detected at an early stage rather than at the end of the production process, preventing faulty components from being produced.
Whereas the existing ToolCobot and DiscCobot are application-specific solutions for the tooling and aerospace industry, the new CompactCobot is a universal solution applicable to all industries to verify surface state and dimensional accuracy of also large components.
The Turbine Cobot is used for the automatic measurement of break edges on turbine cases. Up to 500 measuring positions are taught-in and measured automatically.
The new measurement solution "µCMM and Pick & Place" was first presented at EMO 2019. The optical coordinate measuring machine µCMM is extended with a robot arm to automatically pick, place, measure and sort (ok/not ok) components in all sectors of the metalworking industry.
Dimensional metrology in combination with collaborative robots
Stepper is one of the technology leaders in the field of high-performance punching tools. At EMO 2019 was shown how the the tool expert uses the optical coordinate measuring system µCMM in combination with collaborative robots. The range of applications includes embossing inserts, embossing dies, bending inserts, bending dies, etc.
The machined component is removed from the machine by the robot, clamped on the measuring system and measured automatically. Depending on the manufacturing strategy, there are different options of continuing the production process afterwards. Either the measurement result is fed back into the tool machine following a closed-loop strategy, where machine parameters are corrected automatically and manufacturing continues in a self-controlling manner. Alternatively, an automatic sorting into OK/NOT OK pallets follows after the 3D measurement for further processing.
The user teaches-in an automated procedure in only three step with no programming knowledge required. The robot handles component manipulation including the positioning on the measuring system and further sorting in OK/NO OK pallets. Regardless of the number of components, only four parts per pallet have to be pre-defined. At the push of a button the operator starts the entire process in production. After the measurement is finished, the component is sorted by measurement results OK/NOK and put in the respective pallet by the robot.
The application areas of Alicona optical 3D metrology are manifold. Users benefit from automated, traceable and repeatable 3D measurements in a laboratory as well as in production. The optical high-resolution measurements enable manufactures to verify accuracy of machining centers and achieve higher reproducibility of processes and products. That way, Alicona supports users in increasing reliability of processes while retaining a high degree of standardization.
Turbine engines are higly specialized aircraft components that must meet enormous safety requirements. One way to meet these new metrological requirements is the use of high-resolution, optical 3D metrology.
The following highly critical turbine engine parts can be measured optically:
High measuring accuracy and a significant reduction in the reject rate are decisive factors in increasing production efficiency. One way to follow a continous improvement process is the use of high-resolution, optical 3D metrology.
Applications of optical 3D metrology in the automotive industry
Alicona measurement solutions enable the optimization of mold making through electrode savings of more than 10%, quality assurance of micro molds and molds in precision manufacturing, geometry measurement of both electrode and eroded mold, verification of surface finish throughout areal surface texture measurement, process optimization, e.g. optimized separation behavior, prevention of sink marks and joint lines, the numerical verification of geometric deviations of the colded part from the injection mould and much more.
“With our machining centers we help our customers to eliminate manual rework as both, the accuracy of the contour and surface quality of the cavity achieved is superior. At this level it is tough to measure the quality, though. With Alicona we have a partner who helps us to prove it.”
Andreas Walbert, Head of Marketing and Product Planning, Makino Europe
Alicona measurement solutions enable the optimization of 3D printing process, quality assurance of additive manufactured parts, surface texture measurement for quality evaluation of entire surface, analysis of porosity throughout volume measurement (Vvc, Vmc), automatic measurements to identify form deviations to CAD dataset or reference geometry, 3D measurements to achieve optimum finishing process, e.g. polishing and much more.
“Our Alicona system has proved invaluable for analysis of the complex surfaces generated by laser processes such as additive manufacturing and high precision manufacturing, providing reliable measurements when other instruments struggle.“
Duncan Hand, Director, EPSRC Centre for Innovative Manufacturing in Laser-based Production Processes (CIM-Laser), School of Engineering and Physical Sciences
High-resolution optical 3D metrology is indispensable in the manufacture of instruments, implants and other medical devices. Bruker Alicona measuring solutions enable the automatic area measurement of shape and roughness.
Applications of optical 3D metrology in the medical industry:
Alicona measurement solutions enable the automatic measurement of micro gears; includes area based measurement and verification of the entire tooth flank of all teeth, measurement of complex shapes with small radii and angles even, at high measurement volumes, determination of shape and roughness via large lateral and vertical scanning areas within one single measurement process, checking and verification of dimensional accuracy and finish quality, measurement of composites with various materials and reflective properties, failure analysis, incoming goods inspection and integrated tools compensation, 3D measurement of dies, quality assurance in stamping and forming technologies.
“We mainly use Alicona’s option of full form measurement. And we believe that Alicona has no competition in this field. ”
Frank E. Pfefferkorn, Associate Professor, Mechanical Engineering, University of Wisconsin-Madison
Cutting edge defects, high wear, long machining times or unsatisfactory results on drills, milling cutters etc. are challenges with which manufacturers are confronted. The optimal tool and machining parameters can be determined with optical 3D metrology.
Applications of optical 3D metrology in the tooling industry:
The applications of optical 3D metrology are manifold. Read more about where Alicona optical 3D metrology is still used.
"When investigating human or animal bones, we usually face rather difficult surfaces that show very steep flanks. Also, weapons or synthetics with reflecting metals were difficult to view and measure before we worked with InfiniteFocus. It is the perfect tool to measure in a high resolution even with difficult surface conditions.“
René Pietermann, Forensic Scientist, Nederlands Forensisch Insituut