Carl Zeiss Optotechnik GmbH - Optische Messtechnik
IDEAL Automotive Oelsnitz GmbH has optimized processes at its Slovakian production site with ZEISS T-SCAN

SYSTEM / APPLICATION
ZEISS T-SCAN 

FIELD
Automotive system supplier 

CUSTOMER
IDEAL Automotive Oelsnitz GmbH 


TASK 
A vehicle's technical features are not the only thing customers consider when buying a car. They increasingly focus on comfort and design – particularly on the interior. IDEAL Automotive Oelsnitz GmbH produces textile lining components for a vehicle's interior, exterior, and trunk. As system supplier for brand-name manufacturers like Audi, BMW and Mercedes-Benz, the company offers comprehensive industry expertise and knows how to meet its customers' demanding requirements. In addition to the look, functionality, and durability of its products, cost efficiency plays a key role. Hence, the need for optimized processes. The German company saw particularly strong optimization potential for the quality-assurance measurements of parts manufactured at its sites abroad.

As the individual locations did not have their own measuring equipment, all test fixtures had to be transported to headquarters in Germany where the company has its own measuring lab, equipped with a contact measuring system. Here the company checked, if the parts met the OEMs' requirements. It was a complicated logistical feat: the test fixtures – known as 'cubing models' – can weigh up to a ton, are quite large, and had to be shipped by truck to Oelsnitz in Eastern Germany and back again. This process meant that, for several days, the fixtures could not be used in production to align the parts. This caused significant costs. To solve this problem, the automotive supplier began a pilot project for optical and mobile measurements – with ZEISS T-SCAN – at its site in the Slovakian city of Bratislava, approximately 600 km away from Oelsnitz.

SOLUTION AND PRODUCT
Now everything works a lot more smoothly: "The mobile scanner has made us significantly more flexible. My colleague and I take turns traveling to Bratislava every two weeks to measure the parts – because the measuring system remains stationied in Germany," explains Jochen Rödel, a measuring technician at IDEAL Automotive Oelsnitz. "We travel there, set up the system, measure, dismantle our equipment, and then head back." The employees at the Slovakian production site requested the ZEISS system. They first researched the different options on the market and identified ZEISS T-SCAN to be the best scanner for their needs. The modular system is user-friendly and suitable for many different applications. The hand-held laser scanner makes intuitive and highly precise 3D scanning quick and easy.

"ZEISS T-SCAN does everything we had hoped for," confirms Rödel who has been using the scanner for more than a year. The three elements are perfectly aligned: the hand scanner, the tracking camera, and the touch probe. The major benefits of the system are its speed and the precise results. 210,000 points are captured every second – more than with any other method. The acquired data provide a detailed look at the actual condition of the component. This can also be compared with the nominal values stipulated in the CAD model. Thus, errors can be identified quickly and easily thanks to a false color comparison of the component surface.

Particularly when scanning large parts such as the cubing model, operators benefit from the excellent ergonomics of ZEISS T-SCAN allowing fatigue-free measurements. The light, compact scanner housing also makes capturing difficult-to-reach areas a breeze.

RESULT / BENEFITS FOR THE CUSTOMER
Even with tolerances of up to two millimeters for textile products, IDEAL Automotive Oelsnitz not only wants to ensure precision, but also be customer-oriented. The company is only responsible for developing the components. "We are involved until the start of batch production, and we use measuring technology every step of the way," explains Rödel. The geometry, cut, and placement of the components have to be inspected meticulously and must meet manufacturer’s requirements. This is where the ZEISS software scores. Problems that occur in production can be solved through component testing. "Learning by doing," is how Jochen Rödel sums up the process. He also counts on the expert service his company receives from ZEISS: "We get immediate support if we have problems or difficulties."

When performing measurements at the Slovakian factory, Jochen Rödel not only gets to know new approaches and different ways of thinking about his work, but also often discovers optimization potential. "The measurements are ideally suited for improving products so that they meet customer requirements. This process speeds up development." His colleagues are keen to implement these recommendations, and they are all impressed by the ZEISS system. "Whenever we arrive with the scanner, people are curious, but slightly hesitant at first. However, everyone is convinced by the time the results are in." Thus, it is planned for additional production sites in the Czech Republic and Poland, that have just opened and are gradually being equipped for production, to benefit from ZEISS T-SCAN as soon as possible.

