Ranjan Kumar, Asst. Professor, Dept. of ME, RVSCET Jsr.

Automated inspection systems

Automated inspection systems In process gauging systems, Co-ordinate measuring machines:

Construction, operational modes and different probes. Automated assembly systems.

1. Explain the construction of a gantry type coordinate measuring machine(CMM).(2016, 15M)

2. Give any two example application of a CMM. (2016, 5M)
3. Explain automated assembly systems. (2015, 20M)
4. Discuss the principles of coordinate measuring machines in detail. (2014, 10M)
5. Explain automated assembly systems. How this is helpful in industries.(2014, 10M)
6. Explain automated assembly systems (2011, 10M)
7. Describe the construction of CMM. (2010, 10)
8. Dicuss in detail the following: (2009, 20M)
(i) Automated inspection system
(ii) Automated assembly system
9. Write short notes on: (2010, 20M)
(i) In process gauging system
(ii) Automated assembly system
 Automated assembly systems
The term automated assembly refers to the use of mechanized &automatic devices to perform various
assembly tasks in an assembly line or cell. An automated assembly system performs a sequence of
automated assembly operation to combine multiple components into a single entity.
A typical automated assembly system consists of the following subsystem:
(i) One or more workstation at which the assembly steps are accomplished
(ii) Parts feeding devices that delivers the individual component to workstation
(iii) A work handling system for the assembled entity
(iv) For an effective automated assembly system controlled function is necessary for:
(a) Sequence control: The purpose of this control is to co-ordinate the sequence of action of the
associated workstation.
(b) Safety monitoring function: it ensures that assembly line doesn’t operate in an unsafe
manner. Safety implies to both the human worker in the area &equipment itself.
(c) Quality control: in the quality control function, certain quality attributes of the assembly as
well as assembly work part is monitored. The purpose is to detect &possibly reject the
defective product.

 Different types of Automated assembly systems are:

(i) Inline assembly system: It consists of a series of automated work stations located
along an in-line transfer system. It is the assembly version of the machining transfer
line.

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Ranjan Kumar, Asst. Professor, Dept. of ME, RVSCET Jsr. Automated inspection systems

(ii) Dial type assembly machine: Base parts are loaded on to fixtures attached to
circular dial components are added or joined to the base part at various work
stations located around periphery of dial. This is common in beverage bottling
&canning plants.

(iii) Carousel assembly system: It takes the advantage of both inline &dial type
assembly system.

(iv) Single station assembly machine: In this assembly operations are performed on
base part at single location. Also it involves placement of base parts at a single
position in the workstation, followed by addition of components to the base &finally
removal of completed assembly from the station.

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Ranjan Kumar, Asst. Professor, Dept. of ME, RVSCET Jsr. Automated inspection systems

AUTOMATIC INSPECTION SYSTEM

Inspection is the means by which poor quality or non conformities is rejected &good qualities is assured
The term inspection can be defined as an activity of examining the products, its components, sub-
assemblies, and to determine whether they adhere to design specification as specified by product
designer.
Automated inspection is defined as the automation of one or more of the steps involved in the
inspection procedure. Automation of the inspection process will be almost anywhere reduces inspection
time/piece, automated machines do not experience the fatigue & manual errors suffered human
inspectors. Automated or semi automated inspection can be implemented in the number of alternative
way .This alternative ways are as follows:
(a) Automated presentation of parts by an automated handling system with a human operator still
performing the examination and a decision steps.
(b) Automated examination & decision by an automatic inspection machine, with manual loading
(presentation) of parts into the machine.
(c) Completely automated inspection system in which parts presentation, examination &decision
are all performed automatically.

In order to have an efficient inspection mainly two alternatives can be adopted:

1. Offline inspection
2. Online inspection

(1) Offline inspection system is performed away from the manufacturing process and there is
generally time delay between processing &inspection.

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Ranjan Kumar, Asst. Professor, Dept. of ME, RVSCET Jsr. Automated inspection systems

(2) Online inspection system(In process Gauging)

(a) In-process: This is achieved by performing the inspection procedure during the
manufacturing operation. Technologically in-process inspection of the product is usually
difficult and expensive to implement.

