FARO staff will demonstrate the FARO Edge touchscreen computer for basic measurements, the FARO Laser ScanArm HD with the lightest laser line probe for non-contact measurements and the revolutionary high speed FARO Laser Scanner Focus3D for detailed 3D modeling and image documentation. To help illustrate the FARO Edge ScanArm HD LLP remarkable data-capture and transfer capabilities it will be connected to a Laser Lines 3D printer.
TCT Live is the event for Product Development and Additive Manufacturing in Europe. It is an essential event for everyone involved in the concept, design, specification and manufacturing process to learn about the latest in Additive Manufacturing, 3D Printing and other cutting edge product development software and technology.
The Aturia S.p.A. Group, based in Gessate in the province of Milan, is currently one of the leading industrial groups in the pump industry at an international level. The main fields of application are submersible pumps (used in heavy industry and in various segments including shipping, off-shore infrastructure and mining); surface pumps (used, for example, in water supply and heating and air conditioning systems); special pumps (used in reverse osmosis, desalination and cryogenic applications) and, last but not least, pumping units used in firefighting, in particularly high demand at refineries and in the petrochemical industry.
Andrea Guercilena, Group Quality & Test Manager, explains: “The Aturia Group is able to offer high-tech products thanks to its integrated design, 3D modelling and FEM (finite element method) analysis systems. The production cycle begins with the design phase. With our long-term experience and vast database, we are capable ofdeveloping and manufacturing pumps for special fluids with power values that reach 1,000 kW, pressure values up to 150 bar and temperatures up to 500°C.”
The various phases of the industrial process are completed at the Gessate production facility, which facilitates coordination among the various company departments. Guercilena notes: “The large fleet of numerical control machines and the networked management of project specifications allow operators to easily obtain the required precision.”
Product quality is guaranteed by “full control” over all components. Pump shapes, sizes, tolerances and performance are checked in the testing room using traditional as well as latest generation devices and software. In this regard, the Quality & Test Manager talks about how the Aturia Group has recently managed to take a significant step forward: “As our workloads increased in recent years, we realised that we were not able to quickly carry out measurements and inspections with our fixed coordinate measuring machine, resulting in the risk of delaying deliveries and disappointing our clients. At the same time, we were witnessing an increase in requests for larger than average pumps, which are difficult to measure using traditional methods. Therefore, we decided to invest in a portable 3D measuring machine with a laser line probe, which is considerably more suited to our new requirements.”
As a result, in late 2013 the companypurchased the FARO Edge ScanArm, a complete system consisting of the portable Edge FaroArm and the laser line probe, ideal for contact and noncontact measurements. “We had seen the machine in action in other workshops,” Guercilena continues, “and we were really impressed. In addition, by speaking with external colleagues and technicians, we understood that for our needs there could be no better tool in terms of quality and reliability than the FARO Edge ScanArm.”
The FARO Edge ScanArm is a seven-axis measurement system with an integrated laser scanner, which makes it possible to measure individual points with the sensor and to conduct scans when large volumes of data are required. According to Andrea Guercilena: “The very broad scanning range enabled us to immediately measure parts of any shape and size. The rapid acquisition speed, portability, manageability and ease of use of the FARO instrument also provided a great boost in productivity.”
But that’s not all: thanks to efficient data processing and management and the possibility to immediately generate easy-to-analyse reporting, with the FARO Edge ScanArm scans can be checked in real time. This is a very important feature since, as Guercilena explains, “it allows inspections and checks to be conducted on-site at the premises of clients or certification bodies. This is a very valuable service that guarantees complete security, even for the most demanding users.”
The technical features of the FARO Edge ScanArm provide very accurate, reliable and repeatable measurement data: “Our pumps,” Guercilena continues, “are complex objects with specific, difficult to measure shapes that require accuracy to the hundredth of a millimetre and just as strict concentricity and parallelism tolerances. Thanks to the FARO ScanArm, we have expanded our measurement possibilities and sped up certification and inspection activities. The high-quality scans also allow us to analyse our products in detail and continuously improve them.” Therefore, the introduction of the FARO Edge Scan- Arm triggered a small but significant revolution at Aturia. “Yes, absolutely,” Andrea Guercilena concludes. “The results achieved are attributable to this excellent technology as well as the FARO personnel who, besides providing the training course, fulfilled our needs by passionately and skilfully responding to our specific requests and supporting us during our technological training and development process.”
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.
Please see this short feature produced by Muc-Off, to tell the story of how their Hydrodynamic Chain Lube was formulated, both as an answer to one of cycling’s unanswered questions and how a concept develops into a product.
Watch this video to “find out more” about its origins and the reason its existence is a necessity for one of the worlds most advanced cycling teams, Team Sky.
Bradley Wiggins and Carsten Jeppeson of Team Sky talk about the substantial gains and advantages to be made over their competitors following an advancement in technology in this area.