ADVANTAGES / STATEMENT
- Maximum portability means high flexibility
- Less logistics expenses for factories abroad
- Precise measurements and optimization impress even sceptical employees

"With ZEISS T-SCAN we are mobile. Our customers benefit from a faster development process based on the measuring results."
Jochen Rödel, Measuring Technician, IDEAL Automotive Oelsnitz GmbH



Published in Optical Measurement
Tuesday, 21 August 2018 14:17

A Quick Fix

The company SLR Elsterheide has significantly sped up their measurement process with the ZEISS T-SCAN

SYSTEM / APPLIKATION
ZEISS T-SCAN CS 

BRANCH
Casting house 

CLIENT
SLR-Elsterheide GmbH, Elsterheide, Germany 


TASK 
Well-known companies such as Caterpillar Inc., the world's largest manufacturer of construction machinery headquartered in Peoria, USA, put their trust in the quality of the vehicle parts cast in the town of Elsterheide, Germany. SLR-Elsterheide GmbH is part of the SLR Group, which produced around 120,000 tons of nodular cast iron machine parts in 2016. The carbon in this particular type of cast iron has a nodular shape. Companies are very interested in nodular cast iron parts for industrial applications because of their outstanding mechanical properties and the relatively low cost of manufacture. As a system supplier for drive systems and components, the SLR Group's customers not only include companies from the construction machinery industry. It is active internationally, supplying its axle parts, gear housings and engine mounts to companies in the commercial vehicle, agricultural machinery, rail technology and mechanical engineering industries.

"Whether it's an excavator or a tractor, the vehicle almost always has a cast part from SLR," says the Head of the SLR Group, whose annual revenue totals 140 million euros.

Today the family-run company has around 700 employees. Its roots go back to the early 1980s: the SLR Group's main factory was first built in St. Leon-Rot, a small city in southwest Germany, in 1981. Located near Dresden, SLR-Elsterheide GmbH produces nodular cast iron parts and has an automatic molding facility. It joined the SLR Group in 2009. Many of the 280 employees working at this site fill orders for quality-conscious customers from Europe, the US, China and Japan. That the SLR Group continues to thrive in a country like Germany where wages are relatively high is primarily the result of their sharp focus on quality. This is evident in the company's reject rate of just 0.5 percent, which is remarkably low for this sector. The quality assurance employees in Elsterheide were looking for a digital solution to further increase the quality of their products as well as the number of nodular cast iron and gray cast iron parts that could be inspected. They wanted a system to replace a coordinate measuring machine that had become a bottleneck in the quality assurance process.

SOLUTION AND PRODUCT
Multiple suppliers presented their solutions before the company made its decision. As Bernd Macijewski, Measuring Lab Manager in Elsterheide, explains, the decision proved an easy one: "The T-SCAN CS from ZEISS best meets our requirements when it comes to precision, ease-of-use and portability."

The hand-held ZEISS T-SCAN CS laser scanner enables the metrology engineer to perform quick, intuitive and highly precise 3D scans. The hand-held scanner, tracking camera and touch probe are perfectly matched, ensuring the modular system can be used for a wide variety of applications. The exceptional scanning speed and the precise measurement results are particularly impressive. The surface of the component is probed using non-contact measurements: the laser line generated in the hand-held scanner completes the job in next to no time. 210,000 points are captured every second, more than with any other conventional method. Since the tracking camera detects the position of the scanner, 3D surface data can be calculated via triangulation. Contact measurements for additional individual points can be performed using the touch probe, enabling the metrology engineer to capture characteristics such as extremely deep boreholes or difficult-to-access recesses.

The data acquired with the ZEISS T-SCAN CS give the operator a detailed look at the actual condition of the scanned workpieces. Since this can be compared with the nominal parameters stored in the CAD model, serious deviations are identified quickly. Even those employees less familiar with metrology technology notice when a characteristic exceeds tolerance thanks to the comprehensive, user-friendly false-color comparison on the screen.

