Adopting next-gen metrology in the machine shop

Micha Neininger – Director Machine Tool Measurement, Hexagon’s Manufacturing Intelligence division

Adopting next-gen metrology in the machine shop

A comprehensive look at Hexagon’s machine tool measurement solutions

Explore our solutions that streamline every stage of the process – from design to production – delivering real-time, actionable insights for maximum efficiency.

In any machine shop, three critical aspects indicate the mark of success – the quality of the manufactured part, the reliability of the process, and speed, in terms of short process and lead times. Improving these facets has long been the focus of numerous innovations and research, leading to something extraordinary - the world of machine tool measurement. A seminal player in this arena, Hexagon, brings forth solutions that help in various ways.

Assuring quality

Quality in any machine shop is a function of how accurately a part has been processed. Factors defining this include dimensions, surfaces and features, temperature, wall thicknesses of the part just like the condition of used tools. To achieve consistency in quality, real-time checking during production is unavoidable. Hexagon’s machine tool measurement solutions offer on-machine measurements, leading to unparalleled quality assurance.

Ensuring reliability

Reliability in a machine shop depends on machine calibration and accuracy. Constantly verifying and calibrating the machine ensures the integrity of components produced. Devices must work optimally, and ensuring this demands in-depth testing of the linear and rotary axes. Recognising this, Hexagon offers suitable solutions that effectively enhance process reliability.

Minimising time

Time is of the essence in any industry, and in a machine shop, it is predominantly concerned with the speed of the processes and the lead times. Hexagon’s machine tool measurement solutions optimise these timelines through automatic part alignment, real-time measurement and easy documentation. These are facilitated by efficient measurement programs, systematic alignment strategies with Best Fit, comprehensive documentation of measurement results, and easy export to statistical evaluation software, like Hexagon’s own Q-DAS solutions.

The legacy of Hexagon in machine tool measurement

Hexagon’s journey in machine tool measurement solutions has always been pathbreaking. Hexagon were the first to introduce a working, small radio-wave probe to the market. The momentum didn’t stop as Hexagon rolled out the first-ever measurement software for machine tools - 3D Form Inspect, a measurement software that enjoys undisputed leadership even today. Recently, Hexagon went on to pioneer sensor technologies to set industry standards covering workpiece temperature and wall thickness capture. 

Moving towards a future where production processes will be heavily automated, Hexagon prepares its customers for the upcoming revolution. This is evident in solutions like Best-Fit alignments or HxGN NC Server, which are setting the new standard – automated probing on machine tools.

Laser scanners for machine tools can quickly capture the complete surface data for a part while it is still clamped

Figure 1. Laser scanners for machine tools can quickly capture the complete surface data for a part while it is still clamped, bringing new levels of speed, precision and flexibility to machine tool inspection.


Automated wall thickness measurements on the machine tool with ultrasonic probes

Figure 2. Automated wall thickness measurements on the machine tool with ultrasonic probes replace time-consuming manual measurements with external devices, without the need to move heavy and large parts to dedicated measurement spaces, ultimately resulting in significantly faster inspections and enhanced data capture.

Hexagon’s shift of metrology towards the machine shop

Reimagining the classical form of metrology to an even more efficient system has always been a goal of Hexagon. While manufacturing keeps relying on certified measurements on measuring machines as per the ISO 10360 standard, Hexagon also transposes metrology right into the heart of machine tools. Various sensor technologies capture and measure all kinds of specifications and pieces.

While Hexagon ensures measurements are captured with accuracy and reliability, it is how they utilise the data that’s rather ingenious. The results are statistically evaluated to discover the unexplored potentials in the production process while simultaneously resolving bottlenecks like process time on CMMs, part transports and personnel shortages.
The mainstream role of machine tool probes in the past was limited to simple probing tasks, such as defining the raw part’s position before machining. For more precise measurements, the utility of other devices, such as coordinate measuring machines, became inevitable. To make the best use of all devices and at the same time remove bottlenecks, Hexagon’s goal is to perform detailed measurements also directly on the machine tool with advanced measurement technologies like ultrasonic measurements, laser scanning and highly accurate probes. In essence, these technologies facilitate on-machine inspection processes, which streamlines quality control procedures significantly.

Hexagon accompanies these technologies with dedicated calibration and verification devices that monitor the geometric condition of the machine tool to derive correction values. This ensures the measurement process capability and reduces dependency on external measurement devices. The combined use of advanced technology and calibration methods not only maximises the potential of CMMs but also reduces the process times, while considerably minimising the demand of highly skilled operators.

