Checking large complex parts on the factory floor to a known standard part is a quality control measure used by many manufacturers to ensure end products meet specified tolerances. Parts deviating from defined manufacturing specs can lead to defects, malfunctions and poor performance.
Regular in place checks on the production line help maintain manufacturing consistency, as even small variations can result in significant issues over time. Identifying production discrepancies early reduces the need for rework that can be costly and may cause production downtime. It also ensures all parts conform to the same specifications, minimizing the chance of failure and ensuring they meet regulatory standards.
Factory Floor Measuring System
Manufacturers can conduct these checks on the factory floor using a laser alignment system that evaluates multiple test units, ensuring they are within specification when compared to an approved, production-ready standard component.
Ruggedized for demanding industrial environments, these laser systems provide precise measurements, to tight accuracy, on an ongoing basis. They can measure linear displacement, and angular orientation, along both the X and Y axes, which is essential for parts to meet tight tolerances. The laser system is capable of detecting even minute deformations and misalignments with a measurement sensitivity of 0.0001 inch and accuracy of 0.0005 inch.
Laser systems excel at measuring large production parts, in place on the line, when it is inconvenient and costly to move these parts to a special QC area or measuring facility. They offer fast results without interfering with the manufacturing process, with measurement times ranging from approximately 20 to 30 seconds, depending on the size and complexity of the test part.
The Measurement Process
In operation, a laser transmitter produces a reference beam for measurement, while a small digital laser receivers, placed on the ends of the checked parts, detect the position of the laser beam. The laser beam projects across the part or assembly to determine if specific features of the assembly are within defined manufacturing tolerances. A transparent digital receiver allows the laser reference beam to pass cleanly through the receiver so that multiple measurements can be made on a single line.
All you
Frequently, for a production part to be deemed correct, each measured datum location must align along a common centerline to within specific tolerances. The receiver measures in the X-Y axes to a precision of 0.0002 inches. A visual indicator on a display provides immediate feedback. If the readings are within a prescribed tolerance, the screen displays a green indicator. Conversely, if parts fall outside of a defined tolerance, values are highlighted in yellow or red. Readings for each test part can be saved in Excel spreadsheets and other programs for statistical analysis, charting and reporting.
Checking Parts
Operators on the production floor can easily test parts by placing them into a pre-configured test stand. Measurements are displayed on a screen, showing the difference in measured end positions (forward and back) and centerline values for X and Y axes. Readings are compared to tested parts for pass-fail criteria. Using these results, operators identify which parts are out of spec, allowing for corrective measures before further production of units with deviations.
Reducing manufacturing errors leads to better outcomes. Laser alignment systems are user-friendly tools that continuously provide highly accurate, real-time measurements that help manufacturers ensure that their parts meet required production specifications.
