1. NIKON METROLOGY NEWS
Case Studies and Product News VOLUME 11
Continental doubles
inspection throughput
Highly efficient
rock sample categorisation
CT reveals insight into ancient specimens
LASER RADAR
SHOP FLOOR CMM FOR CAR BODY INSPECTION
2. 2
High accuracy non-contact sensor
gear inspection system
HN-C3030
• 3D scans provide better insight into
complex shapes
• Laser scanning offers higher
measurement speed
• Non-contact eliminates the need for
probe tip compensation
• Reveal surface defects not detectable
by tactile measurement
• Measure small features impossible
for tactile probes
NIKON METROLOGY I VISION BEYOND PRECISION
3. 3News I Volume 11
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4 | Next-generation shop floor CMM for car
body inspection
7 | Faster inspection and reporting with 3D laser
scanning
10 | Improved performance and larger CMM sizes
12 | Equipped to double inspection productivity
14 | Ground-breaking knowledge discovered
from ancient specimens using X-ray CT
16 | Cranking up gear inspection
18 | Nikon microscope allows highly efficient rock
sample categorisation
20 | Mindful distraction:
Therapeutic art created with mineral
photomicrographs
22 | Nisan Engineering reduces inspection time
by a factor 5
Content
4
7
14
20 Check out Linkedin-page to find out more about our new
products, events and promotions
4. There is an increasing importance for automotive assembly plants to continuously monitor
process quality throughout the production process. This need is driven by OEMs pushing the
limits of design by using complex shapes, new materials, and cutting edge processes. Locations of
holes, slots, studs, and welding lines along with flush gap of doors, hoods, deck lids, and other
hangers need to be measured and monitored throughout the assembly process. These inspections
ensure that vehicles are built within the ever more stringent tolerances set by automotive
manufacturers.
Next-generation shop floor CMM
for car body inspection
Nikon Metrology – in close cooperation
with key automotive OEM and integration
partners- addresses these challenges by
introducing an innovative approach to
body-in-white (BIW) inspection based
upon its non-contact Laser Radar system.
Unlike a horizontal-arm CMM, the Laser
Radar high-speed measurements fit within
short production cycle times. The new
MV331/351 Laser Radar doubles surface
scanning speed and drastically increases
feature measurement performance. New
usability features such as an integrated
robot mount, removable air filters and
positive air pressurization make the system
even better suited for robotized inspection
on the shop floor.
Traditional body-in-white
inspection is under pressure
Intherecentpast,body-in-whitemeasurements
have been performed in two phases - on the
production line with low accuracy sensors to
monitor process and in a CMM room where
a sample of parts are sent to be inspected
offline by large horizontal arm CMMs for more
accurate measurements and to correlate the
data from the inline sensors.
Although CMMs can provide highly accurate
absolute measurements, they tend to be
slow and require an expensive, dedicated
metrology room. Vehicles need to be
removed from the production line and then
taken to the metrology room, manually
fixtured and aligned to the CMM. The CMM
then starts its time-consuming measurement
process. Taking into account the setup and
measurement time, at best two vehicles
can be inspected per shift on a CMM, but
often only one vehicle is measured. This is
a very small sample considering that over
1,000 vehicles of various styles can be built
each day on a single production line. This
is certainly not a large enough sample to
monitor the production process.
Inline systems typically measure every vehicle
but can require over 100 individual fixed
sensors to inspect the required features.
Although these sensors are very quick to
measure they are demanding to install and
4
5. maintain and do not provide measurements
directly in the car’s coordinate system. In
addition, most assembly lines now are
‘flexible’, meaning that they can produce
more than one type of vehicle. Fixed sensors
cannot be used across different vehicles
styles; every vehicle requires its own custom
set of sensors making them even more
expensive and onerous to maintain.
Recently inline inspection systems have been
moving towards robotic based solutions
which are flexible, but rely on the robot’s
positional precision which limits the overall
accuracy.These systems typically have four or
more robots with a sensor located on the end
effector of each robot that is re-positioned to
measure each of the features that need to be
inspected. Hundreds of locations need to be
programmed, making them time-consuming
to set up and difficult to maintain and they
still do not provide the required accuracy and
correlation to a CMM.
A new approach: Flexible
inspection, absolute
measurement
Innovative inspection stations are being
installed today, both lineside and in-line,
by major automotive OEMs using Nikon
Metrology’s Laser Radar. The Laser Radar
has been used for many years in the
aerospace and renewable energy sectors
and is now providing a unique alternative to
the shortcomings of traditional automotive
metrology systems like CMMs and inline
sensor systems. The new MV331/351 Laser
Radar is further optimized for car body shop
floor inspection. The Laser Radar’s high
speed vision scans at rates of 2.000 points
per second – enable fast measurement of
surfaces, sections and complex features.
The Laser Radar performs automated, highly
accurate, contactless measurements in the
car coordinate system by using a focused
laser that is controlled by a precision azimuth
and elevation system. The Laser Radar
requires a fraction of the reflected signal to
make accurate measurements, enabling it to
inspect almost any material, color or surface
texture, such as bare sheet metal, coated
BIW or painted cars.
New usability features such as an integrated robot mount, removable air
filters and faster measurement directly target robotized inspection on the shop
floor
Features like holes, slots, pins, studs etc are inspected in an automated way at a
scanning rate of 2,000 pts/sec
5News I Volume 11
What customers gain
With the need for shorter and more flexible production cycles, automotive manufacturers
are continuously looking to cut time and costs whilst maintaining quality. For automotive
inline inspection, the automated Laser Radar on a robot offers the right capabilities to
meet the need for flexible and absolute measurements directly on the shop floor. For car
manufacturers this results in:
• Shorter startup of new production line or vehicle model changes: during the
startup phase initial produced vehicles can be completely measured and compared
to CAD. This provides better insight into product conformance and enable faster
finetuning of the production process.