We were able to assist Muc-Off and their drive for chain lubrication perfection, through the use of our very own FARO ScanArm HD which combines the flexibility and the functionalities of a FARO Edge measuring Arm with the high-definition Laser Line Probe HD creating a powerful contact/non-contact portable measurement system ideal for challenging application requirements.
The FARO ScanArm HD itself can be seen being used in the video at 2.15!
To find out more then visit our FARO Website or even check out or FARO GB Youtube Channel! and be sure to keep an eye out for the latest Muc-Off kit too. They’ve currently an insanely busy R&D program so please keep checking to see the exciting products they’re about to launch!
FARO Edge ScanArm HD combines all of the advantages of a hard probing system with the capabilities of the FARO Laser Line Probe HD to provide rapid point cloud collection with high-definition resolution and precise accuracy – all in a compact, easy-to-use, and fully-integrated system.
The FARO Edge ScanArm HD is ideal for product development, inspection and quality control, and offers capabilities such as point-cloud comparison with CAD, rapid prototyping, reverse engineering, and 3D modeling of free-form surfaces.
The FARO Laser Line Probe HD brings together the power of a blue laser, state-of-the art camera and optics to maximize:
In designing the Laser Line Probe HD, FARO’s engineers recognized and seamlessly integrated all the key factors that work in harmony to optimize performance.
For a laser line probe product, the key design parameters impacting performance are:
Today’s scanners employ one of two laser types: blue laser or red laser. The Laser Line Probe HD leverages an optically-superior blue laser technology.
Blue lasers have a shorter wavelength, which delivers improved scanning results with higher resolution thanks to greater ability to discern smaller detail in an object.
Blue laser technology also provides a 50% reduction in speckle noise that is proportional to wavelength and degrades measurement accuracy.
For the user the benefits are immediately evident: the FARO Laser Line Probe HD’s blue laser offers 50% better optical resolution than a red laser scanner. This difference is most noticeable when scanning optically challenging objects with dark, shiny or reflective surfaces. With red laser technology, it is sometimes necessary to use a special spray on the scanned object to make the surface less reflective, or multiple target placements.
The blue laser’s higher resolution dramatically reduces the need to spray parts. This removes an unnecessary step from your measurement process and saves you valuable time and productivity.
Do you want to learn more about the FARO Edge ScanArm HD and its Laser Line Probe HD?
As the UK’s only dedicated market place for global manufacturing technologies, the Advanced Manufacturing Show was the ideal venue for FARO to demonstrate its world-class advanced measurement technologies.
Through visitor demand, FARO’s advanced Edge ScanArm HD was demonstrated throughout the course of the show. The Edge ScanArm HD combines the flexibility and the functionalities of a FARO Edge measuring Arm with the high-definition Laser Line Probe HD, creating a powerful contact/non-contact portable measurement system that is ideal for challenging application requirements.
Also in great demand from customers needing to measure smaller parts were demonstrations of the FARO Gage measuring arm. An industry leader in portable CMMs, this accurate 3D gauge ends users’ reliance on expensive and hard-to-use fixed CMMs. The FARO Gage offers high accuracy levels, improves measurement consistency, reduces inspection time and the ability to generate automatic reports.
FARO UK staff are now busy following-up the large volume of sales leads received at the exhibition and performing in-house practical demonstrations for potential customers throughout the UK.
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.
Based in New Hudson, Michigan, Pratt & Miller is a world-class engineering company that takes automotive programs from concept to reality. They are a respected industry leader providing cutting-edge engineering and manufacturing solutions to their clients. Their total design team uses the most advanced research and development technologies available. Pratt & Miller performs first-article inspection for most parts; reverse engineers models, fabricated parts, and any purchase parts that lack accurate CAD; and verifies complicated bodywork, surface features, machine parts, and full interiors. Basically, they measure everything from small components to complete race cars.
Measuring with hand tools is time consuming and creates inaccuracies due to individual error. These tools also did not provide Pratt & Miller with the means to measure its more complicated parts and freeform surfaces without undesirable contact. This work had to be farmed out and they lost direct control of data.
FARO provided the accuracy Pratt & Miller was looking for at the speed they need. They have the utmost confidence in the results they getfrom FARO. Co-founder Gary Pratt says, “We use FARO to design, construct, and analyze ‘virtual’ components, CFD, systems, and complete cars – every facet of a project from initial conception to the finished product.”
The FARO ScanArm was selected for its portability, flexibility, accuracy, compact design, and reputation. Mike Kurylo, a design engineer at Pratt & Miller, says, “The quality of the FARO equipment, the ease of training, and the knowledge of their support are all first rate. Their customer service goes well above and beyond what one would expect from such a globally recognized technology firm. It feels like having your own pit crew!”
Gary Latham, a lead engineer at Pratt & Miller, says, “FARO is incredibly useful with our tight timeframes. About 30-40 percent of our parts are manufactured in the workshop and they need to be entered into CAD and now we can do that easily with faster data capture.” They also use the ScanArm in their Computational Fluid Dynamics (CFD) to fill in any missing pieces of the puzzle. FARO returns control of the data process to Pratt & Miller and eliminates the need to farm out projects.
