Mechatronic design of a fast-non-contact measurement system for inspection of castings parts in production line

Abstract

Product recalls for suppliers (Tier 1-2-3) and OEM represents high financial losses and reputation damage. This has motivated manufacturers to inspect 100% of the specifications of 100% parts produced to avoid liability risks. In general, the manufactured parts are measured in CMM machines, the main problem is that it takes a long time to make the measurement. Therefore, CMM machines cannot be installed in a continuous line process. This problem has led industries to install gauging machines to have full control over their production. Gauging machines are not flexible, a number of sensors equal to the number of targets to be inspected is needed, complicating the maintenance and increasing the cost. Finally, most gauges are of the go-no go type, which only validates whether the characteristics comply with a standard. In addition, due to the arrival of the concept of industry 4.0, companies have seen the need to develop fast, reliable and accurate inspection machines capable of sending proper information about themselves or the product to the cloud. This work presents a new measurement system for an In-Line die-casting process. The main characteristic is the use of a linear motor and non-contact measurement technology for fast and reliable measurements. Also, the machine uses a novel kinematics coupling configuration to allow easy, fast, and accurate positioning of the part in the measurements area. To be compatible with Industry 4.0 the inspection machine is equipped with sensors to send process information to the cloud like operation temperature, vibrations, and dynamic machine behavior.