In the world of wind turbines, size and shape matters. The quicker its turbine rotates, the more energy a turbine can capture from the wind and the greater its
electricity generating capacity. In addition to size, the efficiency of a wind turbine blade is determined by the precision of its airfoil profile, a shape similar to that of an aeroplane wing. Given the potential difficulties related to the critical measurement of the world’s largest blades used on the record breaking V164-8.0 MW turbines, MHI Vestas Offshore Wind selected FARO Laser Trackers as its preferred large-volume, high-precision measuring technology.
Despite the impressive scale (80m – almost as long Vestas generates the Power of Precision with FARO as a football field) of the V164-8.0 MW turbines blades, the advanced FARO instruments are able to quickly and accurately measure aerodynamic profiles and a wide range of other critical blade features. MHI Vestas Offshore Wind is a joint venture between Vestas Wind Systems A/S and Mitsubishi Heavy Industries (MHI). The company’s sole focus is to design, manufacture, install and service wind turbines for the offshore wind industry. The company aims to drive down the cost of energy from offshore wind parks through reducing the costs and increasing efficiency.
MHI Vestas’ V164-8.0 MW prototype turbine broke the record for power production by a wind turbine in a 24 hour period from the 6th-7th October 2014. The
turbine produced 192,000 kW/h during steady wind conditions. The power produced by the turbine in one day was enough to supply the energy needs of approximately 13,500 households. MHI Vestas Offshore Wind’s CEO Jens Tommerup said the record demonstrates the full capacity of the V164-8.0 MW. “This power production record further underlines both the quality of the technology as well as the skills of the team involved who have been working hard to ensure the turbine is performing according to our testing schedule.”
The company from Lübeck has provided a highly competent all-round service for the die casting industry and mechanical engineering for over 25 years. With the slogan “everything under one roof”, the globally oriented company offers the latest technology and comprehensive services. From the manufacturing of large components, to the repair, modification and modernisation of die casting machinery, right through to analytical measurement and variance analysis at the customer’s premises.
Druckguss Service GmbH relies on the FARO measuring system for the quality assurance of its products and services. With the FaroArm and Maximum accuracy for large dimensions Optimum measuring results thanks to the FARO Laser Tracker the FARO Laser Tracker Vantage, the company is
equipped to meet all the requirements of its customers. “As our company specialises in large, heavy components, large measuring volumes are important to us,” explains André Dylong, Business Development Manager at DSD. For the SHW moving column milling machine UniForce 8, for example, a measuring system is needed which can also record the possible machining operations – after all, the working range of the machine is 12,000 mm in the x-axis and 6,500 mm in the y-axis, with a tolerance of up to 0.01 mm.
Also when it comes to manufacturing replacement parts or master patterns by means of reverse engineering too, the Lübeck company is a reliable partner for its customers. In order to ensure the quality satisfies high standards, DSD relies on the FARO measuring system. “If our customer wants to record the entire actual geometry of a large component or even a whole machine, we can now reliably do that,” says André Dylong. “We offer our measuring services in a wide variety of industries and often face a variety of different tasks and requirements. So we need flexible, accurate, easy-to-use measuring systems like the FARO Laser Tracker”.
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FARO UK invites you to European Portable Metrology Conference (EPMC) 2015 which is the only event solely dedicated to portable and large volume 3D measurement technology. It is the premier technical conference in Europe dedicated solely to the use of precision dimensional measurement technology for process improvement for manufacturers.
Underpinning the event as always is the key theme of Process Improvement Through Measurement Technology. The event will give you the opportunity to learn about the latest developments in large volume and portable metrology. In particular, topics that will be covered will include:
The events takes place in Manchester from 9 – 11th November 2015. Where we will present our cutting-edge metrology products: the FARO Edge ScanArm HD with new LLP to scan challenging materials with high speed and high-definition data clarity! The FARO Gage with the barcode scanner as well as our latest and most accurate FARO Laser Tracker Vantage for large volume measurements. Also the FARO Laser Scanner Focus3D and our new handscanner FARO Freestyle3D, the only industrial-grade handheld device allowing to scan almost any kind of surfaces and environments will be shown!
