Measuring during production means performing measuring tasks directly on the production line rather than in the measuring room. This allows quality assurance to be performed between the different production steps for a product, as an SPC measuring station for operator-controlled inspections, or as a fully automatic system that is incorporated directly into production. Due to the short response times on modern production lines, quality controls must be performed increasingly quickly and flexibly, while also achieving maximum precision and stability. This on-site relationship between measuring instruments and production machines also entails further challenges. Besides fluctuating temperature conditions and partially contaminated ambient conditions, these also include the potential for measurement results to be influenced by the operator.

For these precise reasons, the Jenoptik Industrial Metrology Division has for some years been investing in expanding optical shaft metrology for use in the tough production environment. HOMMEL ETAMIC opticline instruments are designed precisely for these requirements, and with the C series,they offer measuring instruments for operator-controlled inspections during production, as well as the CA series, which are optical non-contact shaft measurement systems that support full automation and achieve the specified production cycle times.

Efficient Camera System

Non-contact optical metrology is almost universally suitable for all shaft-type parts. Whether these are electric motor shafts, crankshafts, pistons, turbochargers or other turning parts, the speed and flexibility of an opticline represents an excellent alternative to conventional measuring systems. Dimensional parameters such as lengths and distances can be measured, as well as form elements, angles, radii, roundness, radial run-outs and much more.

The HOMMEL ETAMIC opticline system is based on a cascaded camera system using the shadow image principle. Its unique diametric probing, i.e. from both sides simultaneously, enables measured values to be recorded quickly with fewer errors on the part. All measurements are taken fully automatically according to the set measuring program, and the optical principle provides measurements in rotation to a level of precision unrivaled by any other technology.

Robust with Long-Term Stability

The measuring machines must provide a high level of insensitivity in order to guarantee reliable results in the tough production environment. Jenoptik has therefore integrated various monitoring functions into the machines, which can respond quickly to changing ambient conditions and eliminate unintended operator errors. This includes automatic calibration with integrated temperature compensation, and thus banishes the setting master for daily use from the operator's work process.

In addition, the robust design and precise construction of the mechanical components ensure the highest level of reliability, guaranteeing consistent long-term stability in terms of quality assurance, specifically for lean production processes. Today, over 80% of Jenoptik's installed optical shaft measuring instruments have already been functioning on the production line itself, right alongside machining centers, for many years and with a low level of wear.

For example, complete measurements are already being taken on engine valves with cycle times of under five seconds. The complete part contour is analyzed quickly and with high precision thanks to the high measurement resolution per individual measured value. This allows the system to measure diameters with tolerances of under 10 nm. The HOMMEL-ETAMIC opticline CA series can also be equipped with a tactile measuring system in order to handle special measuring tasks, such as axial run-outs and special length measurements, or even for features such as perpendicularity.

Simple Operation and Fast Measurement Cycles for Operator-Controlled Inspections

The operator is provided with clearly structured software with an intuitive user interface in Windows, so test plans can be created, evaluated and displayed simply. The straightforward mapping of even complex testing tasks significantly reduces the amount of programming training required, and enables the measuring equipment to be used effectively in the process after only a very short period of time.

The simple but highly precise clamping mechanisms support both manual and automatic loading. The operator can then select from a range of viewing and output options for the measurement results. The measurement reports can be adjusted on a customer-specific basis and clearly document the production quality. If required, the measurement results can be analyzed directly on the screen. In automated processes, the results can also be fed directly in the upstream production process, massively reducing rejection rates.

In contrast to remote measuring stations, metrology that is located close to production, or even integrated into it, can be used to record, analyze and trace comprehensive measuring data. This means that responding to errors is considerably faster and more effective. The measuring systems of HOMMEL ETAMIC opticline products therefore not only ensure the quality of the parts, but also help to shape effective production line process control.

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