9th IFAC Conference on Manufacturing Modelling, Management and

9th IFAC Conference on Manufacturing Modelling, Management and

Control
9th IFAC Conference on Manufacturing Modelling, Management and
Control
Berlin,
9th IFAC
Control Germany, August
Conference 28-30, 2019 Available
on Manufacturing
online at www.sciencedirect.com
Modelling, Management and
Berlin, Germany, August 28-30, 2019
Control
Berlin, Germany, August 28-30, 2019
Berlin, Germany, August 28-30, 2019
ScienceDirect
IFAC PapersOnLine 52-13 (2019) 2782–2787
A
A Closed-Loop
Closed-Loop Inspection
Inspection Architecture
Architecture for
for
AAdditive
Closed-Loop Inspection
Manufacturing Architecture
Based on STEP for
AAdditive
Closed-Loop InspectionBased
Manufacturing Architecture
on STEP for
Additive Manufacturing Standard Based on STEP
Additive Manufacturing Standard Based on STEP
Standard
Standard
Cristhian Riaño ∗∗ Efrain Rodriguez ∗∗ Alberto J. Alvares ∗∗
Cristhian Riaño ∗ Efrain Rodriguez ∗ Alberto J. Alvares ∗
Cristhian Riaño Efrain Rodriguez Alberto J. Alvares
∗ Cristhian Riaño ∗ Efrain Rodriguez ∗ Alberto J. Alvares ∗
∗ Department of Mechanical and Mechatronics Engineering, University
∗ Department of Mechanical and Mechatronics Engineering, University
Department of Mechanical
of Brasilia, and Mechatronics
Brasilia, Brazil, Engineering, University
(e-mail: cristhian.riano@unb.br,
∗ of Brasilia,
Department Brasilia, Brazil,
of Mechanical (e-mail: cristhian.riano@unb.br,
and Mechatronics Engineering, University
efrainrg2009@gmail.com,
of Brasilia, Brasilia, Brazil,
efrainrg2009@gmail.com, alvares@AlvaresTech.com).
(e-mail: cristhian.riano@unb.br,
alvares@AlvaresTech.com).
of Brasilia, Brasilia, Brazil, (e-mail:
efrainrg2009@gmail.com, cristhian.riano@unb.br,
alvares@AlvaresTech.com).
efrainrg2009@gmail.com, alvares@AlvaresTech.com).
Abstract:
Abstract:
Among
Abstract:
Among the
the challenges
challenges posed posed by by thethe newnew industrial
industrial revolution-Industry
revolution-Industry 4.0 4.0 isis the
the integration
integration
Abstract:
of
Among systems the associated
challenges with
posed manufacturing.
by the new In
industrial this sense, the
revolution-Industry inspection4.0 isprocess assumes
the integration
of
Among systems associated
the challenges with
posed manufacturing.
by the new In
industrial this sense, the
revolution-Industry inspection4.0 process
isprocess assumes
the integration
an
of
an important
systems
important role
associated
role since
since it
with
it provides
manufacturing.
provides the
the information
In
information this base
sense,
base to
tothe make
make the
inspection
the decisions
decisions that
that allow
assumes
allow
of
an systems
reaching
important the associated
design
role and
since with
quality
it manufacturing.
specifications.
provides the In
From
information thisthesense,
base tothe
manufacturingmakeinspection
point
the process
of
decisions view, assumes
Additive
that allow
reaching
an important the design
role and
since quality
it providesspecifications. From
the information thebasemanufacturing
to make point
the of
decisions view, Additive
that allow
Manufacturing
reaching
Manufacturing the (AM)
design
(AM) andcontains
quality
contains the potential
specifications.
the potential toFromto meet
From
meetthe production
the manufacturing
production demands
demands point by ofmaking
view,
byofmaking efficient
Additive
efficient
reaching
use of
Manufacturing the design
resources, (AM) and
reducing quality
contains specifications.
manufacturing
the potentialtime, toand
meet enabling manufacturing
production the point
manufacture
demands by view, Additive
complex
making parts.
efficient
use of resources,(AM)
Manufacturing reducing manufacturing
contains the potential time,toand meet enabling
production the manufacture
demands byof complex parts.
The
use ofidea
The idea of
of integrating
resources, reducing
integrating the
the inspection
manufacturing
inspection process
time,with
process and
with aaenabling
robotic
robotic system
the
system for additive
manufacture
for additive ofmaking
manufacturing
complex
manufacturing
efficient
parts.
use
seeks ofidea
resources,
both to reducing
improve the manufacturing
quality of the time,
parts and
producedenabling and theto manufacture
find methods oftocomplex
optimize parts.
The
seeks
The both
idea
of integrating
of to improve the
integrating
the inspection
the quality
inspection
process
of the with
partswith
process
a
produced robotic
a robotic
system
andsystem for additive
to findformethods
additiveto optimize the
manufacturing
manufacturing the
process
seeks
process and
both
and to create
improve
create a
a sustainable
the quality
sustainable system.
of the
system. However,
parts produced
However, to
to make
and
make this
to
this combination
find methods
combination to a
a reality,
optimize
reality, it
the
it is
is
seeks
process
necessary both
andtotocreate
improve
face the the quality
a barriers
sustainable posed ofby thethe
system. parts produced
However,
lack of to make
integration and to this
of find methods toa optimize
combination