• Reduced scrap: By closely monitoring the production quality, the process can be
instantly adjusted when variances occur over time.
• Future proof data: Measurements in absolute coordinates fit in the digital
manufacturing process where data is used as a reference to compare data over time
and to speed up future product development etc.
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6. 6
The measurement accuracy and repeatability
of the Laser Radar is comparable to
measurements taken with a traditional
horizontal arm touch probe, while it is many
times faster. Two Laser Radars working in
parallel can measure 700 features on a BIW
vehicle in less than one hour; this can take a
full shift for traditional CMM.
The configuration of a Laser Radar inspection
station can vary based on the specific needs
of the OEM but typically consists of one or
more Laser Radars that are manipulated by
6-axis industrial robots. The industrial robots
are used to automatically reposition the Laser
Radar to enable it to inspect areas that are
not visible from a single location.
After repositioning the robot, the Laser
Radar automatically realigns to the part by
measuring alignment points on the vehicle
or tooling. Unlike other inline robotic
measurement systems, this guarantees that
all measurements are collected in the vehicle
coordinate system and ensures feature
accuracy is independent of the robots ability
to accurately locate the Laser Radar.
Laser Radar has a spherical field-of-view,
meaning it has visibility to large sections of
the vehicle at any time and dozens of features
on the vehicle can be measured from a single
location. Just like a CMM, measurements are
pre-programmed directly from the vehicle’s
CAD model using the inspection software.After
the initial programming, data collection and
reporting is fully automated.Specific inspection
scripts can also be written for each vehicle
style and model being built on the production
line making the Laser Radar inspection station
completely flexible for changes to inspection
plans and even new vehicle styles. Changing
the features to inspect or adding in new
vehicle styles is completely software based and
does not require any physical changes to the
setup or new hardware.
The application software takes care of the
interaction of the Laser Radar, robot, and
data processing; inspections are completely
automated and do not require manual
intervention during runtime. This improves
both speed and quality of the measurements
compared to traditional methods.
Engines
The Laser Radar is used for nacelle, thrust reverser, and
panel inspections. Tens of thousands of surface points
can be collected on these parts automatically without
the need for ladders or a dedicated operator, as such
improving quality while reducing labor.
Barrel sections
Large barrel sections are inspected with the Laser Radar
both at the factory and in the join station. The Laser
Radar provides data that is used to optimize the fit of
the barrel sections allowing aircraft manufacturers to
build straighter, more efficient planes.
Wings / Flaps / Tailfins
More aerostructures are being built with composite materials,
which drives the need for higher tolerance part fitting. The Laser
Radar is used to measure the as-built condition of wing ribs, skins
and other control surfaces so proper shims can be installed to
optimizing each build.
Wing to body join
The Laser Radar scans the relative positions of the wing root
and side of body in join position. This data is used to virtually fit
the wing and side of body together allowing shim packs to be
installed prior to the join. It also feeds back the relative location
of the wing to the join automation to ensure an accurate fit and
optimize aircraft symmetry.
Revolutionizing large volume inspection in aerospace applications
Originally the Laser Radar was applied
in aerospace applications for targetless
inspection of objects ranging in size from
a passenger door to an entire aircraft.
The automated, non-contact operation
without a need for retro-reflectors
were unique benefits to reduce labor,
to improve inspection productivity and
increase measurement repeatability.
7. 7News I Volume 11
Based in Redditch, UK, Birmingham
Prototypes started working directly
for JLR two years ago. To receive its
supplier’s code, the subcontractor
needed to be able to fulfil the
OEM’s stringent quality control
requirements in respect of first
article inspection reporting and PPAP
(production part approval process)
documentation. They required an
increase in the number of reports
that had to be produced as well as
more detail on component accuracy
and repeatability than is requested by
other customers in the automotive,
aerospace and other sectors.
Using the former manual CMM at
Redditch, report generation was a
laborious process requiring entry
of data and drawings by hand into
Microsoft Office applications. A
single report took anything from
an hour to half a day, depending
on its complexity, according to
Birmingham Prototypes’ managing
director, Mick Adams. So in 2013 he
decided to install a Nikon Metrology
LK V 15.10.8 ceramic bridge co-
ordinate measuring machine to
automate and speed up the reporting
process. It also allows inspection
cycles to be completed faster and
without operator attendance after
components have been fixtured,
saving further time especially when
measuring a batch of identical
components.
Automotive and aerospace pressings specialist invests in bridge-type
and portable arm CMMs for freeform surface data acquisition
Faster inspection and reporting
with 3D laser scanning
Case study
A significant increase in orders for
the supply of prototype pressings and
bracketry, notably to Jaguar Land Rover
(JLR), has prompted Birmingham Prototypes
(www.birminghamprototypes.co.uk)
to install two multi-sensor co-ordinate
measuring machines (CMMs) from Nikon
Metrology. The goal was not only to
measure the sheet metal parts faster but
more importantly to speed subsequent
report generation. The investment has also
resulted in the establishment of a new
subcontract service offering laser scanning
and inspection work.
News I Volume 11
8. 8
A Nikon Metrology LC15Dx laser scanner is
the default method of inspecting pressings
at Birmingham prototypes. It allows high
accuracy resolution of freeform surfaces and
geometry. For measuring tight dimensional
tolerances and sometimes for initial job set-
up, a touch probe is picked up automatically
from the stylus changer on the LK V 15.10.8
by a Renishaw PH10M motorised indexing
head.
