LK Metrology

MOST ACCURATE LOTUS CAR EVER, THANKS TO CUTTING EDGE METROLOGY

LK Metrology — 21/09/2022

Since the first Lotus car was built in 1948, the company has been a beacon in the automotive industry for the design and manufacture of high performance cars born out of legendary success on the racetrack. The latest sports car, the Emira, is by far the most accurate model ever built by Lotus thanks to an upgrade in quality control at the company’s sports cars factory in Norfolk, England. It includes investment in a 5-axis HC-90TR twin-arm coordinate measuring machine (CMM) from LK Metrology. The automated, multi-sensor inspection cell, part of multi-million pound investments made by Lotus since 2017, delivers absolute, 100 percent, non-contact dimensional inspection at production-line speed, enabling real-time quality control.

The CMM installed in Hethel is set one metre into the floor on a special foundation. It means that a car for inspection carried on an automated guided vehicle (AGV) is able to access the area without the need for any lifting equipment. The machine has a measuring volume of nominally 6.3 x 1.6 x 2.5 m, easily large enough to contain an entire car body. Advanced, triple-laser cross scanners are deployed on both arms to measure features automatically on both sides of the Lotus Emira simultaneously. It is notable that the LK HC-90 is the world's most accurate range of horizontal-arm CMMs, able to measure to a volumetric accuracy of 10.0 μm + L/200 and with 6 μm repeatability. The machine combines the high performance of a bridge-type CMM with the flexibility of the horizontal-arm configuration widely used in car plants.

The CMM completes automated measuring cycles so quickly that it is able to keep up with the quick TAKT time that defines the speed of the Emira production line. The fast throughput enables every car to be inspected, making this Lotus model the first whose manufacture is supported by such comprehensive QC. In two visits of the car at different stages of its build to the LK HC-90TR, a total of 130 measurements are made in scanning routines taking about 12 minutes and 8 minutes respectively. The rapid inspection cycles leave plenty of time for an AGV that has delivered a chassis to the CMM to load it and subsequently return it to the line. Before metrology starts, there is also time to verify the car's alignment relative to the carline reference point system in the CMM, as well as to calibrate the laser scanners using dedicated calibration spheres. For speed and accuracy, they are touch-probed using sensors that are exchanged automatically by the arms from a rack. The same sensor is used for probing some critical internal dimensions of the car, while the laser scanner performs high speed scanning of the freeform surface areas.

Compared to traditional QC practices underpinning the manufacture of these largely hand-built sports cars, which are made from high tech, lightweight composite panels, the benefits of rapid point cloud acquisition and digitisation in the LK cell are enormous. Formerly, a sample chassis would have undergone measurement line-side on a manual CMM having an arm equipped with a touch probe. Fewer features would have been checked in up to five hours on typically one in every couple of dozen chassis, which had to be taken out of production and reinserted afterwards. There was potential for error not only through human intervention but also due to a need to reposition the car during inspection to compensate for the limited axis travels of the old CMM. More seriously, any of the unchecked cars between the samples might be out of tolerance, leading to time-consuming, expensive rework further down the line.

Tom Mackrill, Dimensional Quality Manager at the factory commented, "The Lotus Emira is our last new car to have an internal combustion engine, as we are going all-electric in future. We are aiming the product at the premium segment of the global market, so a very stable production process is required to ensure high build quality.

"Production rate of this car model in 2022 is substantially higher than last year, when we were ending production of the Elise, Exige and Evora, and is increasing strongly. So we need a QC solution that not only supports high precision but is also fast enough to generate large amounts of data quickly to match the production rate.

"We reviewed other inspection technologies including those involving various robot-mounted measuring heads. However we concluded that robots, particularly if they are mobile, would introduce extra potential error in addition to that of the measuring devices they carry and would need a reference measuring system to calibrate and realign them.

"We therefore came to the conclusion that a static CMM was the way to go in the productionisation of our new car, with a twin-arm configuration and laser cross scanners providing the required speed of metrology."

He added that the reliability and repeatability are driving the dimensional quality of the Emira by feeding back data to the production line to validate and control the process, ensuring each vehicle is built right first time. Such feedback is particularly important to the composite panel framing facility due to the potential for variability in the adhesive bonds.

Laser scanners have infinite positioning

The Renishaw PHS-2 two-axis CNC wrists that carry the laser scanners are able to rotate continuously and have infinite positioning, unlike conventional probe heads that only adjust in 7.5-degree steps. Each scanner can therefore be angled very precisely throughout an inspection cycle, allowing optimal positioning both inside and outside the chassis for rapid acquisition of freeform and geometrical data. When inside the vehicle, the PHS-2 is able to rotate under program control to look outwards at the interior of the bodywork to take measurements. The DMIS programs controlling each arm are essentially mirror images of each other, with additional movements inserted separately to address the minor differences unique to each side of the car.

The Nikon XC65DX-LS cross scanner with three laser lines captures in a single orientation and scan pass three times the amount of data that can be acquired by a single-line laser scanner. It enables short inspection cycles on the LK HC-90TR to support 100 percent QC of the Emira. The built-in technology means that the sensor is unaffected by the colour or reflectivity of what is being measured. It also provides automatic, real-time adjustment of the settings not only between successive laser stripes, but also for individual points along each line. The LS variant of the scanner signifies that it has a longer stand-off distance, up to 170 mm, allowing it to access difficult-to-reach features.