the information reality, itthe
produced is
by
necessary
process andto face
create the barriers
a barriers
sustainable posed by
system. the lack
However,of integration
to cycle
make ofthis of the information
combination produced
a produced
reality, by
it by
is
the
the different
necessary
different to computerized
face the
computerized systems
posed
systems throughout
by the lack the
of life
integration ofthe
theproduct.
information Thus, there is no
necessary
integration
the different toofface the barriers
feedback
computerized informationposedthroughout
systems by the
from
throughout lackthe
shop-floorthe
life cycle ofofthe
of integration
necessary
life cycle of for the
the
product.
information
inspection
product.
Thus,produced
and
Thus,
there is by
validation
there is
no
of
no
integration
the different ofcomputerized
feedback information systems from shop-floor
throughout the necessary
life offortheinspection and validation of
the part
integration
part manufactured
of feedback with
manufactured with AM,
information
AM, which
fromdoes
which not
shop-floor
does not allow
allow aacycle
closed-loop
necessary
closed-loopfor product.
digital
inspection
digital
Thus,
thread. there is no
Concerning
and validation
thread. Concerning of
integration
the part
this, the of feedback
manufactured
present article information
with AM, the
proposes from
which shop-floor
does
development not allow
of necessary
an aintegration
closed-loopfor inspection and avalidation
digital thread.
strategy with Concerning
digital dataof
this,
the the manufactured
part present article with proposes
AM, the
whichdevelopment
does of anaintegration
notExchange
allow closed-loop strategy
digital with a digital
thread. Concerning data
model
this,
model based
the present
based on STEP-NC
article
on article
STEP-NC (Standard
proposes
(Standardthe for
developmentthe
for the Exchange of an of Product
integration
of Product model
strategy
modelwith data
with a - Numerical
digital
dataa -digital
Numerical data
this,
modelthebased
Control) present
for proposes the development of an integration strategy data
Control)
model for closed-loop
based
on STEP-NC
closed-loop
on STEP-NC
AM. The
The data
AM.(Standard
(Standard data models
for the in
models
for the in STEP-NC
Exchange
STEP-NC
Exchange
of for
of for the
the AM
Product
Product AM and
and inspection
model
model
data - Numerical
inspection
data -
tasks
tasks it
Numerical it
develops,
Control)
develops, highlighting
for closed-loop
highlighting the
the AM.scenario
The
scenario of
data
of integrated
models
integrated infeedback
STEP-NC
feedback for
for the
for
the closed-loop
the AM
closed-loopand AM digital
inspection
AM digital thread.
tasks
thread. it
Control)
develops,
Are for
presented closed-loop
highlighting
the theAM.
architecture The
scenario of data modelsvalidated
of integrated
integration infeedback
STEP-NC by for for
thethe
using AM and
closed-loop
an open AM inspection
AM digital and
platform tasks
thread.
theit
Are presented
develops, the architecture
highlighting the scenario of integration
of integrated validated
feedback byfor using an open AMAM
the closed-loop platform
digital and the
thread.
results
Are of
presentederror control
the over
architecture the parts.
of Copyright
integration cc 2019
validated by IFAC
using an open AM platform and the
results
Are of errorthe
presented control over theofparts.
architecture Copyright
integration  2019
validated byIFACusing an open AM platform and the
results of error control over the parts. Copyright  c 2019 IFAC
© 2019, of
results IFACerror(International
control over Federation
the parts. of Automatic
Copyright Control)
 c 2019Hosting IFAC by Elsevier Ltd. All rights reserved.
Keywords:
Keywords: Closed-loop inspection, Quality management, Additive manufacturing,
Closed-loop inspection, Quality management, Additive manufacturing,
Keywords: Closed-loop
Interoperability, ISO inspection, Quality management, Additive manufacturing,
Interoperability,
Keywords: Closed-loop ISO 10303,
10303, STEP-NC
STEP-NC
inspection, Quality management, Additive manufacturing,
Interoperability, ISO 10303, STEP-NC
Interoperability,
1. INTRODUCTION ISO 10303, STEP-NC this
1. this technology
technology thanks thanks to to the
the inclusion
inclusion of of new
new materials
materials
1. INTRODUCTION
INTRODUCTION (Lasi
this et al.
technology (2014)).thanks to the inclusion of new materials
1. INTRODUCTION (Lasi et
this technology al. (2014)).thanks to the inclusion of new materials
Within the perspective of the fourth industrial revolution, (Lasi et al. (2014)).
Within the
the perspective of
of the fourth
fourth industrial revolution, The The multiple factors
factors that
that need
need control
control in in the
the production
Within
the concept perspective
of intelligent the
manufacturing industrial associated (Lasi
it is revolution, et al. (2014)).
multiple production
the concept
Within of intelligent
the perspective of the manufacturing
fourth industrialit is associated of
The a part
multiple utilizing
factors additive
that manufacturing