Most drawing tolerances on pressed parts at
Redditch are fairly open, ± 0.25 mm being
typical on surfaces and ± 1 mm for trim
edges. Only hole positions are measured
to within tens of microns. The LK CMM is
capable of measuring to an accuracy that is
at least an order of magnitude better than is
required for these applications.
Software is key to data
handling and reporting
Nikon Metrology’s multi-sensor CAMIO
V8 software in use at Redditch produces
industry-standard DMIS programs that
support both laser scanning and touch
probing. The software applies the optimum
measurement strategy based on the feature
and sensor selected. For measuring complex
surfaces, it automatically generates scan
paths that result in fast and smooth laser
scanning that closely follows the part
surface, with full machine simulation and
collision detection. CAMIO also has instant,
highly productive reporting functionality
based on standard templates. Tabulated
tables, graphics and form plots derived from
scanned point clouds and touch probing are
combined in a single, concise report.
It is Nikon Metrology Focus 10 software that
manages the point clouds acquired during
laser scanning and allows inspection data
to be compared against the customer’s
original CAD model. A typical pressing at
the Redditch factory, such as a prototype
aluminium engine bay mounting plate for a
Jaguar car, comprises seven to eight million
points. Focus software produces annotated,
colour deviation maps showing how the 3D
scanned model correlates with and deviates
from the original CAD file. For such global
comparisons, a 0.1 mm grid is generally
selected by Birmingham Prototypes’ quality
manager, Bob Rose.
Scanning with articulated arm
is twice as fast
Early in 2015, Birmingham Prototypes
installed a Trumpf 5-axis laser profiling
machine so that it could bring in-house the
laser cutting work it was subcontracting at a
cost of £350,000 per year.
Mr Adams commented, “Practically every
job that comes off the machine is a unique
prototype that needs to be inspected, a job
that was previously done by the laser cutting
subcontractors before parts were delivered
to us.
“As our CNC CMM needs to be programmed
for each new part, making it more suited to
our low volume, pre-production runs, it made
sense for us to invest in a manual measuring
system to check the output from the Trumpf
laser.
“Rather than choose another static CMM,
we decided to install a portable co-ordinate
measuring arm, an MCAx from Nikon. It is
twice as fast at producing inspection results
for a one-off part.”
The facility is used in-house on a dedicated
steel table in the quality control room.It often
inspects or reverse engineers components
and fixtures for other manufacturers that
have requested subcontract measuring to
be carried out, a service that was introduced
two years ago when the CNC CMM arrived.
The measuring arm has extended the scope
of the service by allowing off-site inspection
at customers’ premises of fabrications that
are too bulky to be transported easily.
Close-ups of the Jaguar prototype pressing being inspected using the Nikon
Metrology LC15Dx laser scanner head.
“ Rather than choose another
static CMM, we decided
to install a portable
co-ordinate measuring arm,
an MCAx from Nikon. It is
twice as fast at producing
inspection results for a
one-off part.
Mick Adams,
Managing director
9. 9News I Volume 11
The MCAx 7-axis, counterbalanced arm
with continuous rotation is used mainly
with a digital laser scanner at Redditch,
together with Focus 10 handheld scanning
and inspection software. Occasionally a
touch-trigger probe is employed if additional
accuracy is needed.The arm is equipped with
absolute angle encoders for high precision
and the model at Redditch has a four-meter
diameter measuring envelope. Features
of the equipment are the ability to reliably
scan steep sided and reflective components,
temperature stability and zero warm-up time.
Other departments served
The Nikon CMMs have greatly enhanced
quality control of sheet metal parts at
Birmingham Prototypes and allowed the firm
to increase turnover by launching subcontract
inspection and reverse engineering. They
are backed by ISO 9001:2008 quality
management accreditation, which has been
held for over 10 years.
The move to laser scanning has improved not
only the firm’s sheet metalworking activities,
but also its additive manufacturing service
using a Dimension 1200es 3D printer. The
laser scanner generates a CAD model of
components for which there is no drawing
or electronic data. It is altered as necessary,
STL files are exported for printing the plastic
part layer by layer and the customer is given
both the component and the CAD file in any
format.
The factory also houses four Hurco CNC
machining centres including 5-axis models
to manufacture prototype tooling and low
volume production components around the
clock.The output from these machines is also
checked on the Nikon Metrology CMMs.
The MCAx measuring arm with a hand-held laser scanner inspecting part of an aircraft seat.
The CMM control screens, showing on the left hand screen a CAD model with hole comparisons and on the right hand screen a global comparison of the measured
data against the CAD model. Different colours denote where each measurement is within the tolerance band.
Download this case study
10. ALTERA multi-sensor CMM
Improved performance and larger CMM sizes
Nikon Metrology has extended its ceramic bridge CMM range with high
accuracy ALTERA+ and larger size ALTERA models. Thanks to the use
of advanced materials and optimized designs, ALTERA provides high
performance and superior accuracy across a host of metrology applications,
including harsh shop floor environments. Probing support is extended with
REVO 5-axis scanning technology to dramatically improve CMM productivity
for complex tactile inspection applications. Uniquely in this market, ALTERA
is delivered with a manufacturer’s 10 year accuracy guarantee for extra
customer satisfaction.
Advanced design and superior
materials for maximum performance
in any application
Built and designed to exacting standards, ALTERA
CMMs use advanced ceramic components for
structural integrity and enduring performance.
With near perfect stiffness-to-weight ratio, ceramic
guideways facilitate impressive accuracy: 1.4+L/375
(E150 according to ISO10360-2:2009). The ceramic
bridge, with greater resistance to temperature
shifts, makes the ALTERA suitable for metrology
applications in a host of manufacturing and shop
floor environments. The stress-free horizontal ceramic
beam and advanced multi-point bearings counter any
negative effect on accuracy when using long probes.
