Multi-sensor – for when size, shape, speed and accuracy matter most

What is multi-sensor metrology?

Multi-sensor systems use an array of sensors to measure an object’s dimensions and shape in real-time. The approach combines the accuracy of laser touch probe measuring techniques with the flexibility and speed of sensor-based systems.

Sensor-based metrology makes use of a series of interconnected sensors and processing devices to measure an object’s dimensions and shape. These sensors and processors are strategically placed so that every part that passes through it is measured and analysed accurately. This information is then processed using advanced data analysis software to determine the dimensions and shape of the object. Using this data, the sensor-based system can automatically measure to the highest precision – to sub micron levels.

If a part is being manufactured and the dimensions do not conform to specifications, the system can automatically detect the problem and make the necessary adjustments. The system can also automatically reject any defective parts or parts that do not adhere to pre-defined tolerances, detected during the manufacturing process so that they can be repaired or recycled as appropriate.

Why not go all-in-one with multi-sensor measuring?

Multi-sensor measuring equipment together with 3D measuring software like ZONE3, can be used to create highly detailed three-dimensional images of parts that have been produced as part of the manufacturing process. These images can be used to confirm the accuracy of completed products and measure their size to ensure they meet the requirements of the relevant specifications and standards. They can also be used to identify faults in the parts such as cracks or imperfections in the surface that could be used to identify a manufacturing problem or a design fault that needs to be corrected before the part goes into mass production. For peace of mind, and often to satisfy regulation, multi-sensor is the best way to guarantee reliability.

For when size matters

Inspection of finished goods is an important part of the manufacturing process as it helps to ensure that products are free from defects and meet all relevant quality standards before they are sold to customers. When size, shape and weight is essential to the specifications of a component – multi-sensor metrology equipment excels.

For when accuracy matters

More often than not, particularly in industries such as aerospace and medical, exactness is not an option, but a requirement – and can even mean the difference between life and death. In other cases, namely in the automotive industry, each part might be designed with performance in mind to fit into a lightweight chassis capable of world-class performance. Multi-sensor technologies is on-hand for all such needs with an easy-to-use interface limiting human operation, automating the entire measuring process. This means, after inputting the CAD design with specifications, the measuring machine can use this raw data to measure your part, exactly to the letter, taking into account any agreed and pre-defined tolerances deemed acceptable.

For the busy shopfloor

Not always is it possible to stop heavy-machinery doing what it does and making parts – but also making noise, making vibrations in the factory. Measurements can be skewed in harsh environments, and mistakes easier to make. Ensuring you don’t need calm conditions in order to measure your parts, top measuring machines mean you can keep the spindles turning, and the parts moving with fast and accurate inspection in even the roughest environments.

What problems does multi-sensor metrology equipment solve?

One of the main benefits of using measuring equipment in this process is that it can produce 3D images of the surface of the product which can then be used to assess the quality and identify any potential defects in the surface or materials of the product. This can then be used to inform corrective actions to prevent the production of defective products that do not meet quality standards and reduce the risk of injury to customers and workers during use.

Measuring equipment can also be used to check the internal dimensions of a product to ensure that they are within the required tolerances and can be used to determine whether they meet industry standards for health and safety requirements. By using this equipment in the inspection process, it is possible to reduce the amount of time it takes to check the quality of products and improve the quality of the finished product. The use of this technology can also help to improve safety and reduce the risk of injury for workers and customers by ensuring that the products produced meet the appropriate standards for health and safety.

By providing greater visibility into the production process, it is possible to reduce the amount of time required to complete the production process and improve the efficiency of the production process. Manufacturers can also use this data to identify areas where improvements can be made to improve their processes and maximise productivity and ensure that their products are of the highest quality.

There is an array of incredible optical metrology machines available with OGP that have solved production line problems for many of our clients. Why not review some of our case studies, including how multi-sensor metrology helped Cirteq deliver 100% manufacturing accuracy.

Choose OGP for easy user interface & quality software integration

  • Data is made easy with fully-automated data collection, statistical process control (SPC), real-time reporting and data transfer from QC-Calc – allowing quick comparisons to make measuring even more efficient.
  • ZONE3 includes kinematic model simulation updated in real-time, a simple user interface centred on the 3D CAD model and full sensor and deployment mechanisms to effortlessly generate measurement routines
  • Measure X measurement software supports automatic measurement of points, planes lines, circles, distances, cones and spheres…

The benefits of multi-sensor metrology to modern manufacturing

By using sensor-based systems to measure objects as they are being produced, it is possible to ensure that each part meets its requirements before the manufacturing process is completed. There are a number of factors that make sensor-based metrology an attractive option for manufacturers. 

First, it offers an unprecedented level of control over the quality of the manufactured products. This is made possible by its ability to quantify the dimensional characteristics of an object as it passes through the production line. This means that manufacturers can ensure that they produce a consistently high-quality product every time. 

Second, sensor-based systems are faster and more flexible than traditional systems, allowing manufacturers to reduce the time spent on the production line without compromising the quality of the finished product.

Third, it reduces the costs associated with the traditional production process, including labour, raw materials, and equipment maintenance. 

Finally, it is non-invasive and non-obtrusive, which means it does not interfere with the normal manufacturing process and can be used in any environment without the need for specialised facilities or equipment. As a result, sensor-based systems can be used by manufacturers in a wide range of industries including aerospace, automotive, medical, consumer electronics, and oil and gas.

Another potential benefit of sensor-based quality control systems is that they allow manufacturers to monitor production processes in real time and adjust them as necessary to ensure that products meet quality requirements. As a result, it has the potential to improve product quality and decrease the amount of time needed to produce parts and finished products.

Why and when to make the move to multi-sensor measuring?

Faster, more flexible and much more accurate – there are many reasons to make the switch to multi-sensor metrology systems. Here are just a few of the main reasons that multi-sensor is the best of all-worlds. It is perfect when:

  • you require accurate measures for complex parts that are not possible using a touch probe
  • you require fast, reliable measurements every time
  • there are stringent regulations placed on your product, part or production process
  • you wish to reduce your reliance on skilled operators
  • you need to eradicate mistakes and unusable parts
  • you wish to increase capacity
  • you require versatility in your measurement process, enabling you to use lasers, touch probes, rotaries and optical sensors all-in-one.

No matter if your production line is stalling, you need measurements for critical components that are on-point every time or you simply want to see what an OGP machine can do for you, our expert team is on hand to help.

How much can you save with a multi-sensor measuring system?

Multi-sensor measurement is driving companies into a brighter future, producing more parts and quicker to increase production volume. Why not tell us your problem, reason for interest and how much time you are spending measuring and we will come back to you fast to get you a price and an ROI quotation.

OGP machines have solved countless problems on the factory floor for clients across a range of industries. When we audit a factory floor we take time to understand how an OGP machine can fit into your production line, as well as how much time and money you can save in those processes using the bespoke best-in-class software packages like ZONE3 and various machinery from OGP. 

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    Purchasing a state-of-the-art metrology system and software package is just the beginning. At OGP UK, our expert team work tirelessly to make sure the system works for you, and continues to work for you. That is why we offer comprehensive services including:

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    Graham Shaw - A metrology industry insight

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