need control in (temperature,
the production
the
with concept
processes of intelligent
operating manufacturing
in cooperative it
and is revolution,
fully inte- of
associated a part
Thea multiple utilizing
factors additive manufacturing
that uncertainty
need controlininthe (temperature,
the production
with processes
the concept operating
of intelligent in cooperative
manufacturing and
it fully
is fully inte-
associated speed,
of part material)
utilizing produce
additive manufacturing results
results that
(temperature,
with
grated processes
environments operating
through in cooperative
digital technologiesand offer speed,
that inte- of a part material)
utilizing produce
additive uncertainty
manufacturing in the(temperature, that
grated environments
with processes through
operating intodigital technologies
cooperative and fully that offer
inte- affect
speed, the final
material) quality
produce of the parts
uncertainty produced
in the (Qin etthat
results al.
grated
useful environments
real-time through
information digital
learntechnologies
and improve that offer affect
working speed, the final
material) quality
produce of the parts
uncertainty produced
in (Qin
the results et al.
that
useful
grated real-time
environments information
through to learn
digital and improve
technologies working
that offer (2017)).
affect the Considering
final quality the
of context
the parts ofproduced
expansion (Qinthat
et is
al.
useful real-time
conditions information
(Bortolini to learn and
et al. (2018)). The improve
objectiveworking of the (2017)).
affect the Considering
final quality the
qualitythe context
of the parts of expansion
produced (Qinthat is
et for
al.
conditions (Bortolini
useful real-time et
information al. (2018)).
to meet
learn andThe objective of the evident
(2017)). where
Considering factors are
context decisive,
of the
expansion search
that is
conditions
manufacturing (Bortolini
industry et al.is to(2018)). The improve
objective
production working
of the evident
demands (2017)). where quality
Considering factors
the are
context decisive,
of the
expansion search
that for
is
manufacturing
conditions industry
(Bortolini et al.is to meet
(2018)). production
The objective demands a strategy
evident that
where manages
quality to
factors identify
of the a strategy that manages to identify manufacturing errors are manufacturing
decisive, the errors
search for
manufacturing
by efficiently industry
using available is to meet production
resources to improve demands
perfor- evident where quality factors are decisive, the search for
by efficiently
manufacturing using available
industry resources to improve perfor- and
a compensate
strategy that within
manages the
to manufacturing
identify chain
manufacturing will solve
errors
by efficiently
mance using
and achieve moreis sustainable
available toresources
meet production
to improve
processes demands
perfor-
(Lu and and asome compensate
strategy that within the
manages to manufacturing
identify chain willerrors
manufacturing solve
mance and quality issues that prevent consolidation chainin sectors
mance
Xu and achieve
by efficiently
(2019)). achieve
Within
more
using available
more sustainable
resources
sustainable
this trend,
processes
to improve
processes
new challenges
(Lu
(Lu
that
and
and and
perfor-
seek some
and
compensate
quality
compensate
within
issues that
within
the
the
manufacturing
prevent consolidation
manufacturing chain
will
in solve
sectors
will solve
Xu
mance
Xu
to
(2019)).
and
(2019)).
insert
Within
achieve
Within more
avant-garde
this
this trend, new
sustainable
trend,
technologies new challenges
processes that
challenges
to accomplish
that and with precise requirements in these aspects (Zheng et al.
seek
(Lu seek
this goal
with
some precise
quality requirements
issues that in
preventthese aspects
consolidation (Zheng
in et
sectors
al.
to insert avant-garde technologies to accomplish this goal some
(2018)).
with quality requirements
precise issues that prevent in these consolidation
aspects in sectors
(Zheng et al.
Xuinsert
to
are (2019)). Within
avant-garde
constantly renewed this trend,
technologies
(Xu et new
al. challenges that
to accomplish
(2018)). this seek
goal (2018)).
are constantly renewed (Xu et al. (2018)). with
(2018)). precise requirements in these aspects (Zheng et al.
to insert
are avant-garde
constantly renewed technologies to accomplish this goal Dimensional inspection used as a tool for verification and
(Xu et al. (2018)).
The additive manufacturing
are constantly renewed (Xu et due significant progress in (2018)).
to(2018)).
al.to Dimensional inspection used as a tool for verification and
The additive manufacturing due validation of the
the specifications
used as of aa product plays
plays an es-
The additive
matters of manufacturing
speed, quality, and to significant
dueflexibility
significant
in the
progress
progress
manufac-
in Dimensional
in validation
Dimensional of inspection
specifications
inspection used
a tool
as of
for verification
product
ainteroperable
tool for verification anandes-
and
matters of