Multi-sensor technology for the
broadest range of metrology
applications
ALTERA CMMs support an extensive range of tactile
and non-contact probing and software options. Multi-
sensor technology extends the ALTERA capability
to measuring parts which are large or small, 2D or
3D, hard or soft and prismatic or free-form. With
almost 30 different models and 7 bridge sizes, the
ALTERA offers solutions for an array of applications
and requirements. The extended sizes range from the
smallest measuring volume - 7.7.5 to the largest –
60.20.15, of the standard sizes available. Software
options consist not only of CAMIO and CMM-
Manager, but also MODUS – to operate the Renishaw
REVO-2 probe head.
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11. 11News I Volume 11
Ready for shop floor use
The shop-floor-ready ALTERA CMM makes
use of several innovative new features.
Folding guideway covers protect the
air bearing guideways from airborne
contaminates such as dust and oil. Superior
pneumatic, self-levelling vibration isolators
provide optimum performance in areas
subject to high levels of low frequency
vibration. Automation capability for manual
or fully automated FMS production cells, can
integrate machine tools, transfer systems and
material handling.
Unique accuracy guarantee –
Nikon Metrology are the only
manufacturer to guarantee the
accuracy of their CMMs for 10
years.
Accuracy of the ALTERA is fully ISO 10360
compliant, and comes with the Nikon
Metrology 10 year original accuracy
guarantee – demonstrating the utmost
confidence in the quality and reliability
of the ALTERA. With over 50 years of
experience and close collaboration with
its large customer base, the ALTERA builds
on foundations of high quality, exceptional
stability and enduring performance.
Enduring accuracy
Ultra-stable ceramic bridge and spindle
guideway with closed-loop stainless steel
belt friction drive and high resolution
0.05µm optical scales result in volumetric
accuracies as low as 1.5μm + L/375.
Fast and smooth operation
Precision dove-tail table guideway and
unique single orifice grooved pre-loaded
wrap-around air bearings for smooth and
controlled high motion.
Shop floor ready
ALTERA+ and larger ALTERA CMMs feature
an optimized CERAMIC Y-beam resulting in
unprecedented stiffness and
thermal stability.To protect
the machine from dust or oil,
the moving components are
shielded behind machine covers.
Stability above all
Active vibration mounts (AVM) guarantee
stable operation and the highest accuracy in
environments that are subject to vibrations
or where measurement rooms need to meet
the most stringent isolation requirements.
News I Volume 11
12. 12
Continental Chassis Safety installs twin ALTERA multi-sensors CMMs
Multi-sensor metrology paves the road
for faster inspection
In Continental’s measurement laboratory, their single
tactile CMM was handling the vast majority of their
inspection tasks. The Measuring Technician – Peter
Somogyi explained that the main limitation of their
existing CMM was its low capacity and that it was time
to find a quicker solution. Tamas Brunner – Quality
Engineer added that the software wasn’t up to their
standard either requiring automation with latest GDT
measuring standards. They both continued to explain
that with so many measuring tasks to process, their
single, low capacity CMM just wasn’t able to keep up
with their demand, let alone provide the level of insight
necessary.
Vesz-Mont 2000 provide the Nikon
solution
After consulting CMM vendors,Vesz-Mont 2000, a Nikon
Metrology reseller located in Veszprem offered the multi-
sensorALTERA CMM, as the most comprehensive answer
to their requirements. The final decision was made to
install two ALTERA 8.7.6 CMMs, each providing multi-
sensor technology with Nikon’s most accurate digital
Laser scanner – the LC15Dx complemented with CAMIO
The Quality department of Continental’s
Chassis Safety department recently invested
in dual multi-sensor CMMs to revamp the
inspection capabilities of their measurement
laboratory. Continental wanted to gain a
quicker, more comprehensive insight into their
products, therefore began to look into multi-
sensor metrology solutions. They required
a high capacity system capable of high
speed inspection cycles and combined fast
surface scanning with highly accurate feature
measurements. After outlining their criteria,
several companies were consulted, prior to
selecting two Nikon ALTERA CMMs, featuring
the state-of-the-art LC15Dx laser scanners.
Equipped to double
inspection productivity
Case study
13. 13News I Volume 11
software. Both Tamas and Peter strongly
emphasised that the high accuracy of the
LC15Dx (1.9 µm) was the main deciding
factor in choosing the Nikon solution. With
such a wide range of shapes, sizes and
surfaces to deal with, the LC15Dx is perfectly
suited to Continental’s needs. The Enhanced
Sensor Performance (ESP3) eliminates
the need for preparation, such as powder
spraying of dark or multi-coloured plastic
parts. The specifically developed Nikon Lens
provides the sharpest detail to measure the
shapes, edges and features. The new set-up
also includes a TP200 tactile measurement
probe for outlining parts or inspecting new
features. The Renishaw ACR3 change rack
ensures a smooth, automated exchange
between tactile and non-contact probes, all
controlled by Nikon’s CAMIO acquisition and
processing software.
Short term benefits point
towards long term prosperity
The Nikon Metrology solution has
immediately proven to be a resounding
success. The direct benefits such as faster
inspection cycles and increased productivity
point to the inevitable achievement of
Continental’s long term goals. Peter Somogyi
explained that the multi-sensor CMM allows
for almost all type of measurements to be
done with one machine, whilst previously
needing to use a range of inspection
equipment such as tactile probe, microscope,
projector and conturograph.
The Quality department have complete trust
in the multi-sensor system and its insight,
stating that it is also a very good tool for
handling claims. As all measurement data
is stored and available for reprocessing
or further analysis, the new inspection
system serves as a critical tool in handling
potential customer claims. The quality of
the new inspection process has introduced
an increased insight into the parts critical
dimensions, cavities and functional features.
