More,
better, faster is probably the mantra of every manufacturer, especially as it
applies to quality inspection.
The
combination gives Level 3 the ability to perform more comprehensive inspections
on parts in a shorter amount of time. The SmartFAI First Article Inspection (FAI)
process involves verifying every feature on the part by comparing it to a
customer-supplied part print and 3D CAD model. First-article inspections are
done prior to full production release and often while a part is in development.
The
Level 3 approach replaces traditional plate inspection or a CMM system with
WLS, which can capture and calculate precise 3D coordinates for millions of
points in seconds.
CMM
captures only a few points in the time that WLS can capture hundreds of
thousands, so Level 3 is able to do a more thorough inspection. The results are
much more visual and therefore much more easily understood and interpreted.
Turbine
blade inspection poses some unique challenges, such as analyzing the twist of a
newly manufactured blade compared to the CAD model. This is difficult using a
CMM system, which depends on the operator to accurately capture the points that
will show whether or not the blade is twisted within the allowable tolerance.
Often, there is not enough point data to make an accurate comparison.
Level
3 Inspection has the ability to automate twist analysis. Level 3 can align a
cross-section of the scanned model to reference data, and automatically
generate statistics on the twist of the blade. Constraints can be placed on
maximum rotation and twist tolerance.
Level
3 Inspection’s customers are moving quickly to statistically based inspections
in which the qualification is based not on a single piece, but on a sampling of
parts, new part inspection would take much longer to complete without the
ability to automate portions of the process.
Traditionally,
studies based on a sampling of parts are done using CMM to generate metrics on
dimensions for each part. This is a time-consuming process, since each part
must be measured individually. Data is then typically transferred to an
analytic program, evaluated, then published.
Level
3 is replacing the CMM-based process with automated trend analysis. Once a part
is scanned and a report is saved, Level 3 can automatically generate portions
of the capability studies defined by their customer or OEM specifications.
Batch processing enables Level 3 to collect data and generate reports on a
large number of parts. Statistical analysis tools allow Level 3 to compare
parts for pre-defined factors such as repeatability, changes over time, and
variations from part to part.
Speed
is the key. Speed of inspection is always Level 3 Inspection’s main challenge.
Everyone wants the results yesterday and our process is helping us deliver more
complete results much quicker.
Contact us today to start getting superior inspection results in shorter time with
easier understanding leading to higher confidence
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