In today’s ever increasingly competitive conditions, Pratt & Miller is always searching for every last bit of performance enhancement – be it in the form of speed, time, accuracy, or efficiency. FARO answers the call on each of these.
The most intelligent design solutions are centered on the integration of the best tools. Pratt & Miller engineers use the most up-to-date and powerful computer software and hardware in existence. The next logical step for them was a FARO solution.
“We’re constantly updating, expanding technology and FARO opened new parameters in manufacturing and engineering for us,” Gary Pratt says. “FARO has really opened our eyes and they’ve been fantastic for us. Once you get something like this, you can’t see how you did without it.”
Check out the video below which takes a close look over the shoulders of the experts at Capristo and follow an engine bay hood for the Ferrari 458 Spider throughout the whole manufacturing process, all of which is carried out at their plant in Sundern, Germany.
On hand to help is one of our own the FARO Edge ScanArm HD, used to scan the engine bay thus providing a 3D model for use during the design process by providing an accurate model to indicate available space as well as helping create a 3D model of the prototype.
The FARO Edge ScanArm HD combines the flexibility and the functionalities of a FARO Edge measuring Arm with the high-definition Laser Line Probe HD creating a powerful contact/non-contact portable measurement system ideal for challenging application requirements.
The Edge ScanArm HD is the most affordable, high performance contact/non-contact measurement system and is ideal for product development, inspection, and quality control and offers capabilities such as point cloud comparison with CAD, rapid prototyping, reverse engineering, and 3D modeling of free-from surfaces.
In 1972, following a distinguished career in the automotive industry, Gian Paolo Dallara founded Dallara Automobili in Varano de’ Melegari, near Parma, Italy. Since then, the company has expanded, designing and building cars for almost all of the racing competitions and winning races worldwide.
This is a success story, the result of a passion for mechanics, involving the company‘s 180 employees (including 60 engineers) on a daily basis: men and women who work with passion and skill on high-technology projects in order to gain the edge in the fiercely competitive world of motor racing. In particular, it is absolutely necessary that each stage of production and assembly carried out in the factory at Varano de’ Melegari is tested and validated using adequate measurement and control procedures. Paola Carlorosi Quality Assurance & Quality Control Manager at Dallara Automobili, explains: “Our cars are a concentration of high technology and innovation. Quality control is of paramount importance as it must ensure that Dallara cars are produced according to expected standards, providing exceptional performance and reliability.”
FARO‘s sophisticated portable measurement equipment fully satisfies the technological requirements of Dallara Automobili and FARO has been the automotive company’s chosen partner for a number of years. Carlorosi: “Our collaboration has been ongoing since 2007, demonstrating the strength of our partnership. Our latest investment dates back to 2012 when we decided to buy a 2.7m measuring arm, the FARO Edge ScanArm, which we mainly use for non-contact quality control and reverse engineering.” The FARO Edge ScanArm – which combines the FARO Edge portable measurement arm with a laser scanning probe (FARO Laser Line Probe) – is a portable 7-axis coordinate measuring machine (CMM), which allows the user to easily check product quality through 3D inspections, comparisons with the CAD design, dimensional analysis and reverse engineering. The integrated Laser Line Probe for laser scanning ensures a perfect 3D measurement without touching the surface of the product. At Dallara, the FARO Edge ScanArm is mainly used to check the airfoils and the most important structural components made of carbon fibre. “With this new measuring device,” continues Paola Carlorosi, “the speed of data acquisition has increased enormously. Considering that the device operator completed the training course and was operational after just three days, we can only be satisfied.”
And that’s not all: “The data analysis phase has become easier as the CAM2 Measure 10 measurement software develops really clear, easy-to-navigate reports. Today, reporting is much more comprehensive and informative than ever before and, once the point cloud has been obtained, every detail can be analysed section by section – especially the airfoils – by comparing the theoretical project data with the actual measurements. We also execute processes and controls for external customers who are very pleased to receive reports that are easy to read, clear and transparent, even for non-experts. It is an advantage for our business.” Another important benefit is that it is no longer necessary to treat components with opacifiers, which was necessary in the past for the non-contact measurement of black and glossy carbon surfaces. Paola Carlorosi: “The FARO laser probe technology allows polished carbon surfaces to be scanned without having to apply opacifiers, which also required processing to remove the product afterwards. The whole operation has therefore become much faster: we save 30 minutes on average for each square metre to be checked.”
Dallara is currently using the FARO Edge ScanArm in the development and construction of the chassis for the new 2014 Japanese Championship Super Formula. It has been used right from the prototype phase. Paola Carlorosi: “Even in this situation, we have been able to perform quality controls more precisely, saving on average 50% of the time spent on the same activities in the past. It’s an amazing achievement.” And she concludes: “In general, the checks performed during the production and testing phases allow us to reduce errors, improve our core manufacturing processes and, in conclusion, achieve a higher quality level. If these checks are carried out using high-performance equipment that increases quality and reduces workload, then the benefits are definitely worthy of a Grand Prix!”