The additive speed, quality, and flexibility in the manufac- validation
sential role ofin the
the specifications
search for an of a product plays an
manufactu- es-
matters
ture ismanufacturing
of speed,
of parts quality, aand
considered dueflexibility
to significant
mega-trend in the
from progress
manufac-
Industry in sential role in the search for an interoperable manufactu-
4.0 validation ofinthe specifications of a (2018)).
product Throughplays an the
es-
ture of
matters parts is considered a mega-trend from Industry 4.0 ring
sential environment
role the (Moroni
search and
for anPetrò
interoperable manufactu-
ture
(Zheng etofal.
of parts speed, quality,
is(2018)).
considered and
The afacility flexibility
mega-trendto create in athe
from manufac-
Industry
piece from4.0 a ring sential environment
role in on thea(Moroni
search andanPetrò
for (2018)). Through
interoperable manufactu-the
(Zheng et
ture ofmodel
partsal. (2018)).
is considered The facility
afacility
mega-trendto create
from a piece
Industry from a measurement
ring environment part,
(Moroni data
and set
Petròto are
(2018)).acquired,
Through which,
the
(Zheng
CAD et al.makes
(2018)). thisThemanufacturing to create
method a piece from4.0
a potential a measurement
ring environment on a(Moroni
part, dataand set
Petròto (2018)).
are acquired,Through which,
the
CAD model
et al.makes this manufacturing method a when processed on acorrectly, provide to relevant information
(Zheng
CAD
tool model
to meet (2018)).
makes
the thisThe
demand facility
manufacturing
for custom toparts.
create
methodThe a potential
a piece from a measurement
potential
application when
measurement processed on a
part, data
correctly,
part, data
set
provide
set to
are acquired,
relevant
are acquired,
which,
information
which,
tool to meet the demand for custom parts. The application when
for the processed
improvement correctly,
of provide relevant information
CADtomodel
tool
ranges meet makes
the demand
are varied, this more
and manufacturing
for custom
and more method
parts. aare
potential
The application
sectors to use for when theprocessed
improvement of the
correctly,
process.
the provide Information
process. relevant
Information such
such as
information as
ranges
tool to are
meet varied,
the and
demand more
for and
custom more
parts. sectors
The are to
application use manufacturing
for the
manufacturing improvement conditions
of
conditions thein
in addition
process.
addition to the
Information
to the conventional
such as
conventional
ranges
 are varied, and more and more sectors are to use for theofimprovement of the
 The authors would like to thank the financial support of the
ranges are varied,
wouldand like more andthe more sectors are to of use
values
manufacturing
values of deviation
deviation and in process.
and uncertainty
conditions addition
uncertainty can Information
canto betheextracted suchfrom
conventional as
tobe extracted from
 The authors to thank financial support the
Brazilian
Brazilian
government
The authors wouldagency
government like toMEC/CAPES/CNPq/FAPDF.
agency thank the financial support of the
MEC/CAPES/CNPq/FAPDF. manufacturing
values of deviation conditions
and in addition
uncertainty can the
be conventional
extracted from
 The authors wouldagency
like toMEC/CAPES/CNPq/FAPDF.
thank the financial support of the
Brazilian government values of deviation and uncertainty can be extracted from
Brazilian
2405-8963 government
© agency MEC/CAPES/CNPq/FAPDF.
Copyright © 2019, IFAC
2019 IFAC (International Federation of Automatic Control)
2842Hosting by Elsevier Ltd. All rights reserved.
Copyright
Peer review©under
2019 responsibility
IFAC 2842Control.
of International Federation of Automatic
Copyright © 2019 IFAC 2842
10.1016/j.ifacol.2019.11.629
Copyright © 2019 IFAC 2842
2019 IFAC MIM
Berlin, Germany, August 28-30, 2019 Cristhian Riaño et al. / IFAC PapersOnLine 52-13 (2019) 2782–2787 2783
the results of the inspection to be analyzed and shared
within a digital chain. The demands for information and
knowledge are continually growing and creating sources of
data based on measurement result will make the process
more and more sustainable.
Closed-loop systems have already shown their effectiveness
in conventional manufacturing processes and exploit the
potential of acquiring through dimensional and geometric
measurement using a coordinate measuring machine to
obtain data from the process of the additive manufactu-
ring process will not only detect errors of the parts and
compensate them but calibrate and configure correctly the
parameters of the process (Brecher et al. (2006); Zhao et al.
(2011)).
It is necessary to create a solution within the logical layer
of the integration architecture and achieve a semantic and
syntactic homogeneity of the data regardless of the nature
of its origin, to overcome the different interoperability
barriers related to these processes (Hedberg et al. (2016)).
This research presents an alternative for the integration of
data generated both in the additive manufacturing system
and in dimensional and geometric inspection systems. In
