Carl Zeiss Optotechnik GmbH - Optische Messtechnik
The new, advanced 3D sensor ZEISS COMET Pro AE is the second generation of the ZEISS COMET Automated and, as the heart of the robotic optical 3D measuring system the ZEISS AIBox flex, makes modular at-line measurements even faster and more precise. This increase in performance was made possible by countless technical improvements, and by combining different technical high-end solutions that have already proved their worth at ZEISS.

According to Head of ZEISS Optotechnik Markus Eßer, the new ZEISS COMET Pro AE fringe projector is “based on our high-end solutions and [offers twice the] available resolution, measuring speed and light intensity.” With a transfer rate of 4.6 megapixels per second, the shortest measuring time is 1.9 seconds. “Customers benefit not only from higher speed, the new fringe light projector also impresses on account of its high flexibility, robustness, quality and ease of use. 

Flange-mounted LEDs surround the sensor and camera for fringe projection. Much like a ring light, the additional illumination units are switched on one after the other, creating a distinct edge. This enables optimum capture of cutout and borehole contours. The machined housing gives the sensor the necessary stability, making it well-suited for various ambient conditions.

A 16-megapixel camera achieves an outstanding level of precision with a measuring volume of 550 x 370 x 400 mm. Thanks to its resolution of 4,698 x 3,264 pixels, even very small, subtle details can be identified, like scratches on the parts. Adaptive projection (ILC – intelligent light control) is just one aspect that ensures the previously announced halving of the measuring time, and it significantly reduces processing time. Complex components can be scanned with double the light intensity as compared to the previous model. The technology makes it possible to modify, even partially, the quantity of light projected onto a particular surface. This adjustment is made automatically, meaning the system independently configures the necessary parameters, making time-consuming correction and the modification of different elements a thing of the past.

The fusion of 3D data and edge illumination captures achieves greater structure resolution and data quality. That’s because combining the data from the camera and the projector with the illumination possibilities provided by the LEDs achieves the effective resolution of a 30-megapixel camera.

The automatically configured illumination time ensures easier operation. The system sets this live during the measurement. The measuring mode and surface are considered. The system also identifies unwanted external factors such as vibrations and changes to the ambient light, and it separates test objects from the background. The high degree of automation means employees can get to grips with the system more quickly. 

The integrated photogrammetry camera in the middle of the sensor already proved its worth in the previous model. It positions the individual photos within the space and in relation to each other. This means large parts can be scanned, which is why the sensor has been used until now to measure car body parts in the automotive industry. This technical addition makes the sensor interesting for other fields of application. “Since we have optimized the ZEISS COMET Pro AE for the complex requirements in automotive manufacture, it now features an optimum design for other industries and fields of application requiring a high degree of precision,” says Eßer.

Further information:
Brochure ZEISS COMET Pro AE


Published in Press
ZEISS is releasing two new, advanced measuring systems that will bridge the gap between the basic and premium segments and thus round off its portfolio of optical measuring machines. The 3D sensor ZEISS COMET 8M and the 3D scanning system made up of the ZEISS T-TRACK 20 tracking unit and the ZEISS T-SCAN 20 handheld laser scanner will both come on the market.

The new compact 3D sensor ZEISS COMET 8M is equipped with an 8-megapixel camera and is therefore the new, high-res version of the ZEISS COMET LƎD 2. Its high resolution and accuracy mean this fringe light projector will bridge the gap to the premium product, the ZEISS COMET Pro AE.

“We’re using this new resolution to tap into the application fields of turbine blades and consumer electronics,” explains Markus Eßer, Head of ZEISS Optotechnik. After all, to check whether these complex precision parts are in line with the prescribed tolerances, the data captured using the sensor has to be highly precise. In order to complete the different measuring tasks perfectly, users can opt for one of many lenses – and switching measuring fields is still so easy. The ZEISS COMET 8M offers a host of benefits besides: the 3D sensor is easy to transport, construct and calibrate. People are always impressed with the system’s ease of use.


Compact 3D sensor ZEISS COMET 8M
ZEISS COMET 8M


In order to offer one-stop solutions that meet all customer requirements, ZEISS has also developed a mid-range segment for its modular laser scanner systems.As the name suggests, the ZEISS T-TRACK 20 laser scanner tracking unit has a measuring volume of 20 m3: in this field it can detect the scanner and touch probe that belong to the system. In this way, it bridges the gap between the ZEISS T-TRACK CS+ with a measuring volume of 6 m3 and the ZEISS T-TRACK LV with 35 m3 – and it’s the same size, too. The ZEISS T-SCAN 20 handheld laser scanner is perfectly matched to the tracking system and thus ensures a no-hassle measuring process. 