The ZEISS T-SCAN CS also meets even the most demanding ergonomic requirements, making scanning even larger components a breeze. Thanks to the light, compact scanning housing, it is also easy to capture data in difficult-to-reach areas with the ZEISS system. The intuitive, straight-forward operation further expands the range of applications and user groups.

RESULT / BENEFITS FOR THE CUSTOMER
All it took was two days to introduce the system and instruct employees on site, and three days to conduct the software training course for evaluating digitized, 3D data captured with optical measurements. Then the company was able to start using the device for quality assurance and inspection. "Any remaining issues were cleared up quickly as we used the system in our day-to-day work," says Bernd Macijewski, describing the roll-out phase for the innovative ZEISS T-SCAN CS in Elsterheide. Since 2014, two of the site's employees have been using the ZEISS solution to ensure the quality of cast parts manufactured in serial production. "Now we are monitoring a lot more components," says the Quality Manager, immediately highlighting another benefit: "When inspecting new component samples, we are now three to five times faster than with the coordinate measuring machine." This increase in efficiency has also had a positive effect on the reaction times for special measuring jobs, and thus all the workflows in the measuring lab. Not only that: inspecting more components in the measuring lab in Elsterheide has meant no additional costs for third-party measurements. "It used to be the case that, during particularly busy periods, we had to commission third-party measuring labs because we simply could not handle the measurements ourselves," says Macijewski.

ADVANTAGES / STATEMENT
- More workpieces inspected
- First sample inspection is now three to five times faster
- System rolled out quickly

"Introducing the ZEISS T-SCAN CS has definitely paid off. Thanks to this digitization system, we perform our quality assurance and initial sample inspections more quickly, more precisely and more cost-effectively."
Bernd Macijewski, Measuring Lab Manager, SLR-Elsterheide GmbH
Published in Optical Measurement
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
Tuesday, 26 June 2018 16:54

Up to the Challenge

The pump manufacturer Allweiler in Radolfzell, Germany is using the ZEISS T-SCAN to reduce throughput times and costs. 

SYSTEM / APPLICATION
ZEISS T-SCAN 

INDUSTRY
Manufacturer of pumps and cast parts 

CUSTOMER
Allweiler GmbH, Radolfzell, Germany 


TASK 
Located just a stone's throw away from the Swiss border in Radolfzell, Germany, Allweiler GmbH is the country's oldest pump manufacturer and knows exactly what is most important these days: meeting customers' requirements down to the very last detail. The company has been producing pumps since 1860. Most of these must work flawlessly under extreme conditions, which is why materials and designs at this mid-sized company have to fulfill such demanding quality requirements. The pumps produced by Allweiler are not only designed to operate efficiently, but also to have a long service life. Achieving these goals requires outstanding manufacturing precision, so a comprehensive quality assurance system is in place to inspect each part. The key component is the nominal-actual comparison, i.e. the comparison of the manufactured part with the data set from the initial sample or its CAD data. It makes no difference whether the part is supplied by the customer or manufactured in-house. "The dimensions have to be 100% correct," explains Christian Bühring from the Process Planning department for Molding / Sales / Simulation / 3D Scan at Allweiler.

For a long time, an external service provider handled the measurements of cast parts. Yet it became increasingly apparent that outsourcing measurements was slowing down Allweiler's processes and, as a calculation of the company's costs revealed, making them significantly more expensive. "It was clear that, in the long run, it would be cheaper to do the measurements ourselves – even if we had to acquire the necessary equipment."

SOLUTION AND PRODUCT
The ZEISS T-SCAN stood out from the very beginning: the pump manufacturer's hand-held laser scanner will have paid for itself within just two years. Christian Bühring creates the measurement reports for Allweiler's customers and appreciates how user-friendly the ZEISS T-SCAN is. The ergonomic design means scanning is simple and intuitive. "Using this device is really easy. You have three measurement points, and these make scanning so straightforward." This also kept the time needed to introduce the scanning system at Allweiler to an absolute minimum. Within just a few weeks, Quality Assurance employees were using the ZEISS T-SCAN to perform reliable measurements without any problem.