Two-stage inspection

AGVs deliver every Emira to the CMM from the production line, both early on from the end of the framing line (stage 1) and when the car is fully assembled (stage 2). It is deposited without manual intervention in carline and a bar code reader, known as a scripting system, verifies the vehicle's identification number, colour, whether it is right or left hand drive and if a stage 1 or stage 2 metrology program should be run. The car in its stage 1 condition is not conventional body-in-white, as the body panels are already painted and the steering column and wiring looms are in place.

After automatic calibration of the laser scanners, they take 130 measurements around the car over the two stages to assess the accuracy of the vehicle. Suspension and engine mounting points are critical areas for inspection. Control of gap-and-flush is especially important, as the spacing between panels impacts directly on the perceived quality of the car on the forecourt.

Programs are created largely automatically from CAD models of the Emira in LK CAMIO software. It ensures the laser scanners move along paths such that the surfaces being measured are always within their field of view. The low-noise point clouds captured are filtered to produce smooth, highly detailed meshes that can be aligned to enable comparison of the measured data with the CAD model. Inspection tools are included for intelligent feature extraction, GD&T tolerancing and profile analysis, backed by rapid feedback of results to the production line and comprehensive reporting.

Lotus Cars elected to implement this two-stage, offline, in-process metrology solution as it is most expedient for the company's needs. However, in other scenarios one HC-90TR or more could be positioned within the production flow line itself, checking dimensions before the vehicle passes to the next build operation. Other offline applications include quality audits and verification checks.

Turnkey automated solution

The metrology cell was installed and commissioned by LK in the Hethel plant in January 2021, ahead of the start of Emira production. The automated equipment has been instrumental in raising production efficiency and lowering the labour cost content of the cars by ensuring that dimensional inspection controls the manufacturing process, rather than merely qualifying the compliance of the measured data. It is driving production strategy for the continuous improvement of individual parts and the whole process with the goal of zero-defect manufacture, this being the whole purpose of Industry 4.0 with which the LK hardware and software are compatible.

Mr Mackrill concluded, "Lotus had not dealt with LK before but I had previous experience of the CMM brand during employment in another car plant. Once we had decided that the gold standard of static coordinate measurement was the correct metrology route for us to take, we reviewed a number of offerings from different potential suppliers.

"LK stood out as being the best in terms of high-end technology. The ceramic construction of the machine provides excellent stability combined with light weight for accuracy and speed. LK supplied a fully configured, multi-sensor, turnkey solution complete with first-draft measuring programs and ancillaries. Only the fixtures supporting the car body were provided by us.

"The supplier has been and continues to be very supportive, to the extent that we regard the relationship between our respective engineering teams as a genuine partnership."

To underline the faith that Lotus Cars has in LK, the vehicle manufacturer has also invested recently in four further CMMs, all smaller bridge-type machines, for its nearby LAS (Lotus Advanced Structures) division. Used for QC of chassis components, there are three LK ALTERA M machines with measuring envelopes of nominally 3 x 2 x 1.5 m, 2 x 1.5 x 1.2 m, and 1.5 x 1.0 x 0.8 m respectively and a larger, higher accuracy ULTIMA CMM with a 4 x 2 x 2 m inspection volume.

Full article at: MOST ACCURATE LOTUS CAR EVER, THANKS TO CUTTING EDGE METROLOGY: M4SNews.com OR Multisensor CMM Drives Fast Production Line Quality Control – Metrology and Quality News - Online Magazine

Lotus video can be found here: The most accurate car ever produced - YouTube

LK Metrology Introduces Ultra-Accuracy Portable Measuring Arms

LK Metrology — 16/06/2021

An ultra-accuracy 7-axis FREEDOM ULTIMATE SCAN portable measuring arm from LK Metrology. LK Metrology has been manufacturing static coordinate measuring machines (CMMs) since 1963. It has now expanded its FREEDOM arm range of 3D articulating arm metrology systems, or portable measuring arms, with the launch of five ultra-accuracy models in both 6-axis and 7-axis variants. The 10 new arms bring the total number of different varieties available from LK to 34. International sales and support is through the company’s offices in the UK, North America, Belgium, France, Germany, Italy and China as well as via a worldwide distributor network.

Find out more at: https://www.lkmetrology.com/lk_newsite/company/news/lk-metrology-introduces-ultra-accuracy-portable-measuring-arms/

Foolproof Automated Inspection Transforms Medical Manufacturer’s Quality Control

LK Metrology — 06/10/2023

High process capability supported in plastic injection moulding

The two CNC coordinate measuring machines (CMMs) Alltrista Plastics had been using 24/7 for more than 10 years at its Christchurch, UK factory had become inefficient. The accuracy and repeatability of touch-trigger probing were becoming compromised due to the age of the machines. The software would sometimes crash, risking a physical collision, damage to the probe and perhaps even to the component being checked. As the plastic medical parts and assemblies produced had become more complex over time, an angled stylus was often required in an inspection cycle, so an operator had to choose from half a dozen pre-set probe configurations, mount one manually and calibrate it. Additionally, the person would have to sort through different programs on a computer screen to identify and load the correct one.

This whole process has been streamlined and automated with the installation of two new Altera S 10.7.6 CMMs manufactured by LK Metrology in Castle Donington, UK. The supplier’s CAMIO 3-axis scanning and reporting software was also provided along with a Renishaw SP25M scanning probe and PH10M motorised indexing head. It is in effect two sensors in one, enabling continuous path tactile scanning as well as touch-trigger probing of discrete points. Together with a Renishaw matrix plate to allow accurate placement of parts for inspection, the set-up has resulted in a vast improvement in metrology productivity by facilitating fixturing of samples, speeding measuring cycles and virtually eliminating human intervention and the attendant risk of errors. It would not have been feasible to retrofit scanning capability to the older CMMs, as the cost would have been prohibitive and in any case the machines were becoming obsolete.