“The new system was completely revamped – and we now rely exclusively on products from the ZEISS Group. After all, we have the skills for optics and cameras in-house,” says Eßer. The ZEISS T-SCAN 20 enables greater mobility – including for at-line measurements.

“The new systems deliver spotless data at the high speed users have come to expect. We’ve managed to triple the measuring volume and drastically reduce measurement uncertainty,” says Eßer. Accessories that have already been purchased, such as stands, are compatible with the new system.
Published in Press
Friday, 05 January 2018 09:34

Deviations at a Glance

GERKON safeguards quality with the ZEISS COMET LƎD

SYSTEM / APPLICATION
ZEISS COMET LƎD 

INDUSTRY 
Service Provider in the area of coordinate measurement technology and 3D measurement technology 

CUSTOMER 
GERKON GmbH 

TASK
"There is no 'it can't be done'!" is the motto of Gerald Konrad, Managing Director of GERKON GmbH. This company, located in Mooskirchen, Austria, works on customer orders to digitize workpieces, cultural objects, and most recently even indoor spaces and plots of land. The Managing Director's approach to work has paid off. "Business is booming" says the 40-year-old, having generated turnover of more than 300,000 Euros in 2016. There is one additional aspect that is driving sales for this company, founded in 2011: "Companies are starting to recognize that it is worthwhile to allow for the digitizing of parts, instead of creating construction plans manually." This is assuming, of course, that the data quality is good. This is why Konrad, a trained machinist and machine electrician, searched in 2016 for a highly modern scanner with which he could also take orders from companies in the automobile industry. In other words, for clients "who distinguish themselves for operating in a quality-conscious manner." The investment made is "not a small sum for a three-person company" states Konrad, but it satisfies this businessman's requirement to "always strive for the best." Not an empty statement, as emphasized by this Managing Director from Austria, for whom it is also personally important to "keep abreast of the state of the art" and who thus invested approx. 10,000 Euros last year alone, for advanced training for himself and for both of his colleagues.

Within Austria, the company currently belongs to a small handful of companies that can conduct highly precise 3D measurements.

SOLUTION AND PRODUCT
The 3D sensor ZEISS COMET LƎD from Carl Zeiss Optotechnik GmbH, formerly Steinbichler Optotechnik GmbH, is impressive with a resolution of 3296 x 2472, achieved through excellent data quality and highly accurate measurement results. Thus, the device presents itself as the ideal solution for demanding applications in Quality Control and for reverse engineering. The sensor works with an innovative, maintenance-free and economical LED illumination technology. The 3D data collection using the solution implemented by GERKON is fast; the measuring time totals a mere 1.7 seconds per sequence. In addition, the innovative sensor system is extremely compact and light. This fact, together with the high ease of use, ensure that the operator has a flexible functional range for the ZEISS COMET LƎD at his disposal. And thanks to the included ZEISS colin3D software, the measurement results can be compared very rapidly with the 3D data record of the CAD model. In the process, deviations between the specified target values and the yielded current values are comfortably presented as a faulty color comparison, which significantly reduces the margin for faulty interpretations by the user. In addition, the software allows for preparation of detailed protocols for documentation of the measurement results.

RESULT / BENEFITS FOR THE CUSTOMER
After one year of use of the ZEISS COMET LƎD, one thing is certain for Gerald Konrad: "Investment drives the business." Word has already spread that it is now possible to measure parts visually and thus very quickly, and yet with a high level of accuracy. This company, which gets almost all new clients on the basis of referrals, is reporting full order books. This is also because it has enabled the ZEISS system to continue offering reverse engineering. And one additional aspect makes a decidedly positive impact for the Managing Director: "Thanks to the portability of the ZEISS system, we can conduct measurements directly at the customer's location." An offering that has its finger firmly on the pulse of the companies it serves. In the meantime, GERKON employees are conducting measurements "at customer's sites much more frequently than at our own measuring site." To be able to specify for automobile suppliers, more concretely, the deviation tolerances that must be observed so that all parts fit properly during final assembly, the employees now scan e.g., supporting points, locating pins, and welding fixtures for the cars to be manufactured. The greatest advantage is that Konrad can accurately detect, with the fringe projection scanner, every deviation from the target value up to five one hundredths of a millimeter. Thanks to this level of precision, the Managing Director considers the area of application for this ZEISS system to be "almost limitless". From individual parts for vintage cars, to large artist sculptures, "everything has already been digitized" by GERKON.