This enables faster corrective action,
demonstrating the high level of productivity
the Nikon solution brings.
Dimensional inspection of the O-ring fitting of a small speed sensor The dense point clouds are compared to the
nominal CAD of the sample and all deviations are
visible in an easy-to-interpret colour map.
“ The high accuracy of the LC15Dx was the
main deciding factor in choosing the
Nikon solution.
Tamas Brunner, Quality Engineer
14. 14
X-ray ComputedTomography (CT) at the Smithsonian Institution’s National
Museum of Natural History is delivering new knowledge from ancient specimens
Ground-breaking knowledge
discovered from ancient specimens
using X-ray CT
The vision statement of the Smithsonian Institution,
the world’s largest museum and research complex
is as follows: “Shaping the future by preserving
our heritage, discovering new knowledge, and
sharing our resources with the world.” Within this
statement is a commitment to finding and using the
most effective tools to accomplish these ideals. The
following describes how the Smithsonian’s Natural
History Museum together with an engineering
consulting firm are using X-ray computed
tomography (micro CT) to not only scan marine
mammal fossils, but also make 3D scans and all the
data available for knowledge-seekers around the
world.
Case study
The consulting lab - Chesapeake Testing was founded in
2006 by Jim Foulk, originally envisioned as a ballistic
testing laboratory. “We saw a big uptick in the research
and development of armors, with trying to get lighter
weights,better performance,”Foulk says.“Essentially,our
quest to understand armor led us to acquire some unique
complimentary capabilities,”adds Chris Peitsch,lead NDT
engineer. “It’s these capabilities, such as CT scanning,
that allowed us to diversify our business very easily.”
To expand its suite of testing equipment, Chesapeake
Testing started researching X-ray system suppliers and
began working with Nikon Metrology, quickly discovering
the largest offering, a combined 225/450kV micro-focus
X-ray and computed tomography system. The system’s
powerful source, walk-in bay, and panel shift capability
allow Chesapeake Testing the versatility to inspect larger
components that other cabinet CT systems are unable to
accommodate.
15. 15News I Volume 11
Non-destructive testing with X-ray micro CT
continues to make inroads into quantifying
and improving components in many vital
and essential industries such as aerospace,
medical and more.This is mainly due to micro
CT’s ability to inspect and measure internal
and external component surfaces and
even produce component slices that yield
significant information without destroying
the part.These are the same attributes driving
it into new frontiers, one of the most exciting
being the scanning of marine mammal fossils
at the Smithsonian Institution’s National
Museum of Natural History.
How does the fossil record
show us what happened in the
past and how the world has
shaped that since?
Nick Pyenson, Ph.D., curator of marine
mammal fossils at the Smithsonian
Institution’s National Museum of Natural
History (NMNH) says “Climate change is a
critical issue right now, and mass extinction
events in the past point to similar events
going on in our lifetime. The fossil record
comes to bear more importantly than ever
before.”
Pyenson has published research using CT
data for more than 10 years, all in an effort
to understand the big picture of how four-
limbed marine mammals such as whales
descended from land-based tetra-pods and
how the return to the sea over time changed
their anatomy (legs into fins, for example).
“Across 250 million years, many land-based
vertebrates returned to the sea, and the
CT scans help us see some of the resulting
solutions.” Another is colleague Dr. Maya
Yamato’s work on CT scanning foetal whale
specimens from the NMNH’s collection to
model the development of how whales hear.
What the X-rays reveal
Andrew Ramsey of Nikon Metrology
(Tring, UK) says “Computed tomography is
essentially the coupling of ever-increasing
computing processing power with X-ray
technology and digital photography. A
fundamental setup includes the X-ray source,
the object being measured, and a detector.
A rotating platform for the object being
imaged helps keep the subject in the field of
view while penetrating the sample from all
angles.”
A single micro CT session with a single
sample can produce thousands of digital
images. Each two-dimensional pixel in each
image can become a three-dimensional
voxel as computer algorithms reconstruct 3D
volumes. With 3000 images, for example, a
billion or so voxels are produced, and each
is processed 3000 times. The result is a 3-D
volumetric map of the object, where each
voxel is a 3-D cube with a discrete location
(x,y,z) and a density (ρ). Not only is the
external surface information known, such as
with a 3-D point cloud from laser scanning,
but internal surfaces and additional
information about what is in between the
surfaces from the fourth dimension (density)
is provided.
“We have a mission to expand and
commercialize applications for micro CT,
we hope the work with the Smithsonian
will open some eyes”, says Peitsch. It’s very
interesting how the work we’re doing with
the fossils correlate with industrial work
we’re doing in composites, among other
industrial areas.
Pyenson and the Smithsonian are using
a number of digital tools: 3D printing to
make copies of valuable originals; 3D web
platforms (3d.si.edu) for downloading CT
and other digital scans, and the CT scans
themselves. “Nothing replaces the original,
but with micro CT you get surface and
internal structures that will definitely further
research,” Pyenson says. “It’s the middle
schoolers that will get the most out of this
from artistic and creative standpoints as well
as scientific.We cannot foresee the impact of
this technology.”
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Chesapeake walk-in CT facilities X-ray of blue whale foetus
16. 16
High speed, high precision,
non-contact gear inspection
Cranking up gear inspection
HN-C3030
Nikon Metrology introduces the non-contact HN-
C3030 3D measuring system for precise, high-
speed measurement of complex components
including gears, impellers, turbine blades and more.