the following sections, an integration alternative of an
additive manufacturing system composed of a linear par-
allel delta robot, an inspection system based on inspection
techniques with coordinate measuring machine (CMM)
and a quality control system to is presented. This work
is part of a series of researches developed by the authors
for integrating manufacturing data based on STEP-NC in
additive processes (Rodriguez and Alvares (2019)), robotic
machining Toquica et al. (2018) and closed-loop inspection
(Riaño and Álvares (2018)).
2. BRIEF LITERATURE SURVEY
2.1 Additive Manufacturing
AM is defined in ISO/ASTM 52900:2015 (2015) as the
”process of joining materials to make parts from 3D model
data, usually layer upon layer, as opposed to subtractive
manufacturing and formative manufacturing methodolo-
gies”. These processes provide never-before-seen abilities
to manufacture physical parts with complex shapes mi-
nimizing the material waste by not being tooling based.
Indeed, complex assemblies can now be achieved into
single multi-material and multi-color geometries, reducing
manufacturing time and complexity. Moreover, with the
recent advances in terms of materials, process parame-
ters, and machine utilities, the idea of AM only for rapid
prototyping has been left behind to achieve functional
parts as well. This consolidated the AM now as a primary
manufacturing process like machining or incremental sheet
forming.
Complex design freedom and a higher degree of customiza-
tion are potential benefits offered by AM for developing
products to fulfill the varied and ever-changing market
demands. Nonetheless, there are some disadvantages re-
garding the poor surface finishing and low accuracy of
parts manufactured with AM due to the layering process
of nature. Therefore, post-processing operations are ne-
cessary in most of the cases to achieve the desired final part
quality. By inspecting the manufactured part is possible
2843
to determine drawbacks that can be feedback into design
and process planning stages to define the post-processing
operations. An efficient way to feedback the process is by
using a closed-loop inspection strategy. The closed-loop
inspection concept is treated to follow.
2.2 Closed-Loop Inspection
Inspection is a fundamental step of the process chain to en-
sure the quality of a manufactured part. The measurement
of the piece is performed by using a measuring device, i.e.
coordinate measuring machine, to collect dimensional data
from the geometries of interest. Then, the inspection data
is analyzed through a computer-aided inspection (CAI)
system to determine drawbacks of the part related to
dimensional and geometrical tolerances. Results of that
analysis are used to feedback the process forming a closed-
loop (Xu* et al. (2005)).
3. ARCHITECTURE FOR CLOUD CLOSED-LOOP
AM
The concept of metrology in manufacturing industries has
evolved from its inception as a tool for verification of com-
pliance to the point of deducing mathematical models and
reconstructing surfaces from a cloud of points (obtained
with measuring devices). Are varied the possibilities of
application of the dimensional and geometric inspection
due to the amount of information that deduced from
the data collected in the measurement of a part. New
approaches such as Digital-Twin and challenges created
with the digital age and IoT technologies are already being
linked in manufacturing but depend on direct communi-
cation between processes involved in the production.
Although there is currently an integration in the appli-
cation layer of the processes that make up the digital
manufacturing chain, interoperability barriers prevail that
can only overcome if it focused on complete integration in
each of the layers (logical and physical application).
Fig. 1 shows an outline of the architecture and data flow
used to integrate additive manufacturing and inspection.
The architecture allows meeting the demand for infor-
mation generated in each of the processes to create a
global model that incorporates semantically and syntac-
tically based on neutral standards such as Standard for
the Exchange of Product model data (STEP) and Quality
Information Framework (QIF).
The standard format used for the exchange of product
information in additive manufacturing is the STL format,
which is not feasible to share design specifications and
tolerances. The digital model of the product is the fun-
damental basis of integration, which is made up of both a
solid model and metadata destined to provide design spe-
cifications such as dimensional and geometric tolerances,
materials, finishes, etc.
The 3D Digital model is reconstructed and updated from
the information contained in a file encoded in ASCII. The
STEP standard manages to provide support in the product
definition through application protocols AP203, AP214,
and AP242 to structure product information together with
the design specifications. The model based on the QIF MBD
2019 IFAC MIM
2784 Germany, August 28-30, 2019
Berlin, Cristhian Riaño et al. / IFAC PapersOnLine 52-13 (2019) 2782–2787