Alltrista’s quality manager Peter Makosa said, “I operated LK CMMs for several years when working for an aerospace manufacturer, which had standardised on their use. When Alltrista decided to upgrade its quality room, we approached four potential machine providers including the incumbent supplier. LK’s response was by far the most comprehensive.

“It carried out an online demo on one of our parts and another trial when we visited Castle Donington. It was the only company to initiate a comprehensive on-site survey at our factory to check the feasibility of machine installation.

“On the basis of the measurements taken, bearing in mind that LK machines are taller than our previous CMMs, the manufacturer offered to reduce the height of the Altera S models during their build so they would fit comfortably through our doorways and in our refurbished inspection room.

“What finally clinched our decision to opt for this supplier were the favourable price of the equipment, the knowledgeable engineers that dealt with us throughout the entire sales process and the company’s reputation for good after-sales service.”

The Christchurch site is one of five Alltrista manufacturing locations, notable for being the first facility within the holding Jadex group to be powered entirely by renewable electricity. The ISO13485-accredited firm specialises in plastic injection moulding of devices such as drug delivery systems, and packaging such as contact lens blisters, for the medical, pharmaceutical and nutraceutical industries. The injection moulding machines are mainly housed in one Class 7 and two Class 8 clean rooms. Medical devices are increasing as a proportion of turnover as well as in variety and production volume, climbing over the past decade from 30 to 50 percent of throughput and still rising. Another trend is towards ever tighter drawing tolerances on newly designed products and more stringent GD&T (geometric dimensioning and tolerancing) requirements.

A rigorous validation process underpins the manufacture of all products at the Christchurch facility. Typically at the outset of a new production run, 30 shots containing, say, 15 components each will be run off and checked, with customers requesting a process capability of at least Cpk 1.33 and often 1.67 or 2 (six sigma). Tolerances are generally fairly open on plastic items, normally in the range 50 to 100 microns, but any inaccuracy of measurement is undesirable, as it would consume part of the tolerance band. Even more important for validation is a high level of repeatability.

Required also by Alltrista was more data to better understand certain features on mouldings, such as the flatness of sealing faces, freeform profiles and chamfers. The use of a Renishaw scanning probe has resulted in an order of magnitude more information to feed back to the production department for fine-tuning toolmaking and manufacturing. It also makes for a much richer report for customers to understand in more detail the manufacture that is being carried out on their behalf. Furthermore, the layout of the reports is much better now, as the previous open Excel spreadsheets have been replaced by locked PDFs generated in CAMIO. They include a colour-coded part-to-CAD comparison showing product conformance, with all the accompanying data, Alltrista logo, date and time.

When the CMMs were installed, LK wrote core programs for inspecting components for four major Alltrista customers and also devised a PC screen dashboard so the whole process is menu-driven. The first screen displays an icon for each customer, which when clicked reveals every part that is injection moulded for that company. Clicking on the appropriate icon automatically sends the program to the CMM, whereupon the operator keys in their name, whether it is a standard or first article inspection report that is needed and clicks start.

Before the program can be run, however, an array of components has to be placed in a known position on the granite table. To facilitate and speed the procedure, LK supplied a Renishaw matrix plate with each Altera S 10.7.6. At no extra cost, anchor bolt holes were drilled into the granite at non-standard centres so the plates could be secured from underneath, avoiding retaining clamps projecting from the table surface. Included on-screen in the dashboard, alongside the relevant inspection program, is an SOP (standard operating procedure) showing the operator the exact location across the numbered grid of holes on the matrix plate that the batch of fixtured samples should occupy.

Nobody will ever say that human fallibility can been removed entirely, but this system of positioning components correctly and accurately coupled with LK’s CAMIO system for program instigation, CNC inspection and automatic reporting comes very close to eliminating all potential errors. Having used the new quality control process since March 2022, Mr Makosa describes it as “foolproof”.

The Altera S controllers and CAMIO software were supplied to accept data input from a laser scanning sensor in the future should Alltrista decide that the increasing complexity of its plastic devices requires this further upgrade. For now, though, tactile scanning and touch probing, including with a multi-tip stylus to access the underside of components without probe change, provides sufficient capability and capacity.

Find out more at: Foolproof Automated Inspection Transforms Medical Manufacturer’s Quality Control – LK Metrology

Simplified CMM inspection provides a flexible approach to more productive quality control

LK Metrology — 09/11/2021

'It is unusual within manufacturing industry to see a coordinate measuring machine nested with multiple components, but it is a perfectly feasible way of operation.'
Tony Blood, Quality Manager, WLR Precision Engineering

Two coordinate measuring machines (CMMs) manufactured by LK Metrology, Castle Donington (www.LKmetrology.com) have largely superseded the use of a pair of smaller capacity, 15-yearold machines in the inspection room at contract machining specialists WLR Precision Engineering,Wilford, Nottinghamshire (www.wlrprecision.co.uk). To enable production operators as well as quality inspectors to operate the new CMMsand access the measurement reports easily, the machines have been supplied with LK Launchpad, an icon-driven, touch-screen operator menu, and a network of viewing screens and tablets.

The simplified operator menu lists all the available inspection programs and the exact position the part should be placed on the machine table for inspection, giving operators the confidence to perform measurement tasks in just a few clicks. It greatly enhances flexibility and opens up the system for use by non-specialist CMM operators. Measured results and automatically generated reports may be shared between screens, tablets and other networked devices for easy access and viewing from any location.