In the world of wind turbines, size and shape matters. The longer its turbine blades, the more energy a turbine can capture from the wind and the greater its electricity generating capacity. In addition to size, the efficiency of a wind turbine blade is determined by the precision of its airfoil profile, a shape similar to that of an aeroplane wing.
Given the potential difficulties related to the critical measurement of the world’s largest blades, used on the record breaking V164-8.0 MW turbines, MHI Vestas Offshore Wind selected FARO laser trackers as its preferred large-volume, high-precision measuring technology.
Despite the impressive scale (80m – almost as long as a football field) of the V164-8.0 MW turbines blades, the advanced FARO instruments are able to quickly and accurately measure aerodynamic profiles and a wide range of other critical blade features.
MHI Vestas Offshore Wind is a joint venture between Vestas Wind Systems A/S and Mitsubishi Heavy Industries (MHI). The company’s sole focus is to design, manufacture, install and service wind turbines for the offshore wind industry. The company aims to drive down the cost of energy from offshore wind parks through reducing the costs and increasing efficiency.
MHI Vestas’ V164-8.0 MW prototype turbine broke the record for power production by a wind turbine in a 24 hour period from 6-7 October 2014. The turbine produced 192,000 kW/h during steady wind conditions. The power produced by the turbine in one day was enough to supply the energy needs of approximately 13,500 households.
MHI Vestas Offshore Wind’s CEO Jens Tommerup said the record demonstrates the full capacity of the V164-8.0 MW. “This power production record further underlines both the quality of the technology as well as the skills of the team involved who have been working hard to ensure the turbine is performing according to our testing schedule.”
Encouraged by the outstanding efficiency of the world’s most powerful wind turbines, MHI Vestas Offshore Wind has invested in upgrading the production hall at the Vestas Blades Technology Centre, to enable serial production of the V164-8.0 MW. The impressive Isle of Wight, UK facility was specifically designed to develop large blades for the latest wind turbines. The site has two halls, each 170m long and 50m wide, one for testing and verification, the other for blade production.
Durham Oktoberfest, the north east’s premier engineering and manufacturing show is the driving force for the promotion of engineering and manufacturing in the north east region and is being held on 22nd October 2015 at the Xcel Centre in Newton Aycliffe.
FARO offers you the opportunity at Durham Oktoberfest 2015 to meet one-on-one with FARO experts and receive a demonstration of our impressive range of 3D measurement and imaging solutions, including the FARO Arm, FARO Gage and FARO ScanArm
We are happy to also announce that our brand new FARO Edge ScanArm HD, the world’s most affordable, high performance contact & non-contact portable measurement system on the market, will be showcased and demonstrated to attendees at Durham Oktoberfest.
For more information visit the event website!
CAM2 Measure 10.5 leads the market with its capability to connect multiple 3D measurement devices, within the same coordinate system, and simultaneously scan into a single seat of software on one computer. This capability allows users to seamlessly scan large objects with higher speed and more precise accuracy in order to complete 3D scanning jobs faster.
“The new CAM2 Measure 10.5 provides significant advancements that support our customers’ needs to measure faster and more efficiently with improved ease-of-use,” stated Kathleen J. Hall, Senior Vice President and Managing Director – Americas.
Significant advancements to Geometric Dimensioning and Tolerancing (GD&T) functionality provide users with streamlined analysis and visual reporting. A part inspection can now be displayed just like a print to easily visualize and determine part quality. This enhanced functionality eliminates the need to look at each feature in sequence to make the same determination.
Workflow efficiencies are maximized with the ability to automate repeat inspections by programing data analysis to automatically occur after the measurements are taken. This new capability reduces required training time, significantly reduces the risk of operator error, and accelerates job completion times.