With the HN-C3030, featuring an advanced laser
scanner, Nikon is making a leap forward in ultra-
fast shape evaluation compared to traditional
tactile measurement methods. By scanning and
comparing the complete shape to the original CAD
file, customers obtain better insights in product
conformity resulting in faster problem-solving and
earlier go-to-market.
Advanced optical technology
Due to the development of more complex components,
the demand for high speed, precise measuring of
these parts has also increased. As a long-established
manufacturer of high-quality optical instruments, Nikon
now introduces the HN-C3030, a next-generation
non-contact inspection system. In order to achieve the
highest precision, Nikon has developed special optics for
the laser scanner that also enables scanning of glossy
or dark surfaces without manual preparation, such as
powder spraying.
High-precision five axis control for
optimum scanning angles
The precise positioning by the synchronised 5-axis
17. 17News I Volume 11
hardware control is an important element to
deliver the accurate measuring results. The
HN-C3030 controls a high-precision 3-axis
drive system, as well as an unlimited angular
rotary stage and a laser scanner swing
arm with an arc angle of -20° to +135°.
This enables laser scanning of wide areas
covering top and side surfaces, and even
bottom surfaces, of parts. In addition, the
direction of the laser scanner can be changed
(-180° to +180° rotatable), allowing scans
of various shapes from optimum angles.
A calculated combination of
speed and accuracy
Nikon Metrology’s compact HN-C3030
solution is capable of inspecting all toothed
surfaces on a single automotive bevel gear
in only 5 minutes. The laser scanner acquires
surface point clouds at a rate of 120,000
points per second. This is a massive multiple
of the number of points that are measured
using classical tactile inspection. The result
is a full 3D scan of the part, while tactile
scanning only provides individual points
or scan lines. This detailed 3D digital copy
provides not only full shape or section
information, but also deep insight into the
surface waviness and tooth wear, hardly
detectable by tactile measurement.
Powerful acquisition software
combined with advanced
analysis
The main HN-C3030 software features
acquisition and analysis tools for optimum
scanning of various sizes, shapes and
surface conditions. Comparison of acquired
point clouds to original CAD file provides
colourful, easy-to-interpret 3D deviation
reports. However, for more advanced
gear inspection, dedicated gear software
enables easy creation of teaching files and
gear tooth analysis in the same format as
with conventional contact gear measuring
systems.
The highly operable solution
for a variety of applications.
The HN-C3030 particularly excels in the
measurement of highly detailed, complex
shapes such as hypoid, bevel, helical and
all other types of gears with a maximum
diameter of 300mm. It is also suitable for
inspection of impellers, blades, oils seals,
hob cutters etc. The HN-C3030 system
isn’t restricted to use inside of temperature
controlled rooms. At facilities such as
production sites, the HN-C3030 can be used
as a shop floor system when equipped with
the optional thermal regulator.
–20˚
+135˚
Rotatable laser scanner arm
Benefits
• Dense 3D scan provides better insight
into complex shapes (part-to-CAD
comparison, waviness, wear)
• Laser scanning offers high
measurement speed
• Non-contact eliminates the need for
probe tip compensation
• Higher resolution than tactile
measurement
• Reveal surface defects (e.g waviness)
not detectable by tactile probes
• Measure small parts or features
impossible for tactile probes
Compressor wheel for
automobile turbo charger
Hypoid gear Helical gearBevel gear
Profile error/lead error indicationInspection of all tooth surfaces on an automotive
bevel gear can be done in only 5 minutes
18. 18
CASP is a non-profit, charitable trust carrying out field-, literature- and
analysis-based geological research in prospective hydrocarbon basins.
Funding comes entirely from subscriptions by the oil and gas industry. CASP
members of staff publish the results of their research in internationally
renowned peer-reviewed scientific journals after a suitable delay.
Fieldwork forms the core of CASP’s work.
This not only involves field descriptions and
photographs of rock outcrops, but also the
collection of samples for analytical work
back in Cambridge. In the CASP laboratory,
microscopy is a core element of the research
work to enable the samples that have been
collected to be studied and categorised.
When it was established in 1975, CASP
focusedongeologicalresearchinsedimentary
basins of the Arctic, but its activities are now
worldwide, with current active projects in
Russia, Greenland, Canada, the Black Sea,
the Adriatic and Ethiopia, among other
locations. Another area of research is the
North Atlantic Margins, for which Dr Simon
Schneider is project leader. He received a
PhD in palaeontology in 2010 from Ludwig-
Maximilians-University, Munich.
The importance of efficient
microscopy
Dr Schneider explained,“The fossil specimens
that we analyse are often a few centimetres
in width and similar in height. In addition, we
look at a lot of 30- to 70-micron rock thin-
Nikon microscope allows highly
efficient rock sample categorisation
CASP researchers use advanced stereomicroscope for geological research
Dr Simon Schneider using the Nikon Metrology SMZ18
stereomicroscope at CASP.The screen is showing a close-up of the
bivalve image, showing the shell formed by calcite, and, on the right
side, part of the surrounding limestone matrix.
Case study
19. 19News I Volume 11
sections made using a diamond saw and
grinding machines, and these also measure
several centimetres across.
To view some of the fossils satisfactorily
under a microscope, we need a range
of different magnifications and more
importantly a reasonable working distance.
We had a couple of binocular microscopes
here on which the transmitted and incident
lighting was less than satisfactory. The
instruments also took a long time to set up.”
The alternative was to use a powerful Nikon
monocular microscope that had been in use
at the laboratory for many years, but its x200
to x2,000 magnification range was too high
to allow Dr Schneider and his colleagues
to assess the larger samples in detail and
to characterise easily the mineral and fossil
content of the rocks.
The latter instrument was fitted with a Nikon
digital microscope camera, so when CASP’s
researchers looked for a more efficient, lower
power stereomicroscope for their needs,
the prospect of a model from the same
manufacturer was attractive, as the same
camera could be used on both microscopes.