The system comprises three components: a tracking camera, a hand-held scanner and a touch probe. Thanks to its modular design, the ZEISS T-SCAN can be set up in line with the customer's needs. This makes the system suitable for various applications, including measuring difficult-to-reach areas. The lightweight, ergonomic scanner housing is ideally suited for the technology, making measurements a breeze. The exceptional scanning speed and the precise measurement results are particularly impressive: the surface of the component is probed using non-contact measurements and at lightning speed with the laser line generated in the hand-held scanner. 210,000 points are captured every second, more than with any other standard method. Since the tracking camera detects the position of the scanner, 3D surface data can be calculated via triangulation. Contact measurements for individual points can be performed using the touch probe, enabling the metrology engineer to capture hole boundaries or difficult-to-reach areas such as recesses.

RESULT / BENEFIT FOR THE CUSTOMER
Sometimes customers require pump parts with extremely intricate designs. Christian Bühring remembers a plate with twelve individual models on top of it. All of these needed to be scanned. The most important factor was the suspension points. These were affixed to components to lift up and secure them, and needed to be balanced accordingly. Allweiler uses a wet casting process where the model is recreated using a molding material made up of sand and a bonding agent. The mold is hardened by pouring in molten metal and can shift in different directions. "When using the scanner to perform inspections, it became clear that each part had to be measured differently starting with the suspension point." This meant that there was a difference between the outer and inner shape. "Here we were able to use the scanner to great effect to accommodate these dimensions. Since then, we have not had any problems in this area." Another benefit is that the number of defects in the machining phase has been drastically reduced.

"We scan everything we cast – from a rotor or a lid all the way to the housing," says Bühring, citing some of the various components comprising a pump. "First and foremost, doing these measurements ourselves has saved us time." The company's external service provider had estimated they would need about two weeks to inspect each component. By doing on-site measurements, the throughput time at Allweiler is approximately just six hours. Allweiler passes on the time and costs it saves with the ZEISS T-SCAN directly to its customers. For Bühring, it is clear how customers benefit from these optimized processes: "They get the results more quickly and, what's more, test reports have become significantly less expensive."

In the future, not only will new parts be measured with the ZEISS T-SCAN, but the company will also start using the scanner for components it has been producing for years. "This is really exciting for us because we can identify wear in the casting molds early on by comparing the scan with the CAD model," says Bühring. This enables Allweiler's employees to manufacture components that correspond to the ideal first model with fewer interruptions.

BENEFITS / STATEMENT
- In-house measurements increase flexibility and lower costs
- Data sets are captured quickly for initial inspection
- Optimized production processes

"The ZEISS T-SCAN enables us to act a lot more quickly than before. Thanks to the precise measurements, defects in the cast parts are identified at such an early stage in the manufacturing process that the number of rejects has been reduced dramatically."
Christian Bühring, Process Planning department for Molding / Sales / Simulation / 3D Scan, Allweiler GmbH


Published in Optical Measurement
Thursday, 09 November 2017 10:23

For perfect gap and joints

BMW in Munich increases process reliability for front and rear end assembly with ZEISS T-SCAN. 

SYSTEM / APPLICATION 
ZEISS T-SCAN 

INDUSTRY
Automotive 

CUSTOMER 
BMW Group Plant Munich 


TASK 
1,000 vehicles are rolling off the assembly line at the BMW Group Plant Munich every day. Only models of the BMW 3 and BMW 4 series are produced in the Bavarian state capital. These include the models BMW 3 Touring, BMW 4 Coupé, and M4 Coupé which are only assembled here and then exported worldwide.The front-end decisively characterizes the silhouette of a vehicle. For this reason, perfect assembly and strict adherence to the joint plan are of great importance to BMW. For a long time gaps have been tested only with gap gauges. In this process deviations of tolerances are effectively visualized, however, it does not contribute to determining the cause of an error. In the past in order to track down this error, vehicles with a conspicuous joint and gap profile therefore had to be driven to the measuring room and measured there. So, the department searched for a digitizing system to optimize the assembly process. It should be used right after the final assembly, and should provide as precise results as did the system in the measurement room.