trol format and transferred for processing on the machine.

Parallel Delta Robot Part Although the system manages to be integrated, it still
retains some interoperability barriers generated in the
Post-Processing information transfer base, which makes it difficult to follow
the process and monitor the evolution of the final product.
The link to achieve intelligent manufacturing is to use
- AP242 STEP File comparable neutral data easily accessible by any technol-
- QIF MBD
- STL File format ogy, and that includes not only product specifications but
also knowledge, operation condition data, and inspection
CAD
results. This information is processed by an expert system
CAIP
Design project
to make decisions that increase the sustainability and
Inspection planning
- AP242 STEP file quality of the products.
- QIF MBD (PLM siemens NX
(PLMsiemens
PLM siemensNX
NX
inspection)
inspection) The data generated in the inspection process as well as
- QIF Results
- QIF Plans being used to improve the final quality of the part, are
- QIF Rules
- QIF Statistics - QIF Resources stored and shared with other systems. Fig. 2 presents a
- DMIS
scheme with the systems that make up the smart integra-
CAI
tion strategy for cloud closed-loop additive manufacturing
Reporting and system and the mechanisms that support the flow of data
Execution
analysis of
- DMIS Inspection between them.
results
(MCOSMOS Coordinate
(MeasurLink® Quality
Management)
Measuring Machine) Figure 2 shows a control system for the additive manu-
- DMIS facturing process using data obtained from the inspection
- I++ DME
system as feedback. The CAD model with GD&T and PMI
information is the central element in the control system.
CMM execution
The CAD model data shared within the digital manufactu-
inspection ring chain through the ISO 10303-242: 2014 format, which
guarantees interoperability and preserves the integrity of
the information. From the AP242 STEP file, a model
Crysta PLUS M 574 based on definition generated in the QIF MBD format for
use within the inspection system. The Computer-Aided
Fig. 1. Information flow for additive manufacturing with Inspection Planning (CAIP) system adheres to the QIF
closed-loop inspection Document information from Metrology Resources (QIF
definition defines a digital data format to transfer infor- Resources) and Metrology knowledge (QIF Rules).
mation from a CAD model with metadata that includes The inspection plans are used in the execution and gene-
necessary information in both quality processes and PMI. ration of the CNC DME program sent to the controller
It is necessary to establish a relationship between the ma- of the coordinate measuring machine. The result of the
nufacturing decisions made and the impact on the results evaluation exported in the QIF Results format to transfer
obtained, as well as to create a mechanism to identify to the system in charge of carrying out the analysis and
the causes that produce the variation in the parts. This generating the quality report. In the analysis process, the
information can be extracted with the correct processing expert system is in charge of evaluating the conformity
of the data obtained in the process of dimensional and with the design specifications, and the results exported in
geometric inspection of the piece. the QIF-Statistics format. The process ends when the
compensation system makes the necessary adjustments to
A subsequent analysis allows generating the set of cor- reduce the error detected in the manufacturing process.
rective actions designed to compensate for the error. In-
teroperability barriers affect the inspection process in its
four main activities that make up the measurement sys- 4. CLOSED-LOOP CONTROL STRATEGY
tem. The main problem of interoperability found in the
dimensional inspection process is the lack of a neutral and To create a closed loop of addictive manufacturing and
standardized data structure that supports the information inspection is necessary to implement a control strategy
generated in each of the functional activities. The ideal that uses the data obtained in the measurement of the
thing to automate the process is that the report made in part to compensate and correct the resulting uncertainties
each of the phases is transmitted within a similar data in the manufacturer. In the inspection process, values are
structure that guarantees the access and integrity of the acquired that allows digitally reconstructing the surface
information in real time by any system involved in the of the manufactured piece. These values used by the
manufacturing process. control system are obtained through measurements made
in different dimensional planes of the manufactured part.
3.1 Components and functions The uncertainty of the real model concerning the desired
model calculated. The next step to be followed by the
In conventional additive manufacturing processes, the tra- control system is to determine the causes of the variation
jectories of the final effector generated from a file in STL and generate actions to correct the problem. A set of
format that contains the geometry of the part. The paths rules and intelligent knowledge-based techniques support
of the tool are encoded in a computerized numerical con- decision-making.