Find out more at: Simplified CMM inspection provides a flexible approach to more productive quality control - LK Metrology

LK enhances Altera C CMM accuracy and speed

LK Metrology — 23/06/2021

Castle Donington-based LK Metrology, a coordinate measuring machine (CMM) manufacturer has designed a new, more-efficient air bearing and carrier which are now being fitted as standard to its Altera C range of ceramic-bridge, multi-sensor CMMs.

By significantly augmenting the pre-load on the structure, stiffness has been uprated without making the guideway thicker, leading to more precise motion control.

The results are higher measuring accuracy, whether a touch trigger probe or scanning probe is used, coupled with the possibility to increase speed of operation and hence raise inspection efficiency.

The compact Altera C CMMs, which are available in three sizes with measuring volumes of 700 x 650 x 500mm, 1,000 x 650 x 500mm and 1,000 x 650 x 650mm, carry an unrivalled 10-year accuracy guarantee covering dimensional stability.

In terms of speed, all machines now accelerate at 1,900 mm/s², representing an increase of 15% for the two smaller models and 20% for the largest model. Velocity is up by 38% across the product range to 720mm/s.

Find out more at: https://www.lkmetrology.com/lk_newsite/company/news/lk-enhances-altera-c-cmm-accuracy-and-speed/

LK Metrology and Wenzel Technologies enter into a strategic partnership

LK Metrology — 11/05/2022

New alliance draws on 100 years of metrological knowledge and experience

LK Metrology and Wenzel Technologies have entered into a strategic partnership with immediate effect. In addition to a joint technological cooperation, Wenzel Technologies will sell LK’s innovative, high-performance coordinate measuring machines (CMMs) and other metrological products in southern Germany.

For more than 50 years, the name Wenzel has stood for the highest standards in metrology. Frank Wenzel, who once built the measurement technology company founded by his father into a world market leader and since 2018 has been successfully concentrating on milling solutions for automotive design studios, is now opening the next chapter. With products from LK, he is expanding his portfolio again with powerful systems for measurement, inspection and quality control.

Frank Wenzel, CEO of Wenzel Technologies explains, “LK has an impressive equipment portfolio that surpasses even my previous products in terms of accuracy and customisation. I am firmly convinced that we will be able to meet the high expectations of the German customers with these solutions.”

Find out more at: LK Metrology and Wenzel Technologies enter into a strategic partnership – LK Metrology

Metrology Gate Provides Remote Reports

LK Metrology — 22/07/2021

LK Metrology has launched Metrology Gate , a web-based Industry 4.0 solution for monitoring and controlling inspection activities.

LK Metrology has debuted Metrology Gate, a web-based platform to help production departments remotely monitor and control inspection activities. The company aims the software at both multinational companies with production in multiple countries and small companies with several factories in one country.

Metrology Gate provides remote access to measurement results, a summary of errors, a record of program changes and a log of coordinate measuring machine (CMM) uptime and overall equipment effectiveness (OEE). Historical logs assist troubleshooting and warn when routine maintenance is due, not only of the inspection machines but also of machine tools and other equipment.

Find out more at: Metrology Gate Provides Remote Reports - LK Metrology

Investment in quality control of engineered bearings helps green energy initiative

LK Metrology — 19/08/2021

The Dudley, UK factory of The Timken Company supplies the engineered bearings it manufactures into a multitude of industries including mining, food and beverage, pulp and paper, cement, marine and waste water. Recently there has been a significant increase in demand for larger bearings up to 1,200 mm in diameter for use in the construction of wind turbines, which promises exponential growth in the coming years as countries across the globe work towards meeting their green energy targets.

In May 2021, to enable the company to inspect these larger bearings, it purchased an AlteraM 15.12.10 ceramic bridge coordinate measuring machine (CMM) with axis travels of 1,500 x 1,200 x 1,000 mm manufactured by LK Metrology, Castle Donington. Assisting further in Timken’s quality control department is a Mitutoyo CMM capable of measuring ball and roller bearings with bores up to 800 mm in diameter. This machine was upgraded at the same time by LK with a new controller and identical CAMIO 2021 software for measurement, programming, analysis and reporting so that inspectors are able to swap programs conveniently between both machines.

Find out more at: Investment in quality control of engineered bearings helps green energy initiative - LK Metrology

Park Engineering upgrades machining and measuring capacity for larger parts

LK Metrology — 05/05/2022

Stalybridge-based engineering company Park Engineering has significantly increased the size of parts it can machine and subsequently measure on a coordinate measuring machine (CMM). It follows the installation at the start of 2022 of two new machines, a Spanish-built Correa Fox 50 5-axis machining centre having a 5.0 x 3.25 x 1.6 m working envelope, nearly 16% larger than the previous largest machine, and an ALTERA M 30.20.15 CMM with 3.0 x 2.0 x 1.5 m axis travels built by LK Metrology in Castle Donnington, UK. Compared with the largest of three LK machines previously operated by Park Engineering, it offers twice the measuring volume.

A member of the tooling division within the Hyde Group in the North of England, Park Engineering specialises in the design, manufacture, assembly and certification of tooling jigs and fixtures for the aerospace, nuclear, defence and automotive sectors, so the company is accustomed to dealing with large components. It also provides a subcontract machining service. When looking to invest in new technology to offer even larger capacity, there was a desire to inspect the bigger parts on a ‘gold standard’ CMM platform rather than rely on portable measuring systems, which may have a larger measuring volume but are usually lower in accuracy.

