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QBOX_05_OK

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Hello, I’m Francesco Tamburo, an Application Engineer at QFP, and I’m here today to tell you about the QBOX Minicobot. As you can see, the system consists of a UR collaborative robot on which a ZEISS Comet Led 5M fringe projection sensor has been installed. It is completed with the stand and a rotating table with a payload up to 300 kg; this allows the component to be rapidly positioned with limited clamping, so that the part can be moved as it is measured. As you can see, this is an extremely compact solution, so it can be easily accommodated in any metrology lab. As we shall see, it is also highly flexible and easy to use. The benefits obviously stem from the combination of the strengths of the collaborative robot and the ZEISS optical solution. As we said, the cobot offers high flexibility and is easy to use and program, while the ZEISS Comet sensor makes it possible to obtain extremely precise measurements with minimal preparation of the component and, as you can see, minimal equipment. The system can be used in a variety of environments and sectors, such as plastic injection moulding, sheet metal forming, casting, die-casting, and so on. It is particularly suitable for difficult components that would be problematic for other traditional technology, like probe technology. So let’s see how the system is programmed. Programming is extremely intuitive and simple, thanks to the machine’s integrated software. Let’s start by creating a new project. You input the name and click on “Next”. The opening screen of the project is displayed. As you can see, the number of commands are very limited, which helps the operator as they create the program. All you have to do is click and then set the positions of the robot. Since this is a collaborative robot, positioning is extremely simple and, thanks to the instrument’s laser pointers, the object can be framed easily and intuitively. Once the position has been set, we’re ready to scan. You set the exposure time and you can also run a preview to check that the object fits into the measuring volume. As you can see in the preview screen, the components fits into the instrument’s measuring volume, so we can accept the scan. So a first position associated with the first scan appears in the project tree. Then we create a second position. In this case we can use the rotating table to make a 40-degree turn. Next we scan again. The same screen as before. Now we’re ready for the second measurement. At this point, the software will automatically combine the two scans we’ve just completed, one on top of the other, using the component’s complex geometry. On the screen, you see a preview of the first scan, the second scan and the combination of the two scans. Alignment is automatically handled by the software, which generates a successful result message. Now we can add other scans until the component has been completed. When you’ve finished, you click on the back-to-home trajectory and move the robot close to the initial position. The robot returns to the initial position by itself. At this point we save the project, which can also be done automatically. Now we switch from manual to automatic operation by turning the selector. We also close the project we’ve just saved, and switch to automatic mode. As you can see, the software lets us choose from a number of pre-compiled programs that have already been released. We select the program we want and start the measuring cycle. We can start the measuring cycle. The program is executed automatically, following the sequence of positions set by the operator. As you can see, the operator can move inside the Minicobot without any difficulty. This is thanks to the collaborative robot, which as we said, easily adapts to typical metrological lab environments. On the screen, the process is the same as we saw before. The component math is also shown, with the first measurements we took. At the end of the cycle, the data will be processed automatically and the point cloud will be converted into STL format for dimension control management. You can also see how the collaborative robot enables us to see the object from any viewpoint. We can measure any part of the component. This is thanks to the solution’s compact design and high flexibility. You can also see that the component clamping is relatively simple, which means the Minicobot adapts easily to small batches of a large mix. So we’ve finished measuring the object. The robot is going back to the home position, and the data we have acquired so far is automatically processed by the software. The point cloud that has been generated is processed and converted into STL format ready to be checked and compared with the mathematical model. As you can see, the processing time is extremely fast and the operator is not involved in this stage. The best-fit alignment with the math has been rapidly executed and now the STL is processed by the inspection software and the report is generated automatically. So now we have our inspection report on the component we’ve just measured. You can see the CAD model, the processed STL and the alignment check. The next steps are the definition of the alignment points of the measured component with the CAD component. The advantages of contactless scanning technology compared with traditional measuring methods are evident here. We can inspect the entire surface of the object by comparing it with the mathematical model, in this case through a chromatic map comparison. The areas with more material compared with the mathematical model are shown in red. The areas with a shortage of material are shown in blue. In addition to the chromatic map comparison, we can also measure characteristic values of the object, that is all the design values. Here, the centre-to-centre distances of the component are being checked, obviously against the nominal value, in other words by comparing the measured and the nominal value. And the tolerance test enables the operator to check easily and immediately whether the tolerance is correct. The usual GD&T checks are also possible, in this case a planarity check. Having the entire surface of the object means we can fully map the planarity check on all the component areas, and so on all the data actually measured. Then we can check the footprint measurements and run a cross section check. This means we can obtain a virtual section of the STL and compare it with the mathematical model, again with a chromatic map and deviations.

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Duration: 11 minutes and 24 seconds
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Language: Italian
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Posted by: gabriella61 on Apr 16, 2020

QBOX_05_OK

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