The Service Provider, who also conducts tactile measurements, believes that the great interest that companies have in visual measurement technology is also compounded by the fact that rather inexperienced customer employees can now technically "interpret the measurement report much faster and better". This is because with the ZEISS system, the deviation between the actual value and the target value are presented visually as a false color comparison. "This is something that truly everyone can understand, the results can be easily interpreted", emphasizes the Managing Director.

GERKON has many advantages thanks to use of the scanner - requiring only a quick training of employees by ZEISS on safe operation of the system.

ADVANTAGES / STATEMENT
- ZEISS COMET LƎD drives business for this Measurement Services Provider thanks to its speed, its accuracy, and the portability of its system
- Visual representation of the deviations between the current value and the target value reduces the risk of misinterpretation by the client
- With the ZEISS system, the Service Provider expands its portfolio with the option of reverse engineering

"Since we started working with the ZEISS COMET LƎD, we scan a large spectrum of components, both quickly and in high resolution, for our clients."
Gerald Konrad, Managing Director and Owner of GERKON GmbH, an Austrian Measurements Service Provider.



Published in Optical Measurement
New development of ZEISS Optotechnik convinced trade public at Control 2017. 

Neubeuern/Oberkochen, May 16, 2017: At Control 2017, Carl Zeiss Optotechnik GmbH presented for the first time a price-optimized 3D sensor that enables companies an easy entry point into pioneering optical 3D digitizing. The ZEISS COMET LƎD 2 Base is a product derivative of the 3D sensor ZEISS COMET LƎD 2, which is already established on the market. 

Only a few years ago the complete measurement of parts was extremely time-consuming. Today, however, thanks to optical 3D sensors, millions of points can be captured contactless and lightning-fast on the surface, and visualized in real time as 3D model. An advantage that, among other things, extremely accelerates quality inspection in the production process. In order to ease the entry of companies into this pioneering technology, ZEISS developed a price-optimized 3D sensor - the ZEISS COMET LƎD 2 Base.

The performance with which the 3D data of the components can be captured with the ZEISS COMET LƎD 2 Base is similar to that of the standard model, but the product derivative (including Calypso Manual) is around one third less expensive. However, as Andreas Fuchs, Product Manager of ZEISS Optotechnik, stresses, this price advantage “doesn’t come at the expense of data quality.” As with all sensors from ZEISS Optotechnik, the most modern technology and sophisticated software are also used for the ZEISS COMET LƎD 2 Base. With the software it is possible to do false color comparisons between nominal and actual data, and to easily create protocols for the documentation of measurement results.

The difference between the two models lies primarily in the limitation of the measurement volume to two, in contrast to five measurement fields that come with the standard model. No arbitrary selection, as Fuchs emphasizes, but the “result of an extensive analysis of the measurement tasks of our customers.” Around 75 percent of all companies, as the Product Manager estimates, are satisfied with the given option to choose between the measurement fields 100 and 250. 

Due to the excellent data quality and the highly precise measurement results, the basic model can be used broadly for various applications ranging from quality control, toolmaking and mold construction to rapid manufacturing and reverse engineering. Even though the measuring speed of the innovative complete solution is not quite as high as that of the standard model, Fuchs is certain that ZEISS “has struck a chord with customers with this product.” 

The customer feedback at Control bears him out: “The performance and the price convinced straight away.” The ZEISS COMET LƎD 2 Base will be available as of July 2017. ZEISS generally examines customer inquiries to ensure that the respective measurement task can be satisfactorily processed with the desired solution. This is a service that protects customers from making false investments and ensures that the “high potential of optical measuring technology can really be used,” according to Product Manager Fuchs. 

Additional information
Published in Press
Thursday, 03 August 2017 09:19

Fringe Projection for Fast Scans

New ZEISS 3D sensor speeds up digitalization of parts


Optical metrology is not new to the world, but it is a cutting-edge technology topic for most industries. The fringe projection technology, in particular, opens up various application possibilities. Carl Zeiss Optotechnik GmbH has launched a successor model of this sensor in the market, ZEISS COMET LƎD.

"Even if not all measurement tasks can be solved optically, they are suitable for an increasing number of industrial applications," says Dr. Marcus Steinbichler, Managing Director of ZEISS Optotechnik. The great advantage of all optical 3D measuring methods is their speed with which they capture many measuring points at a time – and is on a continuous technological evolution path. With the 3D sensor ZEISS COMET LƎD 2, ZEISS has now reduced the measuring time by 50 percent per sequence compared to the predecessor model. So, as much as 5 million measuring points can now be captured in one second. "With our new system, fringe projection has become even more interesting for companies", Dr. Steinbichler claims. The CEO's expectations do not seem to be over the top, as the forerunner model, ZEISS COMET LƎD, has already been an industry favorite for several years.