Find out more at: Park Engineering upgrades machining and measuring capacity for larger parts – LK Metrology

CMM controller retrofits enable multi-sensor inspection

LK Metrology — 30/11/2023

Co-ordinate measuring machine still capable of aerospace-standard quality control after 26 years

At one of two factory units in Devizes operated by sealing specialists Cross Manufacturing (www.crossmanufacturing.com), two co-ordinate measuring machines (CMMs) built by LK Metrology (www.LKmetrology.com) in 1997 and 2007 have been given a new lease of life following an upgrade. It involved the OEM future-proofing operation of both machines by retrofitting multi-wired NMC300 controllers with updated firmware and software. Among the many advantages is the ability to deploy different types of sensor in addition to touch-trigger probes. Within the scope of the project, two new Renishaw PH10MQ motorised probe heads were also fitted.

As a result of the improvements, the sealing design and manufacturing specialist has immediately gained the ability to use the Renishaw SP25M tactile scanning probe it has purchased, which it is hoped will cut metrology cycle times by at least one-third when implemented in early 2024. Additional types of contact and non-contact sensor may be integrated in the future should Cross Manufacturing choose to extend the CMMs’ capability and consolidate other automatic measuring functions into a single metrology routine.

Located on the shop floor in one of two adjacent sites in Devizes, the CMMs are an LK G90C 10.10.8 and an LK Evo 15.15.10 having nominal inspection volumes of 1,000 x 1,000 x 800 mm and 1,500 x 1,500 x 1,000 mm respectively. They fulfil a critical role serving the turning section, where brush seals ranging in size from 6 feet (1.83 metres) down to 4 inches (102 mm) in diameter are produced in small batches for high-temperature gas turbine applications in aerospace and power generation. The former sector accounts for the vast majority of throughput, particularly for the US market, more than 80% of the manufacturer’s output being exported. It is the British company’s undisputed world leadership in the technology that motivates aerospace OEMs overseas as well as in Britain to source brush seals and allied equipment from Cross Manufacturing.

The company’s senior project manager Mark Bolwell explained, “The vast majority of our parts are 100% inspected. Upgrading our CMMs means that we will be able to increase throughput by introducing tactile scanning, allowing us to support ever increasing demand without having to invest in another CMM at this time. We are supported admirably by LK’s applications engineers, all of whom are knowledgeable and never cease to be helpful.

“It is testament to the build quality of the LK machines that, so many years after they were built, they are still able to underpin our metrology and traceability requirements. The manufacturer’s UKAS-certified engineers calibrate them annually and every morning we cross-reference the accuracy of the two machines using a calibration ring to ensure the measurements are verified.”

Dave Eldridge, lead inspector for the aerospace and the powergen products added, “Despite their age, the CMMs measure tolerances from ±0.002” (±51 microns) down to ±0.0002” (±5.1 microns), a level of process capability that requires a very high measurement uncertainty. Almost every part we inspect is symmetrical and relatively flat, whether it is a finish-machined product, a segment of a large ring, or a fixture for securing components during batch production.

“Most feature measurements are consequently 2D and three-quarters consist of CTQ (critical to quality) for ensuring correct fit and performance in a turbine. Surface finish is generally in the range 32 to 64 CLA, which is currently checked separately on other equipment. However, now that we have multi-sensor capability as a result of the retrofits, we may decide to carry out that function in-cycle on the CMMs using an LK surface roughness probe, saving a second inspection operation.”

Repeated transfer of parts between the lathes and the CMMs on the shop floor is frequently needed for everything from pre-manufacturing checks through to final part inspection and sign-off. In the case of aerospace brush seals, certification is nearly always performed by trained Cross Manufacturing personnel on behalf of the customer under source released parts agreements. Similar is performed on a large proportion of the products destined for the powergen sector.

About 20 shop floor staff have been trained by LK to use the uprated CMMs, five of whom are also qualified to create and optimise inspection cycles using LK’s CAMIO 2021 programming, analysis and reporting software. Most recently, an offline CAMIO station was supplied to enable programming while inspection is in progress on the CMMs. LK continues to supply ongoing consultancy, engineering support and helpdesk advice from its Castle Donington headquarters.

Automated CMM stylus cleaning

LK Metrology — 08/07/2021

After detailed research into the effects of stylus tip contamination on metrology when using a coordinate measuring machine (CMM), Dr Simon Lawes, Manufacturing Metrology Team, University of Nottingham confirms: “A stylus tip contaminated with tiny particles can lead to measurement errors 10 times greater than the expected.” The problem in inspection rooms and on the shopfloor is that stylus cleaning is a tedious and time-consuming job to do by hand and reduces the amount of time the CMM is available for measuring.

To alleviate the problem, UK-based CMM manufacturer LK Metrology has introduced an automated stylus tip cleaning system, LK StyliCleaner. It takes just 30 seconds to remove debris from a stylus tip, eliminating the tendency to delay cleaning and reducing the risk of taking inaccurate measurements.

Find out more at: Automated CMM stylus cleaning - LK Metrology

Transatlantic heavy-duty mobility solution provider invests in more accurate metrology

LK Metrology — 04/08/2021

Part of the RENK group, Horstman is a manufacturer and global supplier of suspension systems for heavily armoured and tracked vehicles. It also produces safety-critical engineering components allied to its core products for the sub-sea and aerospace industries. A transatlantic investment has seen the company advance its quality control procedures significantly by installing identical new coordinate measuring machines (CMMs) at its factories in Bath, UK and Sterling Heights, USA. Built by LK Metrology in Donington, UK, the new CMMs were supplied with the world’s most compact and versatile tactile scanning probe technology to capture data on the size and shape of components more accurately and much faster than was possible previously using touch trigger probing alone.