Additional enhancements include expanded point cloud capacity and the ability to easily scan trim edges. Users are now able to collect over 20 times more data than our previous versions while maintaining accelerated processing speed. New capabilities also allow trim edges on materials such as sheet metal to be easily scanned, essentially eliminating the need to collect hard-probed measurements on part edges.
“The capability to connect multiple devices for simultaneous 3D scanning, automating repeat inspections, and enhanced GD&T functionality represent major advancements in our metrology software. We are excited to launch this new release, and further enable our customers to use our world-class products to drive productivity gains,” Ms. Hall concluded.
Northern Manufacturing & Electronics is the largest exhibition dedicated to serving the needs of manufacturing and electronics industries in the North of England. Event City, Manchester, makes the show easily accessible to visitors from the North.
Make the Northern Manufacturing & Electronics Exhibition 2015 a firm date in your diary to discover and evaluate quality Northern and UK suppliers who can help you redesign and pioneer new products, increase productivity and improve your profit margin. When it comes to sourcing and investigating emerging technologies locally, you won’t find a more comprehensive display of precision engineering products, materials, components and state of the art manufacturing processes.
The event takes place in Manchester at the Event City from 30th September till 1st October 2015. We will present our cutting-edge metrology products such the FARO Edge with touchscreen computer for basic measurements, FARO Laser ScanArm HD with the lightest laser line probe for non-contact measurements, the FARO Gage with barcode scanner, as well as the brand new FARO Laser Tracker Vantage for large volume measurements.
At 120 revolutions per minute, an imbalance would have devastating effects. Efficiency is also highly dependent on the blade’s precision and positioning. Such turbines are manufactured at Andritz Hydro GmbH in Ravensburg, Germany, a division of the Andritz Group.
In order to optimise the production and alignment of these complex components, Andritz Hydro GmbH sought a solution to carry out measurements with narrower tolerances and at higher speeds. After researching thoroughly and testing multiple products, Andritz Hydro GmbH purchased several portable coordinate measuring machines from FARO, which were customized for their measurement needs: several FaroArms and a FARO Laser Tracker for dimension monitoring, CAD comparisons and iterative alignment procedures.
Measuring a turbine wheel is complex and challenging because of the dimensions of the,components being measured. In addition to that, the components are not freely accessible from all sides, i.e., mounted on a measurement bench. Andritz Hydro GmbH benefits from the portability of FARO measurement solutions, which enable the company to carry out precise and reliable measurements in the production area, warehouse and even onsite.
Measurements are usually carried out at the production site amidst other components and tools, using FaroArms in different sizes and a FARO Laser Tracker. These mobile, tactile measurement instruments are ideally suitable here: while there are not many measurement points, these are often in hard to reach places or even hidden. Due to their versatility, FARO measurements solutions are not only useful for the quality assurance of blades, but also for many other tasks, such as analysis measurements, incoming goods inspections, finding cracks in raw castings, the alignment of welded components, etc.
For several years now, PolyWorks|Inspector software has been used for the organization and analysis of the measurement data. The alignment functions and the functions related to the analysis and export of data are particularly popular with customers. Christoph Müller Henker, who works in Measurement and Testing Technology at Andritz Hydro, appreciates the fact that the oftware is not limited to standard situations: “We can take a variety of paths to reach our goal using PolyWorks. We use the many export and import options and interfaces to find our own solutions.” In addition to that, each division of the turbine manufacture is a “customer” and has needs when it comes to processing data. The software has no trouble handling all of the respective formats.
While the challenges related to the size of the components are no longer an issue, there is no everyday routine. Andritz does not use mass production; each turbine is one of a kind. The measurement requirements are therefore ever-changing. “Each measurement is its own project”, explains Yener Korkmaz, Head of Measurement and Testing Technology at Andritz Hydro, who is responsible for quality assurance for incoming goods and in-house production.
Size and accessibility mean that the FaroArm and FARO Laser Tracker have to be moved around a lot. The software speeds up the implementation of the measurement instruments. It is enough to align the respective measurement instrument within the coordinate system at a new location. The organisation of the measurement data and the management of the various device positions within the coordinate system are controlled by the software. FARO Laser Trackers and FaroArms can also be combined in one measurement process, which increases both flexibility and range.