SOLUTION AND PRODUCT
The hand-held ZEISS T-SCAN laser scanner enables fast, intuitive, and highly precise 3D scanning. Hand scanner, tracking camera and the touch probe are perfectly matched. The modular system can thus be used for numerous applications. Hereby, the unique scanning speed and the precise measurement results are of great value. This is because the surface of the component is scanned contact-free and lightning-fast with the help of the laser line generated in the hand scanner. 210,000 points per second are recorded; more than with any other conventional method. As the tracking camera detects the position of the scanner, 3D surface data can be calculated with the help of triangulation. With the touch probe, it is also possible to take tactile measurements of additional single points, e.g. in order to capture hole edges or not observable depressions. The data captured with the ZEISS T-SCAN thus describes the actual state precisely. This can then be easily compared with the target specifications, as defined in the CAD model. Deviations can be quickly detected in a user-friendly way with a false color comparison of the entire surface.

BMW in Munich increases process reliability for front and rear end assembly with ZEISS T-SCAN

  BMW in Munich increases process reliability for front and rear end assembly with ZEISS T-SCAN

The ZEISS T-SCAN fulfills highest demands with regard to ergonomy. For this reason, larger components can thus be also scanned without fatigue.   The data captured with the ZEISS T-SCAN precisely describes the actual state. Deviations can be immediately detected with a false color comparions of the entire surface.


As the ZEISS T-SCAN also fulfills the highest ergonomic demands, fatigue-free scanning even of larger components is possible. Thanks to the light and compact scanner housing, the ZEISS system can also easily capture data in areas that are difficult to access. The intuitive and easy handling extend the range of applications or user groups.

RESULT / BENEFITS FOR THE CUSTOMER
Since March 2016 three assembly workers have been inspecting front and rear ends of an average of six completely finished vehicles per day. Hereby, joint and gap widths of the two-part and rounded off radiator grille, the so-called BMW kidney, the headlight, and the bumper are measured. The only briefly trained operators of the ZEISS T-SCAN capture 80 to 90 measurement points at the front end and 40 measurement points at the rear end of the various models. The measured actual values are then compared with the set values of the CAD model. Within two hours it can be determined whether the front and rear ends show any defects. In this way the quality engineers of assembly and body construction can counteract much faster. For the quality and process engineers, the ZEISS system is therefore an important prerequisite to more effectively control in-house processes as well as those of the suppliers. Thanks to the portability of the ZEISS T-SCAN system, the apparatus for the assembly of the front and rear end can be measured directly in the production hall.

ADVANTAGES / STATEMENT
- Fast error detection thanks to precise measurement results
- Easy handling allows operation by assembly workers
- Portability of the system supports error prevention by testing apparatus in the production hall
Published in Optical Measurement
Thursday, 26 January 2017 10:56

A new dimension in increased efficiency

3D digitizing with the ZEISS T-SCAN CS+ optimizes quality assurance and product development. 

SYSTEM / APPLICATION
ZEISS T-SCAN CS+ 

FIELD
Manufacturer of office and contract furnishings 

CUSTOMER
Wiesner-Hager Möbel GmbH, Altheim, Austria 


TASK 
Wiesner-Hager Möbel GmbH from Altheim (Upper Austria) can look back on a history covering nearly 170 years ‒ a history filled with innovative decisions. After decades as a carpentry and construction company, the firm diversified and began manufacturing furniture starting in 1921. To great success. By 1930, the company already had 275 employees on its payroll. And because the management set its focus at an early stage on the booming field of cinema and festival hall furnishings, the company also survived the global economic crisis and the war years. The long-established firm didn't lose its flair for profitable trends after 1945, either. In the 1960s and 1970s, the company was one of Europe’s three most renowned manufacturers of seating furniture. The furniture maker reinvented itself yet again in the early 1980s. At that time, it withdrew altogether from the home furnishings, cinema, theatre and restaurants business units, continuing to operate only its office and contract furnishings division. Today Wiesner-Hager is among Europe’s most successful furniture manufacturers, with an export share of 56 percent.