The factory at the company’s headquarters in Bath, which dates back to the 1920s when the original suspension bogie for military vehicles was developed, was an early adopter of CMMs in the 1960s when LK was one of the first to pioneer the measuring technology. Horstman has had a succession of different CMM models over the years, most recently three machines of small, medium and large capacity from a different supplier. The new LK Altera M 25.15.12 bridge CMM, which has a large inspection volume of nominally 2.5 x 1.5 x 1.2 metres and is equipped with traditional touch trigger probing and an advanced tactile scanning probe, replaced the smallest of the three earlier machines.

Find out more at: Transatlantic heavy-duty mobility solution provider invests in more accurate metrology - LK Metrology

F1 SUBCONTRACTOR ACCELERATES QUALITY CONTROL

LK Metrology — 02/05/2023

Portable arm with two-metre reach halves time for inspecting large components

Founded in 2011, toolmaking and subcontract machining company GT Tooling (www.gttoolingltd.co.uk) spent one year using conventional manual metrology equipment to measure the components it was milling and turning before investing in a 3D articulating arm, a 6-axis model with a reach of 1.2 metres. Three years later when the company moved from Petersfield to a bigger factory unit in Fareham, the company invested in a machining centre with 1,651 x 762 x 762 mm travels, which meant that larger prismatic parts being produced had to be inspected in two operations.

Although satisfactory, the procedure was time-consuming and risked the introduction of errors due to the necessity for arm relocation. So in May 2022, a FREEDOM Classis Scan portable arm with a reach of two metres was purchased from LK Metrology, Castle Donington (www.LKmetrology.com). GT Tooling was introduced to this UK coordinate measuring machine (CMM) manufacturer by nearby Mech Metrology & Power Tools, which calibrates the toolmaker’s inspection equipment and supplies it with conventional metrology tools such as verniers and micrometers.

Greg Simmonds, joint owner and director of GT Tooling commented, “We considered manually-operated and CNC CMMs. However, the repeatability of measurement on the former was not good enough while the latter did not offer sufficient flexibility of use. Neither type had the reporting capability that was up to our standards or those of our customers. We also felt that programmable CMMs were better suited to series production, whereas we machine mainly one-offs and small batches.

“We therefore decided to stay with portable arm technology, but instead of returning to the incumbent supplier we chose LK. We were keen to take advantage of the after-sales service for which they are known and we also like the PolyWorks Inspector reporting software supplied as standard with LK FREEDOM arms, which is particularly easy to use. Simply by pulling out the required dimensions and pressing a button, reports can be manipulated freely into different, easily-digestible formats to suit each customer’s preference.”

The precision engineering firm has held ISO 9001 quality management certification since the beginning and takes inspection and measurement very seriously, not least because it is heavily involved in supplying Formula 1 teams during the off-season. During that period motorsport accounts for a large proportion of factory throughput, mainly the manufacture of patterns, jigs, fixtures and aluminium soft tools for producing composite race car parts. Other industries served include aerospace, automotive, food and beverage, while rubber and injection moulds are manufactured in tool steel for a multitude of sectors. Stainless steel is also machined, as are exotic alloys, copper and its alloys, carbon fibre and engineering plastics.

Ryan Leaves, who doubles as a sales engineer and an inspector at GT Tooling explained, “Greg and I witnessed a one-hour presentation on the FREEDOM arm by LK engineers in Castle Donington. It took place online during the pandemic. The demonstration, which included use of the PolyWorks software, was carried out inspecting one of our parts that had been taken away during a previous meeting in Fareham. It showed how easy the equipment is to use and left me feeling relaxed that, even though I do not have a formal metrology background, I would be able to implement the new inspection system quickly.”

A CMM is inherently able to measure tolerances about 10 times smaller than an articulated arm, as positional feedback is from linear scales rather than absolute angle encoders within rotary joints. Nevertheless, the FREEDOM arm provides accurate results when GT Tooling is measuring dimensions to general drawing tolerances of ± 0.1 mm. If there is a need to check tighter features, Mr Leaves uses conventional metrology involving bore and pin gauges, for example.

He confirmed that the entire quality control process using the arm, comprising alignment, inspection and reporting, is now faster and more flexible than previously due to the enhanced usability of the LK equipment. Speed is important, as some urgent jobs for F1 require a 24-hour turnaround. An internal report takes typically 15 to 20 minutes to prepare, while about one hour is required for a full FAIR (first article inspection report). The reason these previously took longer was that the reporting element of the process to GT Tooling’s specification was more time-consuming. Where really significant savings are made is when inspecting large parts that previously required two arm set-ups. In these cases inspection time is halved, as Mr Leaves was essentially doing the job twice.

The main benefit of the new quality control procedure is that the resulting documentation is now exactly what the customer wants to see, without inclusion of unnecessary content and a consequent need for interpretation. GD&T (geometric dimensioning and tolerancing) reporting in particular, previously a laborious exercise, is notably more user-friendly with PolyWorks. The arm is used almost exclusively on a dedicated inspection table for checking components, but occasionally it is mounted on a machining centre table to verify the accuracy of a part before it is taken out of its fixture or prior to further metalcutting.

During pre-purchase discussions, it became clear that laser scanning as an adjunct to touch-probing of discrete points would be of considerable benefit to GT Tooling. It would allow much more comprehensive data to be collected on free-form surfaces in a fraction of the time and hence provide more comprehensive reporting and avoid any risk of machining errors being missed. It was for this reason that LK supplied a 7-axis FREEDOM arm rather than a 6-axis model, together with suitably configured software, as the extra degree of freedom is necessary to enable laser scanning when the additional investment can be justified.