Blue light visualizes geometries
The new generation of the ZEISS COMET LƎD 2 fringe projection sensor uses advanced optical technology. It has a projector module which projects blue LED light as a striped pattern onto the measurement object. This pattern is specifically distorted by the geometry of the respective component and captured by a camera. A software links the individual camera pixel to a point on the part via triangulation calculations. The point cloud generated in this way is then converted to a triangle mesh in STL format, with which a 3D model can be generated. This model can then be used for target / actual comparisons to the 3D CAD model. Compared to laser scanners, fringe projection provides more precise results. For this reason, this method is particularly suitable for quality assurance, as the following applications prove.

Focus on quality – Total Quality Improvement
"Good quality is of crucial importance. There is always room for improvement!” Ernst Mahle, the company founder of MAHLE Group, made this statement more than 100 years ago, but it is still one of the company's most important business maxims. For this reason, MAHLE Behr GmbH & Co. KG, headquartered in Stuttgart, continually defines more effective standards for quality planning during product development and production start-up, and systematically monitors internal production processes. When MAHLE took over Behr company in 2013 - a German family-owned company that e.g. manufactures air-conditioning for cars – a decision was made: the stainless-steel rectangular tubes used for producing EGR coolers for cars and trucks should no longer be purchased from external suppliers, but produced in-house on a production line planned specifically for this purpose. This required random dimensional inspections to be carried out in series testing, combined with a new measuring system.

Focus on total surface
MAHLE Behr defined several requirements for a new measuring system. For instance, it should be able to do even two-dimensional (2D) evaluation of the wall thickness across the stamped area of the tube as well as of the pipe ends. In addition, an automated measuring process and a compact measuring system were required since the plant operators should carry out the measurements in a small measuring room directly on the production line. The measurement system should also be easy to duplicate so that it could be used for future production lines worldwide. The fringe projection sensor ZEISS COMET LƎD met all these requirements. As the entire surface can be analyzed and evaluated using false-color representation, the machine operator is able to make any necessary fine adjustments of the slider on the stamping press while still maintaining the required minimum wall thickness. Moreover, geometric dimensions can now be tested to enable error-free automated assembly.

Reduction in measurement time
Not just MAHLE Behr, but also HERU Werkzeugbau GmbH & Co. KG uses the fringe projection sensor for demanding applications in quality control. Founded in 1987, the company develops and manufactures complex sheet metal parts as well as numerous tools. Tactile measuring machines are used to measure the components in order to ensure high product quality, however, these machines were reaching their utilization limits. The requirement for fast, complex measurements in series production was gradually becoming the primary focus of quality assurance. "We have now become so accustomed to this convenient measuring system that we can no longer imagine quality assurance without it," emphasizes Markus Hesse, Managing Director of HERU Werkzeugbau GmbH & Co. KG, Lennestadt-Grevenbrück, "We should have taken this step much earlier." Due to the possibility to do target / actual comparisons quickly and with minimal effort as well as the easy handling and the fast analysis of new parts, the company decided to opt for a ZEISS COMET LƎD. It fulfills the desire to perform fast measurements – in less than two seconds per sequence, even complex parts are scanned.

Faster product development
The ZEISS COMET LƎD sensor not only proves its advantages in quality assurance, many companies also use the system for product development, such as the shoe manufacturer Lorenz Shoe Group AG from Austria. The development of a new shoe model starts with the creation of a master model that is used as the basis for the subsequent series production. In order to create new models more quickly, the company employing more than 1,000 employees was looking for a measurement system to digitize the shoe lasts and then develop the soles in 3D. With the COMET LƎD and the automated COMETrotary turn-table for positioning of components, the master model is now fast and easy to measure, and the master data can be created and saved in just a few steps. "By introducing the COMET LƎD sensor we have been able to reduce development lead times to a fraction of what they used to be" says Florian Kaidlsdorfer, developer at the Lorenz Shoe Group, "We can respond much faster to fashion trends and develop intermediate collections for our own international retail business."