To continue meeting the increasing quality standards of its international customer base in future while also reducing the time to market for new products, the company management was looking to take its quality assurance to a new level. The manual measurements customarily used in quality control were far too imprecise, and much too time-consuming. A disadvantage that impacted prototype construction; what’s more, it impacted the entire development department. Wiesner-Hager therefore set out to find a fast and precise measuring method. And it found what it was looking for. Carl Zeiss Optotechnik GmbH, formerly Steinbichler Optotechnik GmbH, provided the solution needed to boost efficiency in quality assurance and product development: the handheld ZEISS T-SCAN CS+ laser scanner.

SOLUTION AND PRODUCT
The ZEISS T-SCAN CS+ all-in-one system includes a hand-held scanner, a tracking camera and an optional tactile touch probe. The surface of the parts being scanned is sampled via the contactless laser line integrated in the hand-held scanner. And it all takes place at a rate of 210,000 points per second. During this process, the tracking camera detects the position of the scanner, allowing the 3D surface data to be calculated by triangulation. The touch probe can also be used for tactile sensing of additional individual points, such as perforated edges or impervious recesses. As such the system is extremely versatile and can be used in applications ranging from quality control to tool and die making, design development, rapid manufacturing and reverse engineering.


System setup on site - ZEISS laser scanner  Scanning a component with ZEISS T-SCAN
System setup on site                       Scanning a component

Wiesner-Hager itself uses the laser scanner for a range of tasks in various divisions: Development/CAD, Die-Making and Quality Assurance. The introduction phase at the company was relatively short. “After three days of training, we were already quite good at using the system”, emphasises Günter Weilbold from Quality Assurance, “and after a month of self-directed study, we felt like experts”. The ZEISS system is used specifically for incoming goods inspection, series testing and prototype design, but also to inspect development parts as well as testing and welding equipment.

RESULT / BENEFITS FOR THE CUSTOMER
“Our investment in the ZEISS T-SCAN CS+ laser scanner has paid off. We are now able to detect faults early on, at the product development stage. This allows us to bring high-quality products to market faster and more cost-effectively”, Günter Weilbold continues.
But product development is not the only thing to benefit from the new measuring method, according to Weilbold: “Thanks to the high-speed measurement and process accuracy, we are detecting quality problems in production earlier than before and are thus able to correct them faster”.
Another reason the company decided to invest in the ZEISS T-SCAN CS+ was “because of the ZEISS laser scanner‛s attractive price-performance ratio and ease-of-operation”.

ADVANTAGES / STATEMENT
“Since we have been using the laser scanner, we are measuring faster and more accurately. We are detecting faults earlier and are now more efficient, from the Development department to Quality Assurance”.
Günter Weilbold, Quality Assurance, Wiesner-Hager Möbel GmbH

 
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: 
Flowing through Production:

To dampen dangerous vibrations in ship engines, elastic couplings must be precisely tailored to the needs of each individual ship and its engine. Therefore, the models and varieties of couplings from the manufacturer VULKAN, which produces couplings and gear systems, are appropriately diverse. To exactly analyze this great diversity of couplings, the company looked for a fast and accurate solution to digitize them – and opted for a T-SCAN CS laser scanner from ZEISS.


Challenge: Measure a large variety of couplings
The couplings in the RATO S product line from VULKAN consist of several cast parts. To achieve the required elasticity, two of these castings are joined in a technique known as vulcanization. The problem: technical drawings and actual cast parts did not always correspond 100%. This meant that the employees needed additional time to rework them. To improve the production process, the first thing that was needed was an exact analysis of the cast parts. "We have over 40 versions and sizes in this product line," says Andreas Ladwig, Junior Lean Production Officer. "We would have needed years to capture their geometry using slide gages." A faster and more exact approach was required.

Solution: ZEISS T-SCAN CS manual laser scanner
VULKAN introduced a T-SCAN CS laser scanner from ZEISS. This digitizes the topography of the workpiece with 210,000 single points a second. The data capture software from ZEISS generates a 3D model of the workpiece from these point clouds. The operator first mounts the cast parts on a vise in the production area. During the scanning process a ZEISS T-TRACK CS+ tracking camera mounted on a stand nearby records  the points captured by the laser scanner in a virtually clamped coordinate system.