A further benefit of laser scanning will be inspection of delicate and deformable components, including rubber parts such as car door seals, without fear of damaging or deforming them in the process. Yet another advantage will be the ability to reverse engineer legacy components, such as for vintage cars, for which no data or drawings exist. It will be possible not only to use this capability on parts machined in-house, with the opportunity to win new customers as a result, but also to sell an inspection service to other manufacturers on a subcontract basis if there is spare capacity.

Mr Simmonds concluded, “Until now, we have produced inspection reports on about 40 percent of our machined components, as not every end user requires one. Now that the process is so much quicker and easier with the LK arm, we are looking to more than double the number, as it reflects well on the service we provide, gives customers confidence and may result in extra business.

“I would like to place on record that the PolyWorks software has proven to be even better than we were expecting and the company’s telephone advice is excellent, as is LK’s. This is key for us, as we often have to provide a quick service, especially to F1, and we cannot afford to have our inspection function down for long should we have a problem.”

F1 SUBCONTRACTOR ACCELERATES QUALITY CONTROL – LK Metrology

Website - LK Metrology – We Are Metrology…

LK celebrates 60th anniversary

LK Metrology — 19/06/2023

Established in 1963, LK Metrology (www.LKmetrology.com) has an impressive heritage dating back to the birth of coordinate measuring machine (CMM) technology. Founded by former Rolls Royce engineer and CMM pioneer Norman Key and his father-in-law Jim Lowther, the company is credited with many innovations in the CMM industry. In 1972, in partnership with Rolls-Royce, Mr Key worked alongside the person who would co-found Renishaw a year later, Sir David McMurtry, who today its executive chairman, to develop the now industry standard Renishaw touch-trigger probe.

Other industry firsts accredited to LK include successive introductions to the market of the bridge-type CMM, inspection software, exclusive use of air bearings and granite guideways, carbon fibre composite spindles, microprocessor-controlled drive systems, true thermal stability of the measuring platform, and a high-accuracy horizontal-spindle CMM.

With its headquarters, product development and CMM manufacturing facility in Castle Donington, UK, the company is headed by owner and CEO Angelo Muscarella, whose ASF Metrology group bought the company in 2018. It now not only manufactures CMMs, but has also added to its product portfolio a range of FREEDOM branded portable measuring arms and many metrology accessories. They include a new range of laser scanners, a surface roughness probe, stylus cleaning and sensor changing equipment, an indexing table and a checking gauge for CMM calibration. First written in 1977, LK’s renowned CAMIO measurement, programming, analysis and reporting software is continually enhanced to provide industry-leading functionality, with the new CAMIO 2023 revision due in July.

Mr Muscarella commented: “When I acquired LK, many staff had been with the company for decades and continue to give their total commitment. They and indeed I are proud to work in such a prestigious company. There is dynamism throughout our network of offices and distribution companies around the world, with everyone sharing common values and operating as a family.

“We are looking forward to maintaining our rapid growth and would like to thank all our customers for making this possible. We look forward to catching up with everyone on our stand (9505) at the Control show in Stuttgart in May and at many other trade shows around the world during 2023 and beyond.”

Global successes

LK staff looking after the various sales regions have been keen to add their comments too. For example, Brian Samson, Managing Director of LK Metrology Inc in New Hudson, Michigan is pleased to report strong trading in the United States: “We and the Precision Measurement Group of the Cross Company have finalised an agreement that brings the LK line of CMMs and related metrology products to the Cross Company’s calibration labs and service centres across Southeast and Central US.”

Last year, LK USA was awarded a large contract to supply 35 new CMM cells to a new aerospace manufacturing facility, with installation of all systems due for completion by December 2023. The supplier is also experiencing a resurgence in CMM retrofit enquiries and has added a dedicated technical product specialist to focus on this area. To support contract inspection services, the technology and demonstration centre in New Hudson has been expanded by 21,000 sq ft to accommodate a total of six CMMs and two FREEDOM portable arms.

At the UK headquarters, the customer demonstration area, training facilities and factory were all extensively refurbished in 2022, including a complete redecoration, new windows, doors and flooring, plus environmentally-friendly lighting and ventilation systems. A new engineering research team was put in place and the company was accredited to ISO 17025 for testing and calibration and ISO 9001 for quality management.

Business in Asia continues to be buoyant. Paul Druce, LK’s Service Manager based in Castle Donington who is familiar with this market said: “We have an exclusive master distributor in China. This financial year has seen sales of more than EUR 1.8 million, with 15 machines ordered. It represents a 62% increase on the previous 12 months in this fast-growing market.

“We first exported to China in 1979 and the number of LK CMMs there and in Hong Kong and Taiwan now exceeds 600. Working volumes range from 600 x 500 x 400 mm up to a 6,000 x 6,000 x 3,000 mm Colossus. In two offices in Beijing and Shanghai, LK China currently employs seven staff including two service engineers, both of whom have been with the company for over 20 years.”

In terms of product development, LK has been very active of late not only in respect of its CAMIO software but also with hardware introductions. It recently launched a high-end laser line scanner with a nominal 20 mm line length, the SLK20, and a larger version is imminent that can be interchanged between a CMM and a manually-operated portable measurement arm. Recently released also was the SRP12.5 probe to offer surface roughness measurement as part of quality inspection on a CMM. Orientated using an indexing head, the probe adopts the most convenient pose to perform reliable and repeatable surface measurements. Additionally, with customers requiring more and more probes to complete inspection cycles on increasingly complex parts, LK is about to release a tool changer with a capacity of five probe ports per changer and the option to install multiple units on a single CMM.

