Component measurement - Optical measurement of components as quality control

Component measurements make a decisive contribution to quality assurance in industry. Here, the process is quite extensive and can always vary depending on the measuring method and measuring device - an absolutely essential process to meet customer requirements. 

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What do experts understand by component measurement? Component measurement is used to check geometric properties such as dimensional accuracy, shape and position, roundness and surface condition of components. During the process, a whole range of measurement methods and measuring devices are used. Highly qualified specialists use coordinate measuring machines, optical measuring systems or even X-rays.

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You want to know which technology we use at Q-Tech? Then take a look at our equipment. 

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The importance of component measurement

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The precision of a component measurement is crucial to ensure that the manufactured component meets the requirements. This ensures consistent, high quality.

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Otherwise, scrap, rework, customer complaints, and sometimes safety problems can result. These circumstances cause unpleasant costs and reduce a company's profit. 

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Accurate part measurement , on the other hand, leads to an increase in profitability, a reduction in the error rate and better customer satisfaction. 

Functionality

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The procedure for component measurement can be divided into several steps. The individual phases can vary depending on the measuring method and measuring device. At the beginning, the inspector clamps the component to be inspected into the measuring device or positions it on it.

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The actual measurement then takes place, during which the component is measured and all relevant geometric properties are recorded. For this purpose, it is often necessary to perform the measurement in different positions. 

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The measurement results are then analyzed with evaluation software and compared with the specified tolerances. If deviations occur, the inspector classifies the component as defective. It must then either be reworked or sorted out. 

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Advantages of a component measurement

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Applied, the process offers a whole range of advantages: 

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1. High precision: The actual state of geometric properties of a component is made precisely measurable.
2. Efficiency: Due to the precise measurement, the error rate decreases because scrap is avoided. This increases cost-effectiveness and efficiency in production. 
3. Quality assurance: Precise component measurement plays a decisive role in ensuring consistently high quality in the manufactured components. Especially for safety-critical applications in the aerospace industry, the automotive industry or medical technology, the point plays an important role.
4. Customer satisfaction: Because the components supplied meet the required specifications, customers can be sure that functionality is absolute. This increases customer satisfaction.
5. Cost savings: Accurate part measurement leads to cost savings because the error rate is reduced, resulting in less scrap and rework. 

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Component scanning - Which methods are used? 

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Different measuring methods and measuring devices are used for component scanning - depending on the specific requirements and properties of the components to be tested. 

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Here are some of the most popular measurement methods: 

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• Coordinate measuring machines: Coordinate measuring machines enable high-precision and three-dimensional measurement of components. The devices can be found in many industrial areas and are frequently used there. 
• Optical measurement systems: In optical metrology, inspectors use various sensors and cameras to record the geometric properties of components. Surface finish, roughness, but also shape and position tolerances can be determined perfectly with this method. 
• X-rays: This technique is particularly suitable for detecting internal structures and properties of components that are difficult to examine using other measurement methods. X-rays are used in the automotive, aerospace and electrical industries. 
• Ultrasound: The ultrasonic method can be used to measure the thickness of materials and the quality of welds. Ultrasonic measurements are often used in heavy industry and the chemical industry. 
• Fringe projection: In this method, a light pattern is projected onto the component under test and the distortions of the pattern are measured. This is done to fully digitize the component and then make measurements on the digital image. Fringe projection is often used in the manufacture of glass and plastics, but is also used in the electrical industry or in mechanical engineering. 

Measuring method in house Q-Tech

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Below you will find an overview of the procedures we offer. 

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Keep in mind that there is no "one" measurement method for checking physical quantities - on the contrary, sometimes it is worth combining several measurement methods to obtain a meaningful picture of the functional condition of the component. 

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Computed tomography

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Computed tomography uses X-rays to open up a view into the interior of a component without having to destroy it. The test specimen can continue to be used after the measurement. 

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This makes it possible to detect and analyze hidden defects that coordinate measuring machines, for example, cannot easily detect. Examples are inclusions, blowholes or internal component defects. In addition, soft and transparent materials can also be measured. 

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For all components, the inspector can use this to create entire CAD models with all internal and external structures or simply reproduce the scanned components. This process is part of reverse engineering. 

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Q-Tech uses ZEISS METROTOM 800 and ZEISS METROTOM 1500 G3 machines for computed tomography. 

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Tactile coordinate measuring technology 

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This technique is based on the probing of a component. A probe records the surface contours as signals. The data is then converted into XYZ coordinates using software. 

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Our measuring machines work with the CALYPSO software. We rely on the quality of the manufacturer ZEISS. 

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In 3D coordinate metrology, our inspectors use the ZEISS PRISMO ULTRA, ZEISS PRISMO VERITY, ZEISS ACCURA II, ZEISS O-INSPECT 863 and the ZEISS ACCURA 7. 

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Often the probes are made of a very hard metal. The measurement result contains the form deviation of the probe, form and position deviations of the test piece and the positioning capability of the coordinate measuring system. 

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A CNC control serves as the basis for coordination. By means of correction factors, a stable probing behavior is guaranteed in all three axes during the entire measurement. 

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Optical 3D Digitizing

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Optical measurement of components. Optical 3D digitization can be used to create a digital twin of a component - the digital image of a material test piece from the real world. 

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For this process we use the GOM ATOS Q 8M. This is an extremely versatile LED scanner for small to medium-sized components. 

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Optical 2D measurement

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Similar to 3D digitizing, the test part can be measured here without contact . 

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Optical 2D processes are suitable for symmetrical and flat components, among others. 

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Roughness measurement

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Roughness measurement is part of our coordinate measuring technology. The process runs as a 2D measurement using the stylus method. A tactile probing system is used, which precisely measures the object surface by probing. 

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We then create a surface section and an exact profile. This allows us to determine exactly the surface structure of your test object. 

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This process is used to record all the roughness and waviness parameters of your component in accordance with the standards. 

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Contour measurement

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We do not cut any corners when it comes to contour or geometry measurement of components: Edges, radii and angles are in many cases critical features on a component when it comes to functionality . We measure the geometries precisely and reproducibly - even over long measuring distances.

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You receive the results in the form of a 2D representation with dimensional evaluation in graphical form. Deviations are already recognizable at first glance.

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A ZEISS SURFCOM NEX 031 SD-14 N is used as the measuring device. 

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Gear measurement 

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We perform gear or gear tooth measurement with our high-precision ZEISS Prismo ultra and the integrated rotary table in our precision measuring room. 

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Our gear measurement is performed at a high-precision level. The whole process is done tactilely and allows the evaluation of internal and external gears for almost all types of gears. It does not matter whether these are straight, helical or conical. 

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A measurement report with all geometric properties is generated within just a few minutes. The subsequent analysis is carried out holistically according to common standards. 

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Q-Tech: Your partner for accurate component measurement

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Q-Tech is a leading supplier in measurement technology and stands out due to its many years of experience in component measurement. The highly qualified engineers and technicians from our company have the necessary extensive expertise and use the latest measuring methods and machines to realize precise component measurement.

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We offer our customers tailored solutions for their specific requirements and thus make a valuable contribution to optimizing their production processes. Optical measurement of components and much more.

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Conclusion

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Component measurement makes a decisive contribution to quality assurance. Thanks to this process, individual components can be checked for functionality.  

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In the optimal case, the requirements of the customer are met.  

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Q-Tech is your reliable partner in this field, offering you accurate measurements at expert level. Contact us anytime - the machines and the measurement technicians at Q-Tech work with an unparalleled precision that you will find difficult to find elsewhere. 

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