When changing locations, the FaroArm is calibrated via the tracker’s coordinate system. The software registers the measurement arm in the coordinate system of the Laser Tracker, without needing to record reference points. This combination uses the classic FARO TrackArm.
For hard to reach measurement points on the turbine wheel or shaft, the PolyWorks App|Talisman for mobile devices such as iPhone or iPad is extremely useful. Measurements can be initiated and project data accessed from a PC using remote access. The measurement technician can monitor the measurement data and correct measurement errors directly from the component. The turbine manufacturer has also found these reliable, state-of-the-art measurement systems useful for other applications. The correct positioning of the individual components can be determined prior to initiating the welded root seam. The systems are also used for balancing the welded components, with a maximum position tolerance of 0.4 mm.
Today, this takes only two hours. Using wire and solder, it previously took at least two days to bring the individual elements into position and ensure concentricity. Furthermore, because the equipment is mobile, the quality of supplied components can be tested directly at the installation site.
The FARO Laser Tracker is particularly helpful for Machine Tool production and set up. It supports different types of control and measuring tasks. Companies can speed up and maximize the ROI with a single technology to be learned, extremely useful for a wide range of applications.
The FARO Laser Tracker is an extremely accurate, portable coordinate measuring machine for precise quality and dimensional analysis of large components, machine calibration, alignment and assembly, reverse engineering and tool building.
With the FARO Laser Tracker you can produce more competitive products and machines whilst efficiently optimizing your production processes.
The intelligent and comprehensive CNC solutions stand out across the line in a broad range of industries because the machines are designed to guarantee highly dynamic chipping in consistent quality. The increasingly broad range of variations and the resulting quick succession of product cycles present a huge technical challenge when it comes to reliable and flexible processes. Reichenbacher Hamual GmbH relies on vertical integration and the outstanding develop ment skills within their company, which provides them with decisive competitive advantages.
To continue optimizing their production processes and facilitate perfect coordination between speed and precise processing as well as consistent quality with utmost flexibility, Reichenbacher Hamuel GmbH has chosen FARO portable measurement technology. The first FARO Laser Tracker Vantage was purchased in 2013 in order to keep up with the increasing demands in machine assembly. Increasingly large and precise processing machines had to be installed quickly and properly, as well as configured both in house and at customer locations – a routine task for the FARO Laser Tracker.
With this instrument, it was for the first time possible to uncover weak points related to construction and manufacture in all dimensions during assembly and to counteract them accordingly. During the assembly of the machine – some of which were up to 25 meters long – the adjustment of the axles is carried out with the aid of the Laser Tracker. The live display of 3D coordinates.and the levelling function of the Laser Tracker are essential features for the measurement, configuration and subsequent documentation processes.
But the FARO Laser Tracker Vantage can be used in even more ways:
Through the synchronisation of the tracker’s position measurements using the machine control panel, the actuator can be tested and compensated as needed.
The geometric requirements that the customers demand can now be tested and documented independent of machine-specific transmitters. FARO measurement software CAM2 Measure 10 makes this process very easy and intuitive, which also significantly simplifies company communication with customers and suppliers. Linear compensation has thus become an integral part of machine assembly.
Last but not least, the Laser Tracker is still a mobile 3D-coordinate measurement device. For this reason, the Laser Tracker is regularly used to measure large-scale components as they arrive from external suppliers, and for classic quality assurance in production.
Small-scale components, complex milling and cast components, and drive components have been efficiently measured by a FARO Prime measurement arm since 2014. The measurement arm and Laser Tracker complement each other perfectly. In the meantime, the FARO Laser Tracker Vantage is valued by various divisions. This is why the decision was made to purchase an additional FARO Laser Tracker in 2014. The two Laser Tracker Vantage devices now share the workload. One is kept at the Reichenbacher Hamuel GmbH headquarters in Dörfles-Esbach, Germany, while the other is used across the globe for international projects.