Benefit: Fast digitization, fewer rejects
Ladwig and his colleagues compared the CAD models with the scans using the INSPECTplus software from ZEISS. They then updated the 'old' CAD models and sent them to the cast parts supplier. They subjected the 'new' cast parts to initial sample testing via a laser scan. "It's all incredibly fast," says Ladwig. "If my colleague scans in the morning and I have time for the analysis in the afternoon, then we can complete the initial sample testing for the component in a single workday. We used to need weeks to do this." The optimization process has led to a major reduction in both the reject rate and in the time and effort required for reworking.

> See the video

              Laser scanner ZEISS T-SCAN      ZEISS T-SCAN



Published in Optical Measurement
Thursday, 30 April 2015 08:03

Perfect start with optical metrology

Two ZEISS Optotechnik systems enable 3D scanning of components at Sonnplast GmbH.

SYSTEM / APPLICATION
T-SCAN CS and COMET LƎD

FIELD
Injection moulding and assembly technology

CUSTOMER
Sonnplast GmbH


TASK
Sonnplast GmbH manufactures high-precision technical moulding parts made from thermoplastic polymers using single- and multiple-component injection moulding methods. The company are headquartered in Sonneberg (Thuringia). As a supplier to car manufacturers and well-known motor-industry suppliers, the company are known in the marketplace for their broad portfolio of products, such as seat covers, fan flaps and cup-holders.

To meet the high quality standards required for interior and exterior parts, Sonnplast GmbH make use of various systems for testing quality: 3D coordinate measuring machine, profile projector, measuring microscope, height gauge and hand-held measuring equipment such as sliding callipers and external micrometers.

To expand their measurement lab, the company were in search of an optical measuring system for small and large components. Because Sonnplast GmbH are ISO/TS 16949 certified, the system had to operate with maximum precision. It also needed to facilitate the work of the measurement technicians whilst saving time in their daily work routines.

SOLUTION AND PRODUCT
Sonnplast GmbH found the solution in two systems from ZEISS Optotechnik: T-SCAN CS and COMET LƎD.

With the hand-held T-SCAN CS laser scanner, even large components can be scanned in 3D quickly, intuitively and with great accuracy. The COMET LƎD 3D sensor, which operates on the basis of fringe projection, provides excellent data quality along with highly accurate measurement results, making it ideal for use in quality control.

RESULT / BENEFITS FOR THE CUSTOMER
Both systems are used daily and are suitable for almost all small to large components manufactured by the company, regardless of whether the components comprise one component or multiple components. The measurements include initial samples, re-qualifications and testing in daily standard production.

Significant time savings thanks to use of the systems have already been seen. The main advantages can be attributed to the fact that the components are pre-aligned in the software, allowing for an assessment of the entire component. Until these systems were purchased, components could only be tested with other measuring instruments by means of single-point measurements. Now the company can obtain an assessment of dimensional stability and potential distortion of the component in a very short time. This enables a further feature, for instance, the "false colour comparison". As a result, Sonnplast GmbH can also act much more quickly on current production operations or pending tool corrections for initial sampling.
Portability when shipping ZEISS Optotechnik systems is of great importance for Sonnplast GmbH. Thanks to the simple installation and removal and the supplied rolling case, portability is assured in superb fashion. And the ease of operation and flexibility of the systems make everyday work routines even easier.

If the component range changes or grows over time, the company can expand the systems. This is possible due to various replaceable measuring fields with which each component size can be measured and evaluated.
Because the software is designed to be very user-friendly, all employees were able to work independently with the systems immediately following the relevant training.

"For our company, value for money is always an important consideration, of course. And in my opinion, both systems offer excellent value for money", says Mr Lengert, Metrology Team Leader.
Shortly after a new purchase, the service network is extremely important. Knowledgeable, friendly ZEISS Optotechnik employees are always at the ready on the Service hotline to answer any questions that may come up during daily use of the systems.

Thanks to the ZEISS Optotechnik fringe projection sensor and hand-held laser scanner, the company will at the leading edge of the competition for some time. Depending on whether the company will expand, it will soon become clear whether the metrology department will also undergo an expansion. Because the systems are compatible, a possible expansion in future poses no problem at all.