Hexagon’s machine tool measurement products

Hexagon has established itself in machine tool measurement solutions, boasting a wide range of innovative tools that enhance production efficiency and accuracy in the industry. 

Machine calibration and optimisation 
Hexagon provides system solutions for the accurate and comprehensive geometric analysis, monitoring and accuracy improvement of machine tools, measuring machines, robots and structures with the ETALON machine calibration and optimisation range.

Tactile workpiece measurement systems
Accurately measuring workpieces is pivotal in any machining operation. Hexagon’s tactile workpiece measurement systems utilise radio or infrared transmission to record individual points on the workpiece. This data helps in determining the part’s position in the clamping and inspecting its dimensions and quality.

Tactile and optical tool measurement
Constant production quality can be ensured through accurate tool data. Tactile and laser tool setters monitor tool wear or breakage. Hexagon’s tool measurement solution automatically feeds this precise data into the control’s tool table, enabling a highly reliable and accurate machining process.

Innovative, application-based sensor solution
Keeping customer needs at the forefront, Hexagon develops innovative sensor solutions:

  • Ultrasonic probe for wall thickness measurement
    The RWP20.50-G-UTP ultrasonic touch probe simplifies the process of measuring the wall thickness of larger parts. Unlike manually measuring wall thickness, which generates machine downtime and a lot of manual effort, the RWP20.50-G-UTP ultrasonic touch probe automates the process using ultrasound technology on the machine tool.
  • Temperature probe
    Monitoring part temperature during the machining process has profound benefits. Hexagon’s temperature probe, which measures the temperature automatically, allows for adjustments to the machining parameters during production based on the temperature readings, thus avoiding potential quality issues due to thermal changes.
  • Machine tool laser scanner
    Hexagon’s m&h LS-R-4.8 is a wireless laser scanner that transmits data via radio to the machine control and measuring software. By capturing and analysing a complete, data-rich image of a part while still clamped, it enhances precision and accelerates machine tool inspection, while minimising the need for external measurement devices.

The ETALON X-AX LASERBAR for the geometric analysis, monitoring and accuracy improvement of machine tools

Figure 3. Solutions like the ETALON X-AX LASERBAR for the geometric analysis, monitoring and accuracy improvement of machine tools help to improve the overall quality of produced parts.

 

Touch probes are standard on almost every CNC production machine,

Figure 4. Touch probes are standard on almost every CNC production machine, and Hexagon’s portfolio of probes with radio or infrared transmission benefit from many unique capabilities, such as the combination with other technologies, exchangeable measuring units and more.


Hexagon’s machine tool measurement products

Figure 5. In-process measurement of the component is performed directly in the clamping to avoid measurement deviations due to spring back or warping.

State-of-the-art machine tool measurement software
Hexagon’s suite of software products caters to diverse measurement needs. From performing quick setups and verifying critical dimensions in process to conducting complex quality analyses, it all becomes a streamlined affair.

  • HxGN NC Measure: Simplifying the inspection of a wide range of parts directly on the machine tool.
  • 3D Form Inspect: Enables logging ruled geometries and forms on all sides and axes on the machine tool.

  • HxGN NC Gage: PTB-certified algorithms grant high precision to machines and performance.

  • HxGN NC Server: Connecting machine tools with the power of PC-DMIS measurement software, it enables the execution of CMM-like operations directly on the machine tool and facilitates active monitoring of measurements across multiple machine tools.

In essence, Hexagon’s innovations transform machine shops into highly efficient production units. With thoughtful, productive leaps in every stage of machining processes, right from measurement to quality control, Hexagon stands at the forefront of leading a new age in the realm of machine tool measurement. 

Hexagon’s versatile measurement probes and sensors turn every CNC machine to a multisensor device

Figure 6. Hexagon’s versatile measurement probes and sensors turn every CNC machine to a multisensor device, adding advanced capabilities and applications to the shop floor and removing QA bottlenecks.

With advanced products and solutions that transcend the limits of current processes to offer in-depth real-time measurement, calibration and verification, Hexagon isn’t merely offering tools for quality and efficiency. They are reimagining processes, redesigning methods and recreating systems to form a future where machine tool measurement is integral to the machine shop, making the pursuit of precision less a process and more a standard.

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