3D data for unique glass objects
Cristalica GmbH, a glass factory in Döbern, Germany, is even one step further in product development than the Lorenz Shoe Group. It allows the end user to modify existing 3D models of their products and thus create unique designs. Before the introduction of the ZEISS COMET LƎD sensor, samples had to be manually measured and recorded in order to display them digitally. The portable ZEISS sensor makes 3D data acquisition much easier, faster and more accurate. In addition, the handling is very convenient for its users. The glass factory also uses the 3D data obtained by the ZEISS system for quality assurance and for preparation of series production.

Wide range of applications
Bernstein Innovation GmbH also appreciates the range of applications of the system. "The ZEISS COMET LƎD has paid off from the very first day," says Stefan Niedermair, CTIO of Bernstein Innovation GmbH. The Austrian company develops and produces consumer goods by means of 3D printing and was initially looking for a measuring system that precisely captures complex geometries and can measure a wide range of component sizes ranging from a few millimeters up to 55 cm edge length. With the acquisition of the ZEISS COMET LƎD, another field of application soon opened up: digitalization of components. Thus, the company can easily create 3D components which have not been digitized. This provides enormous potential for the 3D printing.

Universal use
Although ZEISS COMET LƎD can already be used for a wide range of applications, because of its performance parameters and its compactness, the new ZEISS COMET LƎD 2 which has been available since February 2016, will "continue to drive this development," claims Herbert Daxauer, Product Manager 3D Digitizing. A significant advantage for companies looking to scan complex and or large components is a short measurement time of only about one second. They can save up to one hour of measurement time during each project. As the sensor is even more compact than its predecessor, it is even more handy. This is an advantage when, for instance, interior or compact spaces are to be digitized, or when the sensor has to be transported to different sites. As with the predecessor, the modular design allows changing the measurement field easily and quickly. For this reason, companies can solve different measurement tasks with just one sensor. According to Mr. Daxauer, the developers of the ZEISS COMET LƎD 2 have not only limited themselves to improving the existing functions, but have also created new features. The new sensor detects changes in exposure and vibration. An innovation that, according to Mr. Daxauer, "reduces the uncertainty of measurement and thus inspires product developers and quality managers".

 

 

Published in Optical Measurement
Tuesday, 01 August 2017 13:13

3D sensor optimizes 3D printing

ZEISS COMET LƎD enables the research institute Wood K plus to carry out a nominal-actual comparison. 

SYSTEM / APPLICATION
ZEISS COMET LƎD 

FIELD
Research and development 

CUSTOMER
Kompetenzzentrum Holz GmbH (Wood K plus) 


TASK 
Kompetenzzentrum Holz GmbH or Wood K plus for short is a leading research institute for wood and related renewable raw materials in Europe, located in Linz, Austria. Around 115 employees in five research areas at four locations (Linz, Tulln, Lenzing, St. Veit) are currently researching how renewable raw materials can be finished and processed for innovative applications and used for high-tech applications.

The fact that the scientific output of the competence center is internationally recognized is documented by many, in some cases highly ranked publications. In 2015 alone, the team from Wood K plus published more than 100 articles in refereed scientific journals and conference papers, as well as in trade journals and books. In addition to this, the center counted more than 50 ongoing academic works in the same year.

An important focus of research of the scientists in the field of wood-polymer composite materials is the development and processing of composites of renewable raw materials and thermoplastics (WPC: Wood Polymer Composite and NFC: Natural Fiber Composite), including with the use of 3D FLM printing. This is a theme that is of great interest for many companies from the industry due to its enormous practical relevance. In the context of a new international pilot project (Interreg Austria-Bavaria 2014-2020; technology and research platform "Hybrid Materials", AB97), the Kompetenzzentrum Holz was able to expand its infrastructure in Linz with additive production with 3D FLM printing.

In order to be able to manufacture high quality work pieces with this still innovative process, the deviations of the 3D-printed parts from the nominal values of their CAD model must be definable. In 2016, Wood K plus therefore invested in a ZEISS COMET LƎD that for the first time enabled researchers to carry out analyses of this kind.

SOLUTION AND PRODUCT
The Austrian scientists decided in favor of the strip projection sensor of Carl Zeiss Optotechnik GmbH especially due to its precise measurement results, which are "indispensible" for making qualitative statements about the nominal-actual deviations of the ongoing project in the field of wood-polymer composite materials."
The ZEISS COMET LƎD is an innovative sensor for the recording of 3D data that is based on the measurement principle of strip projection and blue LED technology. Here a strip pattern is projected onto the respective measurement object using the blue LED light. This pattern is specifically distorted due to the geometry of the respective component, and is recorded by a camera.