Mr Lengert believes the ROI to be very high. Viewed over the long term, the two systems will provide significant time savings. It will thus be possible to measure many more components in a shorter time. This also entails savings in employee costs. Moreover, except for calibration, both ZEISS Optotechnik systems are practically maintenance-free. Thanks to the cutting edge technology of the LED sensors in the COMET LƎD, the systems have a long service life and excellent energy efficiency. The operating costs of the devices are therefore extremely reasonable, a factor which must also be taken into account for long-term use.

ADVANTAGES / STATEMENT

•    Systems are suitable for small and large components, regardless of the number of component parts
•    Clearly evident time savings
•    Highly portable systems
•    Expansion capability of the systems

"We are 100-percent satisfied with our ZEISS Optotechnik systems. They are quick and reliable. Operation is extremely easy and makes everyday work significantly easier."
Maik Lengert, Metrology Team Leader, Sonnplast GmbH


Published in Optical Measurement
Friday, 06 February 2015 08:45

Potential of optical metrology recognised

Service partner HQM Induserv puts trust in ZEISS Optotechnik digitizing and laser scanning system.

SYSTEM / APPLICATION
COMET LƎD and T-SCAN LV

FIELD
Service partner in the automotive and supplier industry

CUSTOMER
HQM Induserv, Chemnitz location


TASK
HQM Induserv, with branch offices in Chemnitz, Leipzig and Zwickau, is a member of the HQM Group. For over 20 years, HQM Induserv has been a service partner in the automotive and supplier industry in Saxony. The company is DIN ISO/IEC 17025:2005 accredited in dimensional metrology and lab testing. In the field of contract measurement at the Chemnitz location, the company has years of experience in the measurement and sampling of components from a wide range of industries. For component measurement and prototype sampling, a number of different tactile and mobile 3D metrology systems are used.

SOLUTION AND PRODUCT
In order to meet new and more stringent requirements in metrology, HQM Induserv opted for two optical metrology systems from the Neubeuern-based company Carl Zeiss Optotechnik GmbH. The many applications an optical metrology system can offer were a key factor for the investment. The company decided in favour of the COMET LƎD 3D digitzing system. The extremely compact, high-performance COMET LƎD system delivers excellent data quality and highly precise measurement results. Due to the extremely short measurement time, measurements are carried out very efficiently.

For the second system, HQM Induserv chose the hand-held T-SCAN LV laser scanner. Thanks to its overall modular concept, the tracking system can be individually adapted to suit a broad range of applications. Metrologists can efficiently and effortlessly measure large objects with a measurement volume of up to 35 m3. The T-POINT LV touch probe allows metrology staff members to take single-point measurements quickly and easily. The touch probe is also used to align the component.

RESULT / BENEFITS FOR THE CUSTOMER
Staff members need a three-month introduction period to master the ZEISS Optotechnik systems and their many configuration options and to use them for business purposes. The service company is now able to meet a host of customer requirements with great flexibility, speed and mobility.

Moreover, measured values can be displayed in a clearer format. The system also allows measured values to be processed for reverse engineering, resulting in the development of a new business sector. Thanks to the T-TRACK LV / T-SCAN LV scanner-tracker combination, larger components can now also be digitized. On-location measurements at customers' sites have also been made possible with the ZEISS Optotechnik systems. The variety of jobs for optical measurement systems ranges from small parts such as emblems all the way to large, complex components from all industries.

It should also be noted that with increasing experience and a continuous learning process on the part of users, the application possibilities compared with conventional tactile measurement techniques also increase.

ADVANTAGES / STATEMENT

• Flexible, fast and mobile
• Clear display of measured values
• Processing of measured values for reverse engineering


"Thanks to the large demand for services which are possible with a ZEISS Optotechnik system, we have already been able to take on a number of complex measuring tasks. Based on our previous experience, we recognised the potential of the new technology. This gives us a positive outlook for the future".
Bertram Sebastian, Head of Metrology, HQM Induserv

Published in Optical Measurement
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