May 2024 Volume 6

AUTOMATION

But, if you can perform the dimensional measurements and inspec tion while the part is still at the elevated temperature, then you can save a great deal of down time, reduce the chance of running non conforming parts, and increase the through-put of the line. And that’s exactly what MAS set out to do.

family being forged and measured. MAS is accustomed to solving challenging engineering problems like this, and doing so typically requires a customized on-site feasibility study to gather empirical data specific to the application at hand. As I advise customers on their desire to automate metrology and inspection, the one thing that I can’t emphasize enough is that it’s best to start these kinds of studies early. We typically perform sample scanning or feasibility testing for each application, and we’ve found this is especially important given the unique challenges found in the forging industry, and that every forge shop has its own unique nuances when it comes to process, part, and plant. It is an invest ment to gain this valuable understanding that pays great dividends to the forging houses that step into it. The ability to measure and inspect hot parts has a very quick return for most customers. You’re able to effectively reduce set up time, reduce scrap, reduce manual labor, and increase data collection, all at the same time! Intelligent Automation for Manufacturing Our mantra at MAS is ‘Intelligent Automation for Manufacturing,’ and our core product is our QCPlus™ software package which is designed for easy integration with FANUC robots. It is this software package that enables robots to collect 3D data and utilize that data in 3 primary ways (metrology, inspection and adaptive pathing). We have already discussed the forging related use cases for metrology and inspection , but it is worth noting that the same technology can be used for adaptive pathing . Simply put, adaptive pathing allows post-processing robots (i.e.- grinding robots) to automatically handle part to part dimensional variations. This enables the automation of applications such as grinding away burs on a finished forging. After grinding is completed, the robot performs one final 3D scan to verify measurement and inspection compliance. Concluding Thoughts As we have learned more about the forging industry over the past few years, it has become apparent that pushing the envelope with forging automation is a MUST. As companies all over our nation struggle with manpower, it appears that forgers have it harder than most. The tough environment, and labor-intensive work makes forging an undesirable job for the limited workforce we have in our country. This creates a very real need for more automation in forge plants. Working closely with system integrator partners like Adaptec, MAS aims to raise the level of intelligent automation built into robotic and automated solutions for the forging industry with automated measurements, inspection, and adaptive pathing, opening the door to very clear efficiency gains for forgers who are willing to invest in automation. Matta Rizkallah CEO Manufacturing Automation Systems LLC Phone: 607-368-9097 Email: mrizkallah@mfgautosys.com

A Real World Example Here’s an example of the first forging application MAS worked on: This forging customer wanted to inspect cold parts for dimen sional compliance after their trim press and before their machining processes. We found that the tolerances in their forging process (±0.030”) are a good fit for our 3D robotic scanning metrology stan dard products which range in accuracy from ±0.001” to ±0.008”. We took our customer through our normal sales process, which included performing free robotic 3D sample scanning of their parts using our QCPlus™ Core Software, so they could see how our system performs and how the results compared to their CMM. The results were excel lent. We were able to get great fidelity and accuracy with our auto mated system, which was faster than the CMM lab turnaround time, and could measure many more parts per shift. Our customer found that they could achieve an ROI in less than 12 months with our technology. By moving to measurement of hot parts pulled right out of the trim press (1800 degrees F), their business case became even stronger, particularly for high-value forged parts. There are some obvious challenges to this application, but thanks to our 20+ years in auto mated metrology experience, our team had some ideas on how to make it work. We performed some initial tests and confirmed that we can in fact get good scans on red, hot, radiating parts and our QCPlus™ software can convert those scans into useful measurements and defect inspections. This initial opportunity opened our eyes to a whole new application space for our technology. Challenges for the Forging Industry What we’ve discovered over time was that there are many chal lenges to hot part inspection. Challenges like very high temperatures, humidity, vibration, dust, part oxidation, part shrinkage, and more, are factors that must be considered to get quality measurements. These are all challenges that can be overcome but require engineering evaluation of both the environment and the characteristics of the part

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