The intuitively operated ZEISS collin3D software subsequently uses triangulation calculations to establish a relationship between the individual camera pixel and a point on the work piece. The point cloud created in this way is then transformed to the so-called triangular network in the STL format, with which a 3D model can be generated. This is then drawn upon using the inspection software INSPECTplus, also from ZEISS Optotechnik, for the nominal-actual comparison with the 3D CAD model.

RESULT / BENEFITS FOR THE CUSTOMER
Only a few hours were required to launch the ZEISS COMET LƎD for practical usage. Because, according to the employees, handling is "easy and intuitive“, all of those trained could subsequently work independently with the ZEISS COMET LƎD after a brief introduction by ZEISS. After several weeks of intensive usage, the employees of the Kompetenzzentrum Holz were then introduced to the fine points of the system. Thanks to this detailed ZEISS workshop, which took place over several days, "we can now exploit the complete potential of the system."

The Austrian research institute Wood K plus currently uses the ZEISS sensor especially for the analysis of the components created with 3D printing or for the detection of deviations from the nominal geometry defined in the CAD model. Thanks to the precise measurement results, the scientists in Linz are able to adapt the printing process as hoped in such a way that, depending upon the material, the nominal-actual deviation already lies within the strived for or prescribed tolerance range after 2-3 test runs.

In addition to this, the employees can also digitalize various injection molding parts with the ZEISS COMET LƎD. "This makes it possible to evaluate and correlate the process-related differences with regard to the shrinkage behavior of the respectively used materials in the injection mold in comparison with the 3D print more quickly than previously.”

ADVANTAGES / STATEMENT
- "The price-performance ratio of the ZEISS COMET LƎD is convincing: we received an extensive system with a high degree of flexibility and performance capability at a fair price."
- "We were looking for an exact digitalization system. The ZEISS COMET LƎD fulfils our requirements, which is why we consciously chose it."
- "We use the ZEISS COMET LƎD to analyze whether the components manufactured with 3D FLM printing deviate from the nominal geometry (CAD). With this information, we adapt the printing process in such a way that the prescribed tolerances are observed."
- "Thanks to the time savings achieved through the adjustment of the process parameters for the required tolerances with the assistance of the data, investing industrial companies can anticipate a quick return on investments on the foundation of our development results."
DI Josef Ecker, scientific employee and lecturer on wood-polymer composite materials, Kompetenzzentrum Holz GmbH


Published in Optical Measurement
Tuesday, 11 July 2017 10:32

Visualized measurement deviation

Injection mold manufacturer uses ZEISS COMET LƎD to accelerate both quality assurance and the testing of initial samples. 

SYSTEM / APPLICATION
ZEISS COMET LƎD 

SECTOR
Injection molding / module assembly 

CUSTOMER
EMKA-Plast GmbH, Hille, Germany 


TASK 
The eastern Westphalian company EMKA-Plast GmbH has been designing, producing, and assembling plastic items and modules in Hille in the Minden-Lübbecke administrative district for 20 years. In the meantime, the company, with its 25 employees, works for a large number of internationally active companies from a wide variety of industries. 

Seventeen injection molding machines are used in Hille to process the many customer orders. Around the clock. They use pressure to press liquid plastic into injection molding tools, which respectively determine the shape and the surface quality of the parts to be produced. Although injection molding is a common process today, the production process is nonetheless in no sense trivial, considering the strict quality specifications of customers. Especially when, as is usual in Hille, insert parts are inserted into the injection molding tool, which EMKA-Plast usually produces itself, and sprayed with plastic. The inserts are usually threaded sockets, contacts, plates, or coils. The spraying of other components such as magnets or PCBs is also possible in Hille.

In order to assure the quality of its broad product portfolio, the medium-sized company works with a 3D measuring machine that measures optically and tactilely. However, that takes time. Especially when parts with 200 or more specifications need to be tested. The manufacturer of plastic parts therefore searched for a digitizing system that enabled a rapid nominal/actual comparison. The system especially needed to be suitable for initial sampling reports. Also of great importance to the business management was that handling be simple and that the training of employees require no more than a week.

SOLUTION AND PRODUCT
The fringe projection sensor of Carl Zeiss Optotechnik GmbH scored points both with the business management and with the employees in Quality Assurance, who in the meantime use the system on a daily basis. Especially the results, which are very precise in comparison to other 3D digitizing methods, and the impressive speed in comparison with tactile measuring processes were immediately convincing.

