In manufacturing, the measurement of the cutting tools used in machine tools is critical to ensuring that finished products are of the required standard. Why is this the case, and among alternative approaches to measurement why might camera-based systems be the most suitable for the job? Read on to find out…
In this blog, we’re going to answer a deceptively simple question: in manufacturing, why is the measurement of the cutting tools used machine tools vital, and why should you use a camera-based measurement system to do it? To find out, we’ll take a two-pronged approach.
First, we’ll examine an obvious question which is, if you’re using machine tools, why is measurement (of any kind) so critical in the first place? And second, after that we’ll consider why, among alternative approaches to measurement, camera-based systems may be the best suited for the purpose.
When you’re using machine tools in manufacturing, why is measurement important?
There are many reasons why measurement systems applied to machine tools play a central role in helping to ensure successful outcomes for manufacturers, so let’s start by highlighting the major ones to understand why it’s worth investing in measurement technology. They are:
When it comes to precision and accuracy, there can be no compromises
Machine tools must work in a uniform way They are used to repeatedly to ensure that workpieces meet their required specifications (of course the workpieces, too, must be measured).
The necessary consistency can’t be achieved without consistent measurement. And there’s another parameter at play, accuracy. Accuracy too is just as critical as consistency. Without accurate tools, the finished workpiece won’t meet the required dimensions and tolerances specified.
Measurement means quality control
Tools generally need to meet rigorous industry standards as well as delivering to customer requirements, so they need to be continually measured to ensure they remain fit for purpose (over time, continual usage will erode their original dimensions). That makes measurement a key aspect of quality control processes. Statistical Process Control (SPC) generally relies on precise measurements to monitor manufacturing processes.
One size must fit all
Tools may need to be interchangeable, as we alluded in point 1 above, and measurement ensures that they are. That’s because if one tool breaks down in a production process, the manufacturer needs to be confident that it can quickly be replaced, for example in assembly lines. Accurate, standardized measurement of tools allow this to happen, as well as making the need to repair or replace defective parts less likely.
Sustainable, efficient, cost-effective
How can manufacturers reduce waste and rework, use (often costly) raw materials more efficiently, and streamline production processes while reducing downtime due to defects? That’s right…by using accurate tools and proper measurement techniques to reduce waste.
Safety isn’t an afterthought!
Machine tools that meet precise measurements yield fewer malfunctions and failures, and that means they’re safer tools for users. Therefore, measurement is critical to the overall reliability and safe operation of machinery.
We’ve listed five reasons above, but there are many others. Measurement ensures compliance with industry standards, it increases customer satisfaction, and it plays a key role in prototyping and product testing, therefore acting as part of research and development processes.
It’s also central to lifecycle management with accurate measurements necessary to monitor and manage wear and tear on equipment, ensuring timely maintenance and replacement.
In summary, measurement is a foundational aspect of ensuring that in manufacturing, the machine tools used are up to the job and for assuring quality and consistency in output. Directly or indirectly, it affects nearly every phase of the production process from design and development to quality control and customer satisfaction.
What are the advantages of using camera-based measurement systems in manufacturing?
Now that we’ve established why measurement systems play a central role in helping to ensure successful outcomes for manufacturers using machine tools, let’s move on to the second question: why, among the different approaches to measurement, do camera-based systems come to the fore?
Camera-based systems, (they’re often part of an approach known as machine vision technology), offer several advantages in manufacturing compared to the alternatives which, again, we’ll consider closely.
The obvious one: High Precision and Accuracy
Camera-based systems capture high-resolution images, and these are the basis for precise measurements and detailed inspections of components. Particularly where high precision is required, such systems can measure features with sub-micron accuracy.
Fast and efficient
Camera-based systems are capable of rapid processing, and they allow multiple dimensions to be captured, analyzed, and measured in a single capture. Understandably, this speeds up inspection processes, as well as enabling real-time, continuous monitoring and measurement of both the machine tool and the workpiece which enhances efficiency and reduces downtime for manufacturers.
No contact!
Camera-based systems deliver “no contact” measurement which mitigates the risks of damaging delicate components or altering their properties during production. Camera-based systems can also be used to measure a wide variety of materials, whether soft, hot, or otherwise difficult to measure using traditional, contact-based methods.
Automated and integrated
Camera-based systems can be fully automated, thus reducing the need for manual intervention and minimizing the necessity of human effort. They can also usually be integrated with other manufacturing systems, hardware, and software which eases data flows and improves process automation.
Digital cleaning
One advantage unique to Conoptica and the camera-based CU2 Tool is digital cleaning. It’s the only device available that can deliver perfect measurements during the processing of the workpiece. It is uniquely able to cleanse images and compensate for the wear of the tools as occurs.
…and versatile
Camera-based systems can measure complex shapes and geometries that are inevitably challenging for traditional measurement tools. They’re also adaptable to multiple sizes and types of components, from micro-scale parts to large assemblies.
Again, those are just a few of the camera-based systems advantages. There are many others – too numerous to detail here – but on other worth noting is that camera-based systems can also deliver a sustainability advantage by detecting any manufacturing issues early in the production process, thereby helping to minimize scrap and rework costs.
The bottom-line conclusion should hopefully now be clear; camera-based measurement systems bring significant advantages to those who use machine tools. So, if you use machine tools or manufacture them and to see what camera-based measuring solutions can do to enhance the quality you deliver, let’s have a chat!
About Conoptica
Conoptica is a leading source of high accuracy measurement systems, offering a variety of different measurement systems for the machine tool industry. These enable accurate measurement, so users can track consistency and take appropriate actions – avoiding excessive quality deterioration and enabling better production outcomes.
Conoptica has been providing high tech camera-based measurement solutions since 1993. We make sure that the metal working industry has access to key quantitative data about their products and tools