Nevertheless, a number of different makes
was reviewed before a Nikon SMZ18
research stereomicroscope was purchased
in the spring of 2015 from Nikon Metrology,
Derby (www.nikonmetrology.com). The
microscope has macro and micro imaging
in one manually controlled instrument for
convenient viewing and manipulation of
samples. A high performance lens provides
clear images with uniform brightness across
the entire field of view.
Dr Schneider confirmed, “The SMZ18 is a
brilliant microscope. It has 18:1 manual
zoom and our binocular eyepiece provides
a 22 mm field of view. The magnification
range up to x270 and the 60 mm working
distance of our objective are perfect for what
we need. The quality of the optics is world
renowned and the other crucial factor is
the effective episcopic (reflected light) and
diascopic (transmitted light) illumination of
our samples.”
The Nikon SMZ18 as a multi-
disciplinary tool
Simon Schneider is not the only researcher
at CASP to benefit from the new microscope.
Dr Michael Flowerdew, who received his PhD
from University College Dublin, is a geologist
specialising in geochronology and isotope
geochemistry. He uses the instrument for
extracting zircon grains from mineral samples
for radiometric dating purposes.
Another regular user is Dr Li Guo, who
received a PhD from Cardiff University,
and mainly studies the composition and
genesis of travertines, which are limestone
deposits formed by hot springs. Dr Guo
has recently used the camera to obtain
photomicrographs of a 3.5 mm wide sample
of fossil cyanobacteria, which obtained their
energy through photosynthesis and thus
grow in shapes similar to algae. The bacteria
colony studied was encrusting what appears
to be the stalk of a plant. However, this stalk
has mostly rotted away and been replaced
by diagenetic cements.The cyanobacteria are
in turn encrusted by layers of travertine, the
above mentioned, layered limestone.
Magnified 600 times, this photomicrograph shows biogenic calcite
crystals of a bivalve shell (grey) and their organic interlayers (brownish)
viewed in cross section.The compound of crystals and organics is what
makes shells both durable and elastic.
Cyanobacteria (the feathery structures in the central part of the left)
encrusting a potential plant stem (the dark element in the lower left
corner).The actual plant has mostly rotted away and been replaced by
diagenetic cements.The cyanobacteria are in turn encrusted by layers of
travertine.The width of the sample is 3.5 mm.
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20. 20
Stereoscopic microscope fitted with high resolution full frame camera
delivers superior image quality
His success stemmed from a series of images of natural
materials he captured using a high resolution document
scanner to produce designs for a collection of silk
scarves. Introduced in 2010 to the shelves of the Liberty
department store in London, the scarves quickly became
one of the shop’s best-selling lines. Two years later, four
of Prof Weston’s photographs enlarged to five metres
by three metres graced the entrance to accommodation
in the Olympic Village in Stratford during the London
Olympic Games.
Outside the fashion industry, his high resolution digital
images and 3D models offer a vast range of possibilities
in architecture and the design of urban spaces, gardens
and interiors, from printing or etching tiles and digitally
weaving rugs to decorating a wall or an entire building.
The work has led to increasing international recognition,
with recent magazine articles appearing in the USA, The
Ukraine and The Netherlands and two books on textile
design published in the UK.
Current work at the studio (www.richardwestonstudio.
com) is a far cry from early attempts to capture decent
pictures of a £143 ammonite specimen Prof Weston
bought in 2003 from a local crystal shop in Cardiff,
south Wales. He recalled, “My scanner cost less than the
Professor Richard Weston, a renowned
architect, lecturer and author of numerous
books on architecture and mineralogy has also
formed the Richard Weston Studio. The Richard
Weston Studio specializes in creating aesthetic
designs and artworks from small specimens
or minerals, fossils and stones. In 2011 he was
described by a UK newspaper, the Independent
on Sunday, as “the breakout star of Britain’s
Next Big Thing”, a BBC2 TV series in which
the buying teams of three high street giants
asked the public to supply them with the next
bestselling products.
Mindful distraction:
Therapeutic art created with
mineral photomicrographs
Case study
21. 21News I Volume 11
ammonite and resulted in a disappointing,
muddy brown picture”. In 2014, following
a conversation with a colleague at Cardiff
University, he was convinced that a Nikon
based photomicrography station was ideal,
leading to the purchase of an SMZ1270.
The stereoscopic microscope is equipped
with a Prior moving stage and a Z-axis drive,
both with a positioning accuracy of one
micron, a Nikon camera and sophisticated
NIS-Elements frame selection and stitching
software, all supplied by Nikon Metrology
(www.nikonmetrology.com). The scope of
projects that could be carried out increased
dramatically and so did the quality of the
images produced.
The highly controllable set-up allows a
sample to be illuminated with a combination
of transmitted and incident light to bring
out the best in a crystal structure. As the
absorption and reflection patterns of natural
specimens are different, it is possible to vary
the light sources so that two scans can be
obtained from the same mineral sample and
it is nearly impossible to detect any similarity
between the two images.
Individual frames taken of a specimen
are joined in Nikon Metrology’s advanced
NIS-Elements imaging software, which
helpfully selects the best focal plane for each
photomicrograph. The process generates
very high definition composites with file sizes
from tens or hundreds of megabytes up to
several gigabytes.
Before processing, nearly all minerals and
rocks are coated in a light oil, imparting
a flat surface that can be photographed
without light scattering from the rough-sawn
surface, saving the time and costs associated
with having samples polished. The other big
advantage of this approach is that there
are no remnants of polishing powder on
the surface to remove digitally, a procedure
that is time-consuming and sometimes
impractical. Each resulting image is subtly
colourful, intricately patterned and unique.
