In the last few decades, the science and technology of quality control has made significant gains.
What began as pre-industrial single-part inspection predicated on the word and reputation of the craftsman at hand, has evolved into advanced statistical analysis augmented by today’s arsenal of sophisticated 3D measurement devices and portable coordinate measurement machines.
So much has the landscape transformed, that to prospective buyers of the technology, the benefits and use cases of said devices have, on occasion, been challenging to determine.
This article is written to discuss three key probing and non-contact measurement tools and to identify when, where, why and how, each tool is the best fit for your intended workflows.
What Is Quality Control in 3D Measurement?
Dimensional quality control (QC) is a specific manufacturing discipline. It refers to the process of using certified 3D measurement technologies to verify that a part or product meets specified dimensional and geometric requirements, ensuring that manufactured components conform to design tolerances, standards, and performance expectations.
Identifying and staying within range of predetermined tolerances is critical if industry is to function and remain competitive in global market. Additionally, traceability of performed measurements and reports is an important aspect of dimensional quality control.
How to Evaluate Your 3D Measurement Needs
Fortunately, there are a variety of 3D measurement scanning and probing tools available to help make this job easier. Key considerations include accuracy, ease-of-use, portability, the size of the part or assembly to be measured, and of course, return on investment.
Benefits of 3D Laser Scanning for Quality Control
Today, streamlining in the QC arena alone by way of 3D non-contact measurement scanning or probing technology has significant advantages.
Acquiring better, more accurate 3D data faster as parts are being produced and assembled by way of portable coordinate measuring machines, means that greater productivity can be realized. It also means reduced customer complaints, rework, waste and scrap. Combined with optional automated and semi-automated machines, guided by automated quality control software, this has a significant cost reduction value, along with noteworthy quality control efficiency gains.
FARO 3D Measurement Tools at a Glance
The FARO® Leap ST® Handheld 3D Scanner, Quantum X FaroArm® Series, and the Gage Max, are the three quality control products this article will focus on first. Future articles in this series will explore the FARO® Vantage Laser Tracker, the FARO Super 6DoF TrackArm, and the FARO Focus Laser Scanning solution regarding their quality control applications, so stay tuned for later updates.
FARO Leap ST: Compact, High-Resolution Measurement
Leap ST is designed as a compact, high accuracy 3D non-contact measurement scanner with five operating modes whose versatility and portability benefits numerous workflows and industries.
The product is most suited for medium-volume, high-accurate scanning of up to 10 meters. Entire vehicles, including engine chassis, car doors, etc. are great examples of where this product can excel. Smaller parts can likewise be within the Leap ST scanning wheelhouse and include items like car fenders.
Beyond automotive, Leap ST is also useful for measuring aerospace components, wind turbine parts, and shipbuilding. Why? Because traditional CMMs struggle with measuring very large parts and Leap ST allows accurate measurement without requiring the part to be moved or disassembled.
Finally, Leap ST, with its noteworthy ease-of-use, can also be used inline or near-line quality control in manufacturing environments, enabling fast comparison of physical parts against CAD models with high precision, identifying misalignments or wear, as well as for first article inspection for quality validation as well as for reverse engineering.
What is Quantum X?
The Quantum X is designed to offer up to a 15% increase in accuracy over comparable previous generation models. Fully configurable and scalable, Quantum X comes with five lengths and three accuracy performance levels each, and with multiple Laser Line Probes that address various non-contact measurement needs.
For an add-on, Quantum X is compatible with the FARO 8-Axis Max, a rotary worktable, which reduces measurement time by up to 40% while maintaining exceptional accuracy. With Quantum X, users can verify dimensional accuracy and identify deviations from nominal CAD data during first-article and in-process inspection, as well as inspection of incoming parts.
In quality control applications, the Quantum X excels at dimensional inspection, GD&T, and CAD-to-part comparisons. This allows inspectors to quickly probe or scan a part and compare the results to a digital model, producing deviation color maps and inspection reports in real time.
Leap and Quantum X Best Use Cases
While Leap ST and Quantum X share overlapping purposes, the key differences rest with accuracy, portability, and ease of use. Quantum X is generally designed with very high probing and scanning accuracy in mind with up to a reach of 4 meters.
In situations where Quantum X might encounter limitations, like trying to reach into the interior of a car for example, Leap ST might be the ideal choice.
At other times, however, Leap ST might have limitations in tight spaces when dealing with minimum stand-off distance. In these either-or cases, choosing between the two devices comes down to personal preference.
Feeling the Need for Speed?
Another variable to consider is scanning speed and probe time. Not just taking the actual scan or probing the physical object, but the need to leapfrog around a part or assembly. Quantum X, for instance, may require leapfrogging, moving from location to location to measure the part in question.
For reference, Leap ST’s scanning speed is approximately 4.1 million points per second at up to 10 micrometers point distance, while the Quantum X can scan at 1.2 million points per second at up to 15 micrometers point distance.
However, on the other hand, the versatility of the Quantum X with its hybrid solution that allows both larger-area scanning and high-accurate probing is a main differentiator to Leap ST and allows more flexibility when it comes to the inspection of parts with certain larger, complex area AND with small features like holes.
FARO Gage Max: Portable CMM for Precision Inspection
The Gage Max FaroArm allows machine shops and small production lines to meet even the most demanding quality specifications with one efficient, sleek, rugged portable CMM.
Ideal for small-size, high-accuracy tasks, the Gage Max is the most intuitive, ergonomic and versatile articulated portable CMM, enabling machine shops to meet their most demanding quality specifications.
Additionally, the Gage Max minimizes clutter from traditional hand tools such as calipers, micrometers, and height gauges and is ideal for small parts, molds, and assemblies.
This is especially true for small parts with complex geometries, a car’s disc break, for example, or gearbox housings, brake calipers and rotors, fuel injection rails and exhaust manifolds.
In aerospace it can also be used for turbine blades, fuel nozzles, bracket assemblies, control linkages, sensor housings, and more.
Key Questions to Ask Before Choosing a 3D Scanner
As noted above, so often when it comes to selecting a portable coordinate measuring machine 3D measurement device, the choice is a matter of preference – provided you’ve selected the proper tool for the part size you’re looking to measure.
But sometimes the highest accuracy scanning or probing, is beyond what the job entails. In other cases, part access or speed is the highest priority.
The following is a checklist to consider when making your choice:
- What is my main application (quality control, reverse engineering, assembly guidance, machine alignment or machine control)?
- Does the solution support the required tolerances of the parts to be measured (measurement accuracy and repeatability)?
- Is the solution able to measure the required size of parts (measurement range)?
- Is the solution able to detect the required features of the parts to be measured (measurement resolution)?
- Can I reach the parts to be measured (accessibility)?
- Does the solution need to be automated (automation-ready)?
Conclusion and Next Steps
Compared to a few decades ago, today’s 3D measurement toolkit is far more diverse with solutions intended for exacting workflows and for specific part sizes.
Articles like this – and the ones that follow – are designed to provide actionable insights and to help our prospective manufacturing customers make the informed decisions they need to reach in our increasingly competitive global manufacturing and assembly marketplace.
Set up a demo with us to discuss your business needs. This will allow us to match the right 3D measurement device for your needs and provide you with the clearest path to enhance your quality control with the right solution(s) for your workflow today.