Here’s how machines can be aligned with laser trackers.
BY TEAM MT
The popular adage, “If it ain’t broke, don’t fix it”, might be a piece of advice that is dished out often, but perhaps less appropriate if applied in the context of a manufacturing facility. In the world of mass production, machines are put to repetitive tasks each day to churn out large outputs of identical items. Seeing that production volume is key, it is vital to ensure that machines are often checked, so that the manufacturing process never gets disrupted.
When the manufacturing process is halted due to machine misalignment, companies risk losing a significant amount of investment in the form of time delay, reduced productivity, and scraps. “However, these costs can be avoided if companies take careful ownership of preventative maintenance, minimising the likelihood of equipment failure or downtime,” quips Eddy Lek, product marketing manager, Faro Technologies. Besides, machine alignment significantly increases the lifespan of tools, which can be expensive to replace. In order to do this the laser tracker has emerged as a powerful, user-friendly device that can perform multiple measurement tasks in a much shorter time.”
Anthony Lur, product marketing specialist, Faro Technologies explains how a laser tracker works. “The laser tracker is a portable coordinate measuring machine (CMM) that is based on 3D coordinate technology. Fundamentally, these devices provide the benefits of CMMs with the added versatility of being portable, which allows the user to deploy wherever there is a need, without having to move their machine. In addition to being less cost-prohibitive than fixed CMMs, portable CMMs do not require a controlled environment, making it more cost effective to operate and maintain them.”
Designed to handle larger working volumes, laser trackers offer extremely accurate measurements over long ranges. “Put simply, a laser tracker establishes the precise location of a target in spherical space by measuring two angles and a distance, each time it takes a measurement. It does so by sending a laser beam to a retro-reflective target, which has to be held against the object being measured. The return beam re-enters the laser tracker where the distance to the target can be determined using interferometry or phase shift analysis,” elucidates Lek.
The horizontal and vertical angles to the target probe are determined using precision angular encoders attached to the mechanical axis of a gimbaled beam steering mechanism. Using the two angle measurements and distance determined by the laser, the laser tracker can report the coordinate location of the target probe to extremely high accuracy levels. In addition, the laser tracker can follow or track the target probe as it moves in real time. “This unique feature, coupled with the laser tracker’s ability to internally sample rate of up to 16,000 times per second, enables the user to digitise data on complex surfaces or measure the location of moving objects,” informs Lur.
In fact, laser trackers today have impressive measurement ranges and accuracies that provide users with more versatility and better results. For instance, the Faro laser tracker Vantage’s radial distance measuring range is 80 m, and at that range, it captures data at typical accuracies of up to 39 microns (0.039mm). Weighing just under 18 kg, the Vantage offers portability and flexibility on measuring large parts, no matter where production is located within the plant.
The American Society of Mechanical Engineering established a set of standards for the correct and accepted methods to check and align machine tools with a laser tracker. Lek and Lur document scenarios of alignment being performed on a variety of machining centres, machinery, and other equipment.
• Horizontal/vertical machines, bridge, column, or gantry-type machines
On these machines, the laser tracker can be used to check for surface level, straightness, flatness, and squareness. The target is placed on the machine bed to capture measurements, and users can either make adjustments in real-time, or obtain a complete set of points before adjusting the machine bed afterwards. For tool alignment, the target can be placed in the spindle, chuck, or quill of the machining centre. “Measurements can also be obtained by placing the target on a pin nest that gets mounted directly into the drill of the machine. Alternatively, it can also be placed in a ‘puck’, or a drift nest, which can be glued on to a moving bed. As the target sits on its respective locations, 3Ddata points are collected while the machine travels through a range of movements to check for alignment issues,” avers Lek. Apart from checking the machine bed, the laser tracker can also be used to check for plumb, level, or ensure parallelism in the rails. For lathes, in particular, laser trackers can perform turning centre alignment by tracking a target that is affixed on to the headstock with a drift nest.
Presses – platen, stamping, and brake press
“With presses, laser trackers are useful for checking perpendicularity and parallelism of posts, as well as platen parallelism. The ends of each pole on each sides of the plane are measured and compared to ensure it lines up square (between pole and plane) and parallel (between planes) respectively. Any deviation can be corrected based on the readings acquired,” informs Lur.
• Calibration of robots
In this application, the target is ‘held’ by the robot while measurements are being taken. The laser tracker dynamically tracks the target as the robot moves through its programmed path. By analysing the data points, a user can tell how much the robot has deviated from its nominal path, thereby directing him on remapping, calibration, or error compensation actions that will allow the robot to move properly through its range of motions.
In the assembly of power generation equipment like a driveline, the laser tracker can ensure that components are lined up correctly, according to design. The laser tracker is mounted with a magnet to hang off the side of a machine, so that it has a direct line of sight to all the features of interest. In this manner, the laser tracker can take measurements of the driveline while it remains on the machine tool. As checks are being made right on the shop floor, adjustments can be made without taking the set-up apart, which saves time and eliminates the need for rework.
“Evidently, the laser tracker is an effective complement for the practice of preventative maintenance, which reduces downtime, enables cost-savings, and also improves the quality of output. It is a robust tool that can be deployed anywhere on the shop floor, the laser tracker’s multiple functions can suitably replace a variety of hand tools, making it a worthwhile investment. Companies expanding their capabilities to include in-house machine alignment now have the laser tracker as an option apart from traditional methods,” concludes Lur.