Full article here: LK celebrates 60th anniversary – LK Metrology

PRECISION ENGINEERING FIRM TAKES QUALITY CONTROL TO THE NEXT LEVEL

LK Metrology — 09/08/2023

Much of subcontractor Driven Engineering's turnover comes from F1, although the cost cap imposed on teams over the past couple of years has reduced it somewhat, leading to a greater focus on aerospace, automotive and general engineering work. Owner Ray Harris has historically machined mainly jigs, fixtures and moulds for F1 teams, which were telling him that to break into the supply of parts for race cars, he would have to improve his component inspection procedures and quality reports.

British coordinate measuring machine (CMM) manufacturer LK Metrology was a beneficiary of those conversations, as Mr Harris placed an order for one of the company's AlteraC 10.7.7 CMMs. During its build at the Castle Donington factory, the machine was reduced in height by about 100 mm so that it would fit through the entrance to Driven Engineering's latest factory unit in Havant and sit comfortably within a new quality room that was being added. As part of the deal, a single licence of PolyWorks Inspector software was supplied, which is swappable between the CMM and an articulated arm bought in 2020 when Mr Harris worked in a previous location in Portsmouth.

He said, "LK seems to be one of the metrology industry's best-kept secrets. I had not come across them before, but our local calibration company and inspection equipment supplier Mech Metrology & Power Tools introduced me. Although LK is a sizeable operation that is celebrating its 60th anniversary this year, with a factory in Derbyshire and a worldwide customer base, it has a small-company feel. I got the impression that I would receive good support and back-up, which so far has been the case. In addition, the CMM is well-built and the software provided is easy to use, including on the portable arm."

The step up to CMM metrology immediately brought in extra F1 work, mainly prismatic machining on three Hermle 5-axis, high-speed machining centres, two of which are fitted with automatic pallet storage and retrieval systems for automated, 24/7 operation. Parts produced are typically for hydraulic manifolds as well as the race car front and rear wings and floor. A lot of titanium is processed, plus stainless steel, aluminium and some engineering plastics. Unlike jigs and fixtures, which have fairly open tolerances, the latest parts have drawing tolerances down to 25 µm true position, which is impossible to check using the portable arm. The CMM on the other hand is able to measure features an order of magnitude smaller, so is easily capable of completing the inspection tasks.

During programming in PolyWorks, Mr Harris simply picks the features and profiles he wants to inspect. The software then automatically sequences the points for the most efficient inspection routine, including all axis movements, head rotations and collision avoidance strategies. He describes the software is particularly easy to use and ideal for someone new to CNC CMM operation. Data is captured both by touch-probing discrete points and tactile scanning using a Renishaw SP25M probe. Vastly more data is generated in a shorter time compared with touch-trigger probing only, enabling faster inspection and hence improved quality control. It also allows more comprehensive reports to be populated with richer information on the accuracy of freeform areas on components as well as dimensions. The PolyWorks software is able to present this data flexibly in a form that the customer prefers and is able to understand easily.

The pre-existing arm was supplied with a touch probe and a laser scanner, but now is used exclusively with the latter sensor for speed of operation when inspecting, for example, one in five of a batch of 920 aluminium mould tool halves having a complex profile, machined for the aerospace industry. The CMM, on the other hand, was supplied with tactile probing capability only, although it was prepared for laser scanning with a view to adding that capability in the future.

Before he invested in the machine, Mr Harris was invited to visit the Castle Donington factory to see a demonstration of an Altera 10.7.7 inspecting one of his components. It was fortuitous, as he was due to race at the Donington Park motorsport circuit nearby, having recently re-entered the sport by driving a GT car in the British Endurance Championship in early 2022. Unfortunately the Donington fixture was cancelled, so to save him the 350 mile round trip, he sent a water system for an F1 car together with the CAD model to the factory by courier and opted to view the demonstration online. LK showed two ways of inspecting the component, first by touch-probing to orientate it on the granite and then laser scanning, and secondly using an SP25M to probe and touch-scan the part.

Suitably impressed with the latter metrology process, he decided to make the investment in the CMM and PolyWorks, whose ease-of-use is greatly helping his inspection productivity. Programming, due to the level of automation provided by the software, can be carried out in as little as 10 minutes, depending on component complexity and, unlike when using an arm, can be done in advance from the CAD model.

Installation of the CMM has opened up a number of different avenues, as availability of advanced metrology makes new business is easier to win, especially tight-tolerance work. Additionally, Mr Harris has now bought a Ginetta GT race car to hire out for events and intends to start manufacturing a proprietary range of parts for it, such as uprights, bearing supports, axle extensions and drive shafts. The ability to control their quality on the LK CMM to a higher level than would previously have been possible will also enhance this new enterprise.

Find out more: Precision Engineering firm takes quality control to the next level – LK Metrology

Nightforce Optics improves quality with new CMM

LK Metrology — 14/07/2021

Nightforce Optics in Orofino, Idaho, manufactures riflescopes and other high-precision optics for the military special forces, law enforcement agencies, serious competitive shooters and hunters who need the most dependable and best performing optics.

Scott Johnson, quality manager for Nightforce Optics, said that 100 percent of the company’s products undergo a 70-point quality checklist that tests and verifies that each product meets the highest standards for quality and functional accuracy before leaving the facility.

“Riflescopes have a wide range of precision mating parts that are all crucial to the accuracy and performance of each product,” said Johnson. “For example, our scope body tubes are made from aerospace aluminum bar stock and machined by specially designed CNC multi-spindle lathes. We also use complicated multiple start thread designs with very tight tolerances in adjustment parts that require thorough inspections using custom made calibrated gages to ensure precision in each moving part.

Find out more at: Nightforce Optics improves quality with new CMM - LK Metrology