The innovative ZEISS COMET sensor for 3D data recording is based on fringe projection and blue LED technology. It projects blue LED light in a fringe pattern onto the object to be measured. This pattern is specifically distorted by the geometry of the respective component and recorded by a camera. Software uses triangulation calculations to establish a relationship between the individual camera pixel and a point on the work piece. The point cloud created in this way is then transformed into the so-called triangular network in the Stl format, with which a 3D model can be generated. This is then drawn upon for the nominal/actual comparison with the 3D-CAD model.

RESULT / BENEFIT FOR THE CUSTOMER
Five days were enough to introduce the fringe projection or the system from ZEISS at the manufacturer of plastic parts. During this time, one employee of ZEISS Optotechnik trained two EMKA-Plast employees on location in Hille. For the person responsible for quality, "the week was more than enough" to be able to use the ZEISS COMET LƎD safely for a variety of tasks.” This is because, thanks to the excellent data quality, the application range is also broad for the manufacturer of injection molding parts.

According to EMKA-Plast, "the system utilizes all of its strengths”, especially for the creation of initial sample test reports. In addition to the considerable time savings in their own company, the company emphasizes another advantage: Thanks to the colored representation of the nominal/actual comparison, customers can now see at a glance whether all specifications are within tolerances. "That clearly involves less effort and time than working through sometimes endless table columns full of actual and nominal data."

ADVANTAGES / STATEMENT
- "Although concrete figures for a before-after comparison are missing, it goes without saying that the use of the ZEISS COMET system saves EMKA-Plast an unbelievable amount of time in the creation of initial sample test reports."
- "Customers also profit from the use of the ZEISS COMET system. This is because, thanks to the colored nominal/actual comparisons, the initial sample test reports can now be read more easily and quickly, which also reduces the time required by the customer."
- "The handling of the ZEISS COMET system is extremely simple. It can be safely operated after only a few days."
Quality testing, EMKA-Plast GmbH
Published in Optical Measurement
This engineering firm for measurement services has now switched to ZEISS COMET LƎD.

SYSTEM / APPLICATION
ZEISS COMET LƎD

BRANCH
Measurements

CUSTOMER
Andreas Rühmer Engineering Firm, 35088 Battenberg 


TASK 
Battenberg is a small town in Hessen, with a population of only 5,500. It is also the hometown of Andreas Rühmer, the founder and owner of this engineering firm specializing in measurements.

As a Mechanical Engineer, he works on more than 1,000 orders every year – primarily from customers from the automotive industry – together with his seven employees. This figure is also on the increase. The spectrum of services offered by this service provider in the area of contract measurements include the preparation of initial sample reports and the execution of feasibility tests, as well as the digitizing of components for the execution of target-actual comparisons and for reverse engineering.

Due to ever-more complex designs and the increasing number of free-form surfaces on components, important functional measurements continue to be performed only in tactile form or contact-free, using 3D measurement machines. The trend is moving more and more toward the digitizing of components and comparison of data generated in this manner with the 3D data.

In 2011 – following testing of multiple digitizing systems – the Rühmer Engineering Firm invested in a contact-free 3D white light fringe projection system by Steinbichler, known nowadays as Carl Zeiss Optotechnik GmbH. For three years, Rühmer and his employees used the ZEISS COMET 5 system in order to quickly digitize workpieces and compare them with the CAD model.

In 2014, working for more than 60 customers both domestically and internationally, the company switched to the more precise ZEISS COMET LƎD. "We wanted to offer our customers the most current and innovative system on the market", states the visionary engineer regarding his decision.

SOLUTION AND PRODUCT
The special 3D sensor projects blue LED light as a stripe pattern onto the object to be measured. This muster is specifically distorted due to the geometry of the respective component, and is recorded by a camera. The software generates relationships between the camera, the projector, and the projected point on the workpiece, using triangulation calculations. The scatter plot created in this manner is then converted into a triangular network in STL format. This how a 3D model, that can be used for the target-actual comparison with the 3D CAD data set, is created.

RESULT / BENEFIT FOR THE CUSTOMER
Currently, the engineering firm is using the ZEISS COMET LƎD for verification of the profile forms and for the reverse engineering. These are tasks that this service provider had already conducted for its customers using the ZEISS COMET 5. However, the resolution is now significantly higher, allowing for finer details during the target-actual comparison itself. This is an advantage that equally "excites" both quality-conscious customers and measurement technology experts. Furthermore, Andreas Rühmer sees two additional reasons why the ZEISS COMET LƎD represents "a clear step forward in the area of digitizing", in comparison to other systems: 1. an easy modification of the measuring fields, and 2. lower operating and follow-up costs thanks to conversion to the LED technology.