In process Gauging:
 Reduces end-line defects
 Saves time and effort of final inspection
 Helps to fix the problem immediately
 Helps to ensure quality of the product of a production line
 Increase reliability
(b) Post- process: The measurement procedure is accomplished immediately following the
production process. Even though it follow the process , it is still considered an on-line
method because it is integrated with the manufacturing work station , and the result of the
inspection can immediately influence the production operation of the next product.

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Ranjan Kumar, Asst. Professor, Dept. of ME, RVSCET Jsr. Automated inspection systems

 Coordinate metrology
Coordinate metrology is concerned with the measurement of the actual shape and dimensions of an
object and comparing these with the desired shape and dimensions, as might be specified on a part
drawing. In this connection, coordinate metrology consists of the evaluation of the location, orientation,
dimensions, and geometry of the part or object.

 Co-ordinate measuring machines(CMM)

A coordinate measuring machine (CMM) is an electromechanical system designed to perform
Coordinate metrology.
A CMM consists of a contact probe that can be positioned in three-dimensional (3-D) space relative to
the surfaces of the workpart; and the X , Y, and Z coordinates of the probe can be accurately and
precisely recorded to obtain dimensional data concerning the part geometry.
To accomplish measurements in 3-D, a basic CMM is composed of the following components:
 Mechanical structure: mechanical structure that provides motion of the probe in three
Cartesian axes and displacement transducers to measure the coordinate values of each axis.
 Probing system: It is the sensory part of CMM responsible for sensing measuring parameters
required for the measurements.
 Data collection System: It typically includes a machine controller, digital computer system with
application software.
Principle:
The typical 3 bridge CMM is composed of three axis X, Y and Z. These axis are orthogonal to each other
in a typical 3D Coordinate system. Each axis has a scale system that indicates the location of the axis.
The machine will read input from the touch probe as directed by the operator. The contact probe of the
CMM can be positioned in three dimensions relative to the surface of the workpart in order to
measurement of the actual shape and dimensions of an object.

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Ranjan Kumar, Asst. Professor, Dept. of ME, RVSCET Jsr. Automated inspection systems

 CMM Construction

In the construction of a CMM, the probe is fastened to a mechanical structure that allows movement of
the probe relative to the part. The part is usually located on a worktable that is connected to the
structure. The two basic components of the CMM:
(1) Probe and (2)mechanical structure

(1)Probe
The contact probe is a key component of a CMM.lt indicates when contact has been made with the part
surface during measurement. The tip of the probe is usually a ruby ball. Ruby is a form of corundum
(aluminum oxide), whose desirable properties in this application include high hardness for wear
resistance and low density for minimum inertia. Probes can have either a single tip, as in Figure below:

Most probes today are touch-trigger probes, which actuate when the probe makes contact with the part
surface.
A touch-trigger probe utilize any of various triggering mechanisms:
• The trigger is based on a highly sensitive electrical contact switch that emits a signal when the tip of
the probe is deflected from its neutral position.

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Ranjan Kumar, Asst. Professor, Dept. of ME, RVSCET Jsr. Automated inspection systems

• The trigger actuates when electrical contact is established between the probe and the (metallic) part
surface.
 The trigger uses a piezoelectric sensor that generates a signal based on tension or compression
loading of the probe. Immediately after contact is made between the probe and the surface of the
object, the coordinate positions of the probe are accurately measured by displacement transducers
associated with each of the three linear axes and recorded by the CMM controller.
(2)Mechanical Structure (Types of CMM Construction)
There are various physical configurations for achieving the motion of the probe each with its relative
advantages and disadvantages. Nearly all CMMs have a mechanical configuration that fits into one of
the following six types illustrated in Figure below:

(a) Cantilever: In the cantilever configuration, the probe is attached to a vertical quill that moves in the
Z-axis direction relative to a horizontal arm that overhangs a fixed worktable. The quill can also be
moved along the length of the arm to achieve y-axis motion, and the arm can be moved relative to the
worktable to achieve x-axis motion. The advantages of this construction are: (1) convenient access to
the worktable, (2) high throughput-the rate at which parts can be mounted and measured on the CMM,
(3) capacity to measure large work parts (on large CMM,) and (4) relatively small floor space
requirements. Its disadvantage is lower rigidity than most other CMM constructions.