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CAD Design System Process Planning System Compensation System Parallel Delta Robot Part
+0.25
4X 30 - 0.25 150 0.25
4X 44
0.08 M A B C 0.08 A B

Data
0.25 M A B
+
A
CAPP
30
8

-
error Validation

100 0.25
0.05

B
200
140

+-
60

CAIP E
30 44
220
280

CAD model nominal Encode Results

QIF Document Inspection Data (STEP File)
The Inspection process
-MBD
AP242 STEP File

Measurement Plan
QIF Document
-MBD Measurement Results
-Rules QIF Document
-Resources -MBD
-Plans -Plans
-Results
-Statistics

Fig. 2. Components of the closed-loop additive manufacturing system

a). b). 4X
+0.25
7.50 - 0.25
4X 11 0.25
0.08 M A B C 37.50 0.25
A 0.08 A B

0.08 B C

7.50
2
c).

25 0.25
ISO-10303-21; 0.05
HEADER;
50
35

FILE_DESCRIPTION(('HOOPS Exchange Step'),'2;1'); B

15
FILE_NAME(V04_PART_MBD.STP);
FILE_SCHEMA( ('AP242_MANAGED_MODEL_BASED_3D_ENGINEERING_MIM_LF {1 0 10303 442 1 1 4 }') );
ENDSEC;
DATA;
#3=(NAMED_UNIT(*)PLANE_ANGLE_UNIT()SI_UNIT($,.RADIAN.));
#4=PLANE_ANGLE_MEASURE_WITH_UNIT(PLANE_ANGLE_MEASURE(0.0174532925),#3); 11
#5=(CONVERSION_BASED_UNIT('DEGREE',#4)NAMED_UNIT(#6)PLANE_ANGLE_UNIT());
#6=DIMENSIONAL_EXPONENTS(0.,0.,0.,0.,0.,0.,0.); 0.08 A C 7.50 55
#7=(NAMED_UNIT(*)SI_UNIT($,.STERADIAN.)SOLID_ANGLE_UNIT()); 70
#8=(LENGTH_UNIT()NAMED_UNIT(*)SI_UNIT(.MILLI.,.METRE.));
#9=UNCERTAINTY_MEASURE_WITH_UNIT(LENGTH_MEASURE(1.000000E-03),#8,'DISTANCE_ACCURACY_VALUE','Maximum Tolerance applied to model');
#10=(GEOMETRIC_REPRESENTATION_CONTEXT(3)GLOBAL_UNCERTAINTY_ASSIGNED_CONTEXT((#9))GLOBAL_UNIT_ASSIGNED_CONTEXT((#8,#5,#7))REPRESENTATION_CONTEXT('',' WS_06'));
#12=CARTESIAN_POINT('',(0.0,0.0,0.0));
#13=DIRECTION('',(0.0,0.0,1.0));
#14=DIRECTION('',(1.0,0.0,0.0));
#15=AXIS2_PLACEMENT_3D('',#12,#13,#14);
#28=COLOUR_RGB('',0.247058824,0.611764729,0.603921592);
#29=DRAUGHTING_PRE_DEFINED_CURVE_FONT('continuous');
#30=CURVE_STYLE('',#29,POSITIVE_LENGTH_MEASURE(0.100000),#28);

Fig. 3. Definition of the GD&T specifications (a) and the MBD model generated to transfer the information of part
(b) Code extracted from the AP242 STEP file (c)

The compensation of the error is made directly in the file until the system finds a point of operation that meets
sent to the control system of the linear parallel Delta robot the design specifications. The inspection technique using
in charge of executing the printing routines of the part. the coordinate- measuring machine (CMM) is executed
The inspection is repeated after each piece manufactured in a controlled environment, minimizing the external dis-
turbances that affect the determination of the geometric
IF08
error.
IF09
IF07 IF10
IF11 5. CASE STUDY
IF12
IF13 The experiment is projected to generate the data that
needs to be exchanged within the digital chain and to
verify the vision of interoperability exposed in the pre-
vious sections, The measurement operations, as well as in
IF06 manufacturing processes, are created from data extracted
IF05 from a 3D model that contains geometry, topology, and
IF04 IF01
IF03 IF02 characteristics of the part to be manufactured.
The integration of the digital chain CAD model based
Fig. 4. Part example: case study on the ISO10303-242 standard using the AP242 file to

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a). b).

e). d). 3.8

c). 70

60

3.6
135° 45°
IF06_Plane Plano PO(3)

50
A : 179:37:49
B : 89:59:06
3.4 C : 90:22:09

40

3.2

IF03_Cylinder Cilindro Ce(2)

30
180° 0° A : 90:40:20
B : 90:06:06
C : 00:40:48
D: 7.415
Y 20

IF03_POS_y(2)
L: 7.503
10
Dx: 0.000
Dy: -7.503
X

225° 315° - Circulo D = 7.122

[mm]| Ampliação : 89 Y
- Zona tolerancia
. Pts fora tolerância IF03_POS_x(1)
270° o Min./Max. Pnt. L : 7.425
IF008 Dx: -7.424
Zona tolerancia Tol. Sup. Tol. Inf. Número de pontos Dy: 0.002

X
0.250 0.125 -0.125 6

-30

-20

-10

10

20

30

40

50

60
0
Circularidade Desv. Padr * 4 Min./Max. Pnt. [mm]

