STT USES GAGE-CHEK MEASUREMENT TO SOLVE INSPECTION DILEMMAS WITH INNOVATION

September 2011

HEIDENHAINS Gage-Chek component measuring and DRO systems are playing a key role in the success of Specialist Tooling Technologies (STT), a company targeted at developing innovative manufacturing and component/product measurement solutions to clients across all sectors and in particular the automotive, medical and packaging industries, both at home and abroad.

In addition to designing and producing bespoke solutions for workholding (manual, hydraulic and pneumatic) as well as jigs and fixtures, for example, for a wide range of applications, the company successfully marries innovation with cost-effectiveness to provide, for instance:

• Multi-point gauges (manual, semi- and fully-automatic), including attribute and acceptance gauges, vision systems and laser measurement for the rapid inspection of complex often high-volume components, such as turbine blades and bearings;
• Manual and plc-controlled gauging systems, and complementary data recording and analysis systems; and
• Poke Yoke inspection and assembly fixtures, especially for the plastics industry.

Originally founded in 1988, STT was restructured in 2003 and, says director Peter Lee: “We use 3D design technology to develop innovative solutions to our customers’ requirements. It ensures we can manufacture quickly and efficiently to the highest standards. But we pride ourselves as much on our after-sales support, providing support services, applications engineering, project management and service and maintenance. We partner with a number of leading technology suppliers – like HEIDENHAIN – to enable us to maintain our reputation for innovative yet practical solutions to customers’ inspection problems.”

He continues: “Of course, every gauging station or system we provide is effectively a bespoke solution that utilises best-of-breed technologies. We find Gage-Chek easy to apply (and our customers find it easy to use) and so flexible in application that, in an ideal world, we would incorporate it into our designs every time!”

In its latest guise, Gage-Chek features comprehensive functionality that makes ‘go/no-go’ component gauging – of even complex parts - effective and efficient. With a full set of mathematical expressions, programmable digital input/output as well as programmable relay outputs, the system can maximise inspection efficiency by providing instant feedback when dimensions are out of tolerance.

Gage-Chek can accommodate up to eight encoder or LVDT/Half Bridge inputs - including length gauges, and linear and rotary encoders, as well as a wide range of measuring instruments - and is able to measure up to 16 dimensions per part. It is easy to program and re-program to suit workpiece variation, and can hold up to 100 different parts.

The system's versatile go/no go display combines familiar DRO functionality with colour graphics and audio alerts to provide fast and accurate measurement feedback, and its ruggedness and ease of use makes it ideal for shopfloor application.

Inputs can be algebraically and mathematically combined for dimensions such as thickness, flatness, dwell angles and maximum tip heights, for example, and results can be displayed numerically, graphically or archived for process studies such as simple statistical process control (ie, X-Bar and Range charts). The addition of events, variables, programme loops and user-defined functions also allows complex functions to be evaluated.

The device’s DRO mode also provides icons indicating process study has been performed, complete with in/out-of-tolerance alert. It also contains many other features such as Dynamic Max and Dynamic Min, in real-time if using digital inputs and triggering of data logging from a second channel criteria.

Other features for the LVDT/Half Bridge market are the ability to set recalibration times and a check on limits of change for recalibration of LVDTs. In addition, there is a USB port for printing and/or storage to a memory stick and a serial link to a PC for long-term storage and analysis of data is available and also allows transfer of parts and settings to a PC via either port.

Effectively, the device complements traditional ‘go/no-go’ gauging with the added flexibility of multiple workpiece inspection as well as statistical process control, when required.

In one STT application – the use of external crimp depth and diameter gauges for aerosol can process lines – Gage-Cheks are being successfully applied in monitoring the monthly output of 60 million cans. In another, concerning turbine blade inspection routines at Rolls-Royce, Gage-Chek is being used in conjunction with transducers in a novel application of a pressure-based test system.

Commenting that STT’s continued success at meeting customer demands - such as the Rolls-Royce turbine blade inspection - depends on “being able to think outside of the box” to provide particular solutions, Peter Lee reinforces that another key asset for ongoing ‘customer-supplier partnerships’ is the company’s prowess at after-sales service and support.

“We’re an independent company run by highly skilled engineers who understand and appreciate customers’ problems,” he says. “That’s a USP that enables us to cement relationships with clients the world over.” This is backed up by regular investment in production equipment for the small batch (predominantly one-off) machining routines and re-engineering processes that take place at the Castleford site in West Yorkshire.

More information: Web. www.heidenhain.co.uk