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Accurate measurement methods are essential in industry. There are now many different methods for measuring physical quantities. Precise measurements are indispensable in industry for quality assurance and for checking the functionality of technical components. Without testing, no important conclusions could be drawn for production.
Why does industrial metrology play such an important role? Industrial metrology helps to ensure, optimize and monitor the quality of production processes. Physical quantities such as length, temperature or electrical voltages can be measured. Faulty measurements often lead to errors that cause high costs and weaken the company economically.
At Q-Tech, we use a variety of the processes from industrial metrology. The crucial physical quantity on which we focus is length or length measurement technology. If you want to know more about the individual measurement technologies that we offer as a service, then read this article.
The basic meaning of industrial metrology today
While metrology is a very broad term and encompasses many processes and methods, industrial metrology is purely about the application of measurement techniques and measurement methods in industrial processes or in the industrial environment.
An important parameter in industry is the length of a component. If this is not within the technically required tolerance, the component is considered defective. In some cases, customers then refuse to pay for certain deliveries. Without precise measurement technology, therefore, not only quality but also business relationships would suffer.
Requirements for industrial measurement technology
Whereas in the past it was mainly a matter of producing more units per unit of time, today it is more and more important to produce more qualitatively.
Industrial metrology is therefore intended to support production. Based on the measured data, the manufacturing process can be corrected so that no rejects are produced.
Due to today's technological standards, industrial measurement technology is facing new challenges. As a result, the variability of measurement technologies is increasing. This leads to greater economic flexibility for companies.
High-quality industrial measurement technology thus provides fast, objective and usable results for the industrial process.
The most common tools
You can distinguish the measurement tools used into four main categories:
- Manual measuring instruments
- Semi-automatic measuring systems
- Automatic test tools
- Control tables
The choice of measuring tools now depends heavily on the situation.
The tester must take into account many elements, such as accuracy, speed or ease of use, and select the right measuring equipment based on these factors.
A good industrial measuring tool is characterized by automatic, flexible and fast handling.
Nevertheless, it is not possible to say in general which is the "best" or the "most accurate" measuring device per se. In many cases, even the ease of use and handling of the setup is far more important than the accuracy of the device.
Tactile measurement
Tactile measurement technology is used for fast and precise inspection of prototypes and series components. This can be, for example, quality control in the automotive industry, in mechanical engineering or toolmaking. But tactile methods are also used in precision mechanics, medical technology or plastics technology.
Characteristic for the tactile measuring technique are random or 100 percent quality controls in the above mentioned fields of application.
In large series, this technique can also provide good results, for example, when only a few inspection characteristics need to be examined.
During the process, the machine scans the surface of the component using its own sensors. In this way, in addition to classic dimensional metrology, the roughness of the component material can also be recorded, among other things. This method is particularly suitable for workpieces with very small tolerances.
Optical metrology
Optical metrology is ideal for rapid acquisition and 3D digitization of external geometry and complete part analysis of any size workpiece.
As modern industry is always striving for higher production speeds, optical metrology is becoming increasingly relevant. One reason for this is that the entire component geometry can be digitized in a matter of seconds. This is done completely contact-free, with a 3D scanner...
Subsequently, a 3D image is created in which the deviations are graphically visualized. With this target/actual comparison of the surface profile, the inspector quickly recognizes all deviations. The 3D data obtained can also be used to carry out deviations in form and position tolerances, reverse engineering or initial sampling.
3D computer tomography
Using 3D computed tomography, you can look inside a component without damaging it. This allows you to quickly identify porous areas, cracks and defects.
3D computed tomography is particularly suitable for areas where optical or tactile measurement is not possible.
The process can be applied to plastics, light metals or electrical components.
The method opens up various analysis options such as measurements, nominal/actual comparisons, defect analyses, shape analyses, volume analyses and size analyses.
Closely related to 3D computed tomography is 2D X-ray inspection. Here, the analysis is performed using high-resolution X-ray images in which even details in the nanometer range are visible to the inspector. If, on the other hand, a digital impression of an inspection part or a volume measurement is required, 3D computed tomography is used again.
Measurement and test methods depending on the application
In the following, you will learn more about the individual areas of application of industrial measurement technology.
Automotive industry
The automotive industry is faced with short development times and new technologies. In the future, the focus will be more and more on batteries, electric motors, power electronics and fuel cells.
Tactile and optical measurements are used in the automotive industry. But computer tomography is also used here. Individual measuring and testing techniques are also frequently combined to provide even more precise results.
Plastics industry
In the plastics industry, polymer materials must be tested to determine, among other things, whether they can withstand the intended loads. Plastics include thermoplastics, thermosets, elastomers, foams and composites.
Here is a list of items that will be examined in more detail during testing:
- Porosity
- Inclusions
- Geometric shape deviations due to warpage or shrinkage
- Thermal properties
- Material composition
- Fiber alignment
- Volume fractions
Medical Technology
Due to the health background, medicine and pharmaceutical products are subject to strict quality requirements. So if you decide to produce a capable medical device, you must comply with legislation and standards.
Among the products tested are: Implants, medical instruments, pharmaceutical products, ampoules, syringes and vials.
Conclusion: Precise measurements maintain the quality standard in the industry
Precise measurement is indispensable in industry. Especially because quality is assured and the entire industrial process is optimized. This results in an increase in economic efficiency and cost savings.
Depending on the measurement process, industrial metrology uses specific equipment and measurement methods to provide the most accurate result.
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