0.112 0.441 2/ 4
IF003_Position

Fig. 5. Measurement system for correlation of inspection data: a)Inspection planning; b) Measurement execution; c)
Inspection feature(s); d)Tolerance operation; e) Correlation of results system

represent product data and GD&T specifications. The ex- The feature is the central element within the closed-loop
change mechanism is through ASCII text files (p21) based inspection that represents a generic form with a series of
on the ISO10303-21 standard obtained from EXPRESS essential attributes necessary to define each feature of the
schemes. Through the EXPRESS schemes, it is possible part. In certain situations, meeting all specifications of
to structure the information also in the format for XML dimensional tolerances is not enough. An example of this
implementation. situation is commonly found when, for example, making
parts assemblies manufactured by additive manufacturing.
Figure 3 shows the design of the part together with the
specifications that require verification of conformity used From the dimensional perspective, the specifications can
within the experimental context treated (as shown in Fig. be fulfilled, but the part can still have defects such as Par-
3a). The information contained in the CAD model ex- allelism, Perpendicularity, and Symmetry among others.
ported in an MBD through the AP242 STEP file shown
in Fig. 3b for the different CAx systems involved in the In additive manufacturing processes, it is common to find
manufacture of the part. The MBD manages to transmit geometric irregularities that can affect the shape, position,
both the geometry and topology of the piece as the GD&T and orientation of the characteristic elements that make
specifications and annotations necessary for manufactu- up the part. The geometric tolerance definition seeks to
ring. The MBD model is compatible with the different limit these deviations through an additional geometrical
working environments of the CAx systems and visualized control to the dimensional one. To perform the control it
(as shown in Fig. 3c). is necessary to compose an inspection feature from the
information contained in the AP242 data model of the
In the verification of conformity of the GD&T specifica- part.
tions, it is necessary to associate the manufacturing fea-
tures with the inspection ones. The features for geometric From this STEP file, both the GD&T specifications and
inspection include line structure, circle structure, an arc the inspection features necessary to generate each inspec-
structure. For dimensional inspection and shape position tion operation extracted. The information obtained is used
are built by one or more features of basic geometries. in each inspection operation to define a parameter set,
among which are workpiece datum feature(s), orientation,
Figure 4 presents a list of inspection features, and the inspection paths, and inspection strategy.
scheme followed in composing an inspection feature. When
they are outside the specifications, it is necessary to The recognition procedure happens after measuring each
determine the ranges of uncertainty to apply the type of main component and associating with a feature for later
quick correction controlling the upper or lower limit of the through tolerance operations to determine its deviation.
tolerance. When the system detects values outside the specifications,
an analysis is performed to correlate the results with the
Figure 5 shows the scheme followed to determine the devia- different causes of errors in the system and to determine
tion of each feature and within the system generate correc- the type of corrective action to be taken.
tive and compensation actions for the manufacture of parts
in additive manufacturing processes. Table 1 presents the The objective is to register the nonconformity of the prod-
composition of each feature and the uncertainty results uct and the changes undergone over time to identify poten-
obtained in the measurement process. tial reasons for deviation results and attribute corrective
actions. It is possible to create traceability for this routine

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Table 1. Inspection feature definition

Inspection feature Measuring feature Tol.Type Tol.Value (IT/mm) Datum Deviation Oversize
IF01 Plane Perpendicularity 0.08 IF06, IF09 0.046 -
IF02 Cylinder Circularity 0.25 - 0.005 0.005
IF03 Cylinder Position 0.08 IF01, IF06 0.388 0.308
IF04 Plane Parallelism 0.05 IF09 0.064 0.014
IF05 Cylinder Circularity 0.25 - 0.021 -
IF06 Plane Perpendicularity 0.08 IF01, IF09 0.046 -
IF07 Cylinder Position 0.08 IF01, IF06 0.373 0.293
IF08 Cylinder Position 0.08 IF01, IF06 3.86 3.780
IF09 Plane Perpendicularity 0.08 IF01, IF06 0.032 -
IF10 Cylinder Circularity 0.25 - 0.008 -
IF11 Plane Parallelism 0.05 IF09 0.061 0.011
IF12 Cylinder Position 0.08 IF01, IF06 0.686 0.606
IF13 Cylinder Circularity 0.25 - 0.020 -

and collect data to share with other external processes
using the same neutral data structure. Corrective actions
in the process are suggested, and the manufacturing tol-
erances adjusted within the execution schedule to be con-
sidered in the manufacture of the following part.
6. CONCLUSION
A closed-loop inspection allows the implementation of
strategies that lead the manufacturing systems to improve
their efficiency and take better advantage of the resources
involved in the manufacture of a part. To implement
efficient inspection procedures is necessary to digitize data
from operations that are not yet automated.
The architecture presented in this article shows a solu-
tion for the integration of processes with additive manu-
facturing, achieving the feedback of the inspection data
within a syntactic structure and semantically following
the ISO10303 neutral standard. With the data structure
exposed, an alternative is performed to overcome the in-
teroperability barriers in the measurement processes with
certain technological independence, making the implemen-
tation possible within the perspective of Industry 4.0.
Future works intend to integrate the methodology in the
framework Step Modeler (Alvares et al. (2016) to close the
manufacturing loop adhering to the STEP-NC standard.
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