Following a recent discussion between Prof
Weston and a professor in the neurosciences
department at the Swedish University of
Agriculture, it appears there may be a health
benefit from viewing pictures of minerals in
our busy modern world. Apparently, there is
a therapeutic effect when looking at these
natural fractal patterns. They reduce stress
by engaging one part of the brain to create
a state of mindful distraction or fascinated
attention, similar to meditation, allowing
the tired prefrontal and parietal cortexes
to restore themselves more quickly after a
period of prolonged concentration.
Prof Robert Weston, wearing a shirt printed with one of his ammonite fossil photographs,
examines the agate crystal on the screen of the linked PC.
Prof Weston’s photomicrograph of an agate
sample
This image was taken from a sub-millimeter
specimen using the Z-axis capture function of the
Nikon Metrology microscope.
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22. 22
Subcontractor installs new ALTERA CMM and retrofits
Mitutoyo machine with CMM-Manager software
Nisan Engineering reduces
inspection time by a factor 5
Dinesh Prajapati, a director of Leicester-based
subcontract machinists, Nisan Engineering
(www.nisanengineering.co.uk), takes the view
that there is no point machining a component
if you cannot check that it is within tolerance.
The problem was that parts were becoming
increasingly difficult to inspect after the
company, which traditionally used 3-axis
CNC machining centres, installed a 4-axis
horizontal-spindle model and a 5-axis vertical
machining centre.
Much more complicated components were being
produced on these machines and some of the features
were impossible to inspect on the company’s manual
coordinate measuring machine (CMM), which dates back
to the 1990s. If the features were critical and could not
be inspected by hand using other conventional metrology
equipment, work had to be turned away, as in most
instances there would not have been time to send the
parts out for checking.
Purchase of an ALTERA 8.7.6 CNC CMM in early 2015
provided the solution. It is able to inspect the most
complex parts that Nisan produces and in addition, all
parts are measured in a fraction of the time that was
previously needed on the manual machine.
While the new CMM was being installed, Nikon
Metrology retrofitted identical control software, called
CMM-Manager, to the manual Mitutoyo BH504 CMM. It
considerably increased the speed with which components
can be inspected on what was rapidly becoming an
Case study
23. 23News I Volume 11
outmoded facility, giving it a new lease of
life.
Mr Prajapati gave a couple examples of
the significant benefits obtained using the
new CMM and the upgraded machine. The
first refers to a part produced on the 5-axis
machining centre that could not previously
be inspected at all, whereas it is an easy
process on the Altera. The second concerns
a 4-axis machined component that is now
inspected more comprehensively and faster
on the new CMM as well as on the Mitutoyo
with Nikon Metrology software.
5-axis machining productivity
maintained
The 5-axis job is an aluminium housing
measuring 172 mm in diameter by 52 mm
high that forms part of a turbine used for
renewable energy generation. After CNC
turning of the bore and outside diameter
(OD), the part goes onto a German-built
Spinner 5-axis VMC for a substantial amount
of milling and cross-drilling at various oblique
angles. One hole is at 30 degrees, another at
45 degrees and a third at 52 degrees.All are
of 0.8 mm diameter and
intersect at a point.
These holes could not practically be measured
on the manual CMM, even with the new
software, whereas it is an easy process on
theAltera using a very fine touch probe in the
Renishaw PH10T motorised indexing head.
The entire part is checked in two automatic
cycles taking a total of 10 minutes, including
automatic probe exchange, during which
time the operator is free to do other tasks.
Tightest tolerance is 10 microns total on the
OD and bore.
Mr Prajapati said, “Repeatedly repositioning
the head by hand on the manual CMM takes
half an hour each time. Doing this three
times to inspect the holes plus several more
times to access other features would take
five or six hours, far too long to be a viable
method of inspecting the turbine component.
Additionally, it would risk introducing
inaccuracies.
Then for example if a drill breaks during
production and needs to be replaced,
rechecking those machined features would
hold up production, further raising the cost
per part of manufacture.”
Comparison of CNC and
manual inspection
Examining the measurement of a family
of EN8 steel components that have been
produced in the Leicester factory for the past
two and a half years on an Akari twin-pallet,
4-axis HMC sheds light on the significant
advantages of retrofitting Nikon Metrology’s
CMM-Manager software to the manual
Mitutoyo.
The gas flow meter cylinders are machined
in 10 sizes from solid billets measuring from
74.5 to 145 mm in diameter and 270 to
557 mm long. A bore of between 34 and 65
mm diameter is machined during the first
operation, followed by drilling, tapping and
milling around the periphery during op 2.
Bores have to be accurate to 37 microns total
and other dimensions to between ± 0.1 and
± 0.2 mm, while the faces of the component
are tied up to the bore to within 50 microns
concentricity and parallelism.
Using the manual CMM and pre-existing
Mitutoyo software, inspection took 40
minutes. It was followed by conventional
handgauging of a threaded hole and
manual inspection of certain other inter-
related positional features that could not
be included in the CMM procedure, which
added a further 10 minutes.
With the Altera CMM the same process
takes just 9 minutes – less than one-fifth
of the time - and extra measurements are
taken resulting in a more comprehensive
inspection. The cycle has to be programmed
the first time,but on all subsequent occasions
it is available for immediate reuse.
The aluminium turbine component being inspected
in a cycle time of 10 minutes at Nisan Engineering,
Leicester.
“With the Altera CMM the same process takes
just 9 minutes – less than one-fifth of the time
- and extra measurements are taken resulting
in a more comprehensive inspection.
Mr Prajapati, director of Leicester-based subcontract machinists, Nisan Engineering
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