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Ranjan Kumar, Asst. Professor, Dept. of ME, RVSCET Jsr. Automated inspection systems

(b) Moving bridge: In the moving bridge design, the probe is mounted on a bridge structure that is
moved relative to a stationary table on which is positioned the part to be measured. This provides a
more rigid structure than the cantilever design and its advocates claim that this makes the moving
bridge CMM more accurate. However, one of the problems encountered with the moving bridge design
is yawing {also known as walking), in which the two legs of the bridge move at slightly different speeds,
resulting in twisting of the bridge. This phenomenon degrades the accuracy of the measurements.
Yawing is reduced on moving bridge CMMs when dual drives and position feedback controls are
installed for both legs. The moving bridge design is the most widely used in industry. It is well suited to
the size range of parts commonly encountered in production machine shops.
(c) Fixed bridge: In this configuration, the bridge is attached to the CMM bed and the worktable is
moved in the x-direction beneath the bridge. This construction eliminates the possibility of yawing,
hence increasing rigidity and accuracy. However, throughput is adversely affected because of the
additional mass involved to move the heavy worktable with part mounted on it.
(d) Horizontal arm: The horizontal arm configuration consists of a cantilevered horizontal arm mounted
to a vertical column. The arm moves vertically and in and out to achieve y-axis and Z-axis motions. To
achieve X-axis motion, either the column is moved horizontally past the worktable (called the moving
ram design), or the worktable is moved past the column (called the moving table design). Large
horizontal arm machines are suited to the measurement of automobile bodies, and some
CMMs are equipped with dual arms so that independent measurements can be taken on both sides of
the car body at the same time.
(e) Gantry Type: This construction is generally intended for inspecting large objects. The probe quill (z-
axis) moves relative to the horizontal arm extending between the two rails of the gantry. The workspace
in a large gantry type CMM can be as great as 25 m in the x-direction by 11m in the y-direction by 6 m in
the Z-direction.
(f) Column Type: This configuration is similar to the construction of a machine tool. The x- and y-axis
movements are achieved by moving the worktable, while the probe quill is moved vertically along a rigid
column to achieve Z-axis motion.

 CMM control & Operational modes

The methods of operating and controlling a CMM can be classified into four main categories:
(1) Manual drive: In a manual drive CMM, the human operator physically moves the probe along the
Machine’s axes to make contact with the part and record the measurements. The three orthogonal
Slides are designed to be nearly frictionless to permit the probe to be free floating in the X-, y-, and z-
directions. The measurements are provided by a digital readout, which the operator can record either
manually or with paper printout.Anycalculations on the data (e.g., calculating the center and diameter
of a hole) must be made by the operator.
(2) Manual drive with computer-assisted data processing: A CMM with manual drive and computer-
assisted data processing provides some data processing and computational capability for performing the
calculations required to evaluate a given part feature. The types of data processing and computations
range from simple conversions between U.S. customary units and metric to more complicated geometry
Calculations, such as determining the angle between two planes. The probe is still free floating to permit
the operator to bring it into contact with the desired part surfaces.
(3) Motor drive with computer-assisted data processing A Motor driven CMM with computer-assisted
data processing uses electric motors to drive the probe along the machine axes under operator control.
A joystick or similar device is used as the means of controlling the motion. Features such as low-power
stepping motors and friction clutches are utilized to reduce the effects of collisions between the probe
and the part. The motor drive can be disengaged to permit the operator to physically move the probe as
in the manual control method.

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Ranjan Kumar, Asst. Professor, Dept. of ME, RVSCET Jsr. Automated inspection systems

(4) DCC with computer-assisted data processing.

A CMM with direct computer control (DCC) operates like a CNC machine tool. It is motorized, and the
movements of the coordinate axes are controlled by a dedicated computer under program control. The
computer also performs the various data processing and calculation functions and compiles a record of
the measurements made during inspection. As with a CNC machine tool, the DCC CMM requires part
programming.

 Common applications of CMM

1. Dimensional measurement
2. Profile measurement
3. Depth mapping
4. High precision tool manufacturing
5. Irregular shape measurement (turbine blades dimensions)