ADVANTAGES / STATEMENT

- "Our quality-conscious customers value the high resolution of the ZEISS COMET LƎD and the possibility to image the finest details."
- "The training and installation expenditure was low - thanks to our existing knowledge, but primarily because the operation is intuitive."
- "With the ZEISS COMET LƎD we are expanding our spectrum of services and we can thus acquire additional customers."

Andreas Rühmer, Andreas Rühmer Engineering Firm, Battenberg
Published in Optical Measurement
Thursday, 03 November 2016 08:40

Concentrated fringe performance

Fast custom digitizing with the ZEISS COMET LƎD. 

SYSTEM / APPLICATION 
ZEISS COMET LƎD 

FIELD
Aerospace 

CUSTOMER
RUAG Aerostructures Services GmbH, Wessling - Oberpfaffenhofen, Germany 


TASK 
Using the latest technologies in composite forming, sheet-metal forming and metalworking, RUAG Aerostructures Services GmbH in Wessling - Oberpfaffenhofen, Germany, manufactures, develops and integrates primarily structural modules and precision components for aerostructures. The company's core competencies include specialised processing methods, forming technology, surface engineering, assembly technology and environmental technology, which are reflected in large, highprecision individual components, detailed components or complete modules and systems.

The customer base spans many industries, ranging from machine builders and semi-conductor manufacturers to wind power specialists, to companies in the automotive industry; but RUAG's primary customers are the renowned aeroplane constructors.

In order to manufacture products at the highest quality level, quality assurance with guaranteed high dimensional accuracy is absolutely essential. Comparisons of target versus actual component performance are indispensable in this regard, and contactless 3D measurement methods provide the most efficient way to capture data.

The decisive factor in acquiring a 3D scanning sensor was the realisation of a project in which it was necessary to perform optical measurements on the actual condition of approximately 1,500 components with an accuracy tolerance of +/- 0,05 mm, and to reverse-engineer CAD parts from the STL files.

SOLUTION AND PRODUCT
Following an extensive evaluation, RUAG chose the ZEISS COMET LƎD fringe projection sensor from Carl Zeiss Optotechnik GmbH (formerly Steinbichler Optotechnik GmbH), headquartered in Neubeuern, Germany.

This innovative measuring system for 3D data acquisition provides an extremely convenient system solution for the application at hand. An added plus is its intuitive ZEISS INSPECTplus software.

In connection with a very clear, structured system configuration, the software makes it possible for technicians to work independently with the system following a four-day training. The different lenses allow measuring ranges to be adjusted to the various component sizes in the blink of an eye, easily assuring the required dimensional tolerance of +/- 0.05.

Fast custom digitizing with the ZEISS COMET L3D. Fast custom digitizing with the ZEISS COMET L3D.
                              Measurement set-up: ZEISS COMET LƎD with rotary table

RESULT / BENEFITS FOR THE CUSTOMER
Since acquiring the maintenance-free 3D sensor, RUAG is now able to evaluate part documents for components using a completely new approach. Two different production states can be compared immediately and evaluated through rapid generation of STL files. This is accompanied by the possibility of quickly incorporating this new, time-saving type of target/actual data analysis into new quality assurance process chains. Exceedingly short measuring times of under two seconds per individual image allow for a degree of efficiency which was previously lacking. It is also worth noting that the system fits perfectly into its ambient conditions thanks to countless attachment options (from pedestals to wall brackets).

ADVANTAGES / STATEMENT
- Extremely high dimensional accuracy
- Clear, structured system layout
- Simple, flexible and easy to operate
- Only four days required for training
- Target/actual comparisons
- Comparison of various production stages
- Intuitive software

"It's hard to believe how fast we were able to work productively with the ZEISS COMET LƎD. The system provides countless data acquisition options and enables us to define new quality assurance processes which allow more efficient accuracy checks."
Guido Maier, Team Leader, Measuring Technology, RUAG Aerospace Structures GmbH - Gilching
Published in Optical Measurement
Following the acquisition of Steinbichler by ZEISS last year, Central Scanning Limited is now the UK authorized reseller for ZEISS Optotechnik 3D scanning solutions. Central Scanning will continue to support existing Steinbichler customers in the UK as well and provide hardware demonstrations, training and support for all new ZEISS 3D Scanning solution customers.

If you have any other questions please feel free to contact Central Scanning Limited:

Address:
Unit 9, Wildmoor Mill, Mill Lane, Wildmoor
Bromsgrove, Worcestershire B61 0BX

Phone: 01527 558282
Email: 
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