In manufacturing sectors like aerospace, automotive, and heavy equipment, the need for timely, high-accuracy dimensional metrology on large, complex parts is paramount. For manufacturers tackling large assemblies or high-value components, metrology systems must be both flexible and robust enough to handle a variety of surfaces and shapes. The ideal setup combines a targetless metrology device with high accuracy, integrated software for live data processing and model comparison, and robotic deployment that offers intuitive controls, enabling operators to perform automated, in-line inspections.
This metrology setup includes three essential technology components that, when integrated, provide a uniquely capable system:
- Flexible, Targetless Metrology Device: The system must feature a metrology device that captures detailed, accurate 3D data without requiring physical targets. Targetless capability allows it to handle complex geometries with minimal setup, while high accuracy ensures it meets stringent tolerance requirements in large assemblies and high-value components.
- Integrated Software Interface: The system requires software that seamlessly processes measurement data, comparing it against CAD models and providing immediate alerts for deviations. This software should enable easy integration across multiple applications and provide immediate feedback for rapid corrective action, reducing downtime and enhancing quality control.
- Robotic System with an Intuitive Interface: The robotics used in this setup must be adaptable and have an intuitive control system that can be operated and maintained by a large talent pool. The robotics must support flexible path programming, allowing the metrology device to capture measurements across complex surfaces automatically.
This combination of targetless measurement capability, seamless software integration, and user-friendly robotics creates a sophisticated metrology automation system that is simple to operate yet powerful in its functionality. However, it is rare to find all three components in a single, efficient solution due to the complexity of integrating these technologies seamlessly. Many metrology systems require complex setups, have a steep learning curve, or rely on physical targets, which can be impractical for dynamic inspections.
For high-accuracy applications, ATT Metrology Solutions has chosen the Leica ATS800 laser radar, Metrologic iRobot software, and FANUC robotics. This trio combines the necessary flexibility, accuracy, and automation capabilities to handle large-scale metrology tasks in complex manufacturing environments.
1. Leica ATS800: Flexible, Targetless Measurement
The Leica ATS800 laser radar brings the advanced capability of targetless measurement with exceptional accuracy across large structures and complex surfaces. Its ability to capture high-resolution 3D data without physical targets simplifies the setup process, making it ideal for applications where markers would be impractical, such as on delicate composite surfaces or dynamically changing structures. The ATS800 can also capture both large surface scans and pinpoint measurements on specific points, providing versatility across a range of tasks.
In applications like composite part deformation detection, large weldment alignment, and live monitoring during machining, the ATS800’s flexibility and accuracy allow ATT Metrology Solutions to achieve consistently high measurement accuracy without needing to stop and reset the device. This versatility makes the ATS800 a perfect fit for large-scale, complex metrology applications that demand both detail and adaptability.
2. Metrologic iRobot Software: Seamless Data Processing and Live Feedback
Metrologic iRobot software integrates directly with the ATS800 to process measurement data in real time, overlaying it with CAD models and immediately flagging any dimensional deviations. This software offers an intuitive interface for inspection planning, path programming, and model comparisons, making it easy to transition between different applications without complex reconfigurations.
In the ATS800 integration, iRobot ensures seamless data flow from the laser radar to operators, enabling prompt corrective actions in the case of deviations. Whether for deformation detection in bonding processes or alignment checks during welding, iRobot supports detailed, live data analysis, which significantly reduces downtime and enhances quality control. Its compatibility with both laser radar and robotic systems also simplifies the entire workflow, providing a single software for robot path planning and metrology data processing.
3. FANUC Robotics: Robust, Intuitive Automation
ATT Metrology Solutions leverages FANUC robotics for the automation backbone, thanks to its adaptability and ease of use. FANUC robots provide highly programmable path control, making it simple to set and adjust inspection routines for different parts and geometries. The FANUC control interface is also widely recognized for its intuitive design, making it accessible to operators with varied experience levels, and the platform benefits from a widespread talent base for operation and maintenance.
In metrology applications, FANUC robots allow for precise control of the ATS800’s position and orientation, enabling complete surface coverage on complex components. This robotic flexibility is crucial when inspecting large structures like weldments or during machining processes where vibration and movement could impact data accuracy. FANUC’s reputation for reliability and straightforward operation ensures that even the most complex metrology tasks can be performed efficiently and with minimal downtime.
Why This Integrated System is Unique
This combination of targetless measurement, live processing, and intuitive robotics creates a uniquely efficient metrology automation system. While many metrology setups struggle with complexity and require significant manual intervention, ATT Metrology Solutions’ configuration is streamlined for ease of use and reliability.
The Leica ATS800 eliminates the need for physical targets, significantly reducing setup time and allowing for continuous, non-intrusive measurements across complex surfaces. Metrologic iRobot’s software handles data processing with live feedback, ensuring that dimensional deviations are identified and addressed as they occur. Finally, FANUC’s robotics provide the flexibility to deploy the metrology system dynamically, covering complex geometries without compromising accuracy.
ATT Metrology Solutions’ choice to integrate the Leica ATS800 laser radar, Metrologic iRobot software, and FANUC robotics reflects a dedication to delivering a high-performance metrology solution that balances accuracy, simplicity, and adaptability. This combination of advanced measurement capabilities, integrated software controls, and user-friendly automation enables efficient and accurate inspections across complex manufacturing applications.
For manufacturers in need of flexible, targetless metrology for large-scale or sensitive parts, this system provides an unparalleled solution, transforming complex metrology into a streamlined and user-friendly process. In an industry where efficiency and accuracy are key, ATT Metrology’s solution exemplifies the best of modern metrology integration.