Mahr | Application Tips

Measuring large and complex components fully automatically

Marketing Team
Roughness measurement in a bore

Transmission or crankcases, cylinder heads or hydraulic components – they are all heavy and complex to handle, as is the inspection of their surfaces. With the Series 2200 CNC measuring station for large components, Mahr's engineering team has developed a measuring station that inspects surfaces fully automatically – in a fraction of the time that would be required for manual measurement.

With the Series 2200 CNC measuring station with six positioning axes and a probe arm changing unit (TWE), roughness and contour features can be automatically and reliably inspected at almost all points on large components – even at difficult-to-reach measuring locations. "Some measuring points can only be reached with certain probe arms, and this requires a probe arm change. The TWE probe arm changing unit takes care of this fully automatically, so that the measurements are carried out without interruption," explains Karl-Josef Gödecke from the Mahr ServiceCenter and responsible for application technology in the surface area. Within 2:15 hours, a maximum of 292 features can be determined on a component in this way.

Short paths, fast results

The user-friendly CNCplus software ensures that users can operate the measuring station reliably after only a short training period. They can also quickly work through the test plans thanks to the fast positioning options for individual measuring points. The measurement results are quickly available, making it possible to intervene in the production process if necessary. This lowers costs due to reduced scrap rates, because tool change intervals are extended. "Thanks to the active vibration damping system, the CNC measuring station can also be integrated directly near the production line – short distances and fast test results are guaranteed," says Gödecke.

Automatic measuring sequences

Due to the fully automatic sequences, the operator only has to position the component with the hoist in the pneumatically clamping fixture and read in the DMC code via laser scanner. This starts the associated measuring program, and the operator can devote himself to other tasks. The data from the scanned DMC codes is automatically transferred to the log header. Incorrect or incomplete logging is thus ruled out, and unambiguous traceability is guaranteed. The measurement results are logged comprehensively and displayed in a table with tolerance bars. According to the customer-specific data structure, they are exported to the respective folders and files. It couldn't be simpler! Manual testing of the same component, on the other hand, would take more than 16 hours in total. It would also require a consistently high level of concentration on the part of the tester to ensure that he does not forget any measuring points and performs all measurements reliably.

Conclusion: Fully automatic measurements are completed seven times faster and take the tester only five minutes – instead of 16 hours or 960 minutes.

The system consists of the following components:

  • Measuring stand ST 750 CNC and hard stone plate with vibration damping system and base frame
  • Measuring station enclosure
  • Storage cabinet and hoist
  • Control panel
  • Laser scanner for reading DMC codes
  • Measurement of the clamping position
  • Table positioning axes
  • Drive unit and touch probe LD 260
  • Probe arm changing unit
  • Probe arms
  • Positioning axes and clamping system
  • Measuring station ergonomics
  • Enclosure
  • Traffic light and runtime display

All advantages at a glance

  • Fully automatic roughness and contour measurements on large components
  • Measurement of all roughness and contour features also with double probe arms
  • Automatic workpiece recognition with DMC
  • Automatic workpiece recognition with DMC laser
  • Automatic probe arm change
  • Safety concept for fast and safe measuring sequences
  • Measuring housing and vibration damping system for use close to production
  • Maximum measuring accuracy for the smallest tolerances and best repeatability
  • Extremely easy operation thanks to the operator guidance of the CNCplus program
  • Fast amortization thanks to fully automatic measuring sequences and minimum personnel requirements

For more information about the CNC roughness and contour measuring station for large components Series 2200, please contact Christopher Mollenhauer: Tel. +49 (551) 7073-99538 Christopher.Mollenhauer@mahr.com

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