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Selecting the Right Dimensional Inspection Equipment
Are you an engineer, quality assurance manager, technician, or business owner? Are you
considering purchasing dimensional inspection equipment and are unsure what steps to take?
This e-book will help guide you through the selection process so you can move forward with
confidence and clarity.
Virtually any physical characteristic that is specified can be measured through dimensional
inspection.
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Selecting the Right Dimensional Inspection Equipment
Different companies use dimensional inspection for different reasons, but in almost every case
where measuring an object is required, it’s important to measure with precision and accuracy.
In all of these cases, verifying an object through dimensional inspection can help reduce
liability, improve quality, and save you time and money down the road.
For every object you can imagine, from a nano-scale surface to a turbine in an aircraft engine,
there are numerous measurement opportunities. There are also multiple ways to execute
each measurement technique, and multiple devices and manufacturers from which to choose.
The primary objective when investing in dimensional inspection is to find a device that:
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Selecting the Right Dimensional Inspection Equipment
In addition to the above criteria, there are numerous other factors to consider:
The remainder of this e-book is designed to help you identify your dimensional inspection
needs, narrow your equipment options, and select a provider to shepherd you through the
purchasing process.
Therefore, one of the most important decisions when purchasing dimensional inspection
equipment is selecting the right type of sensor. This will depend largely on the characteristics
of the object being measured and may include touch sensors, non-contact sensors, or a
combination of both types.
To narrow down the options, answer a few key questions about the nature of the object:
§ Is the object rigid or pliable? Rigid objects can often be measured with either a touch
probe, laser, or camera sensor.
§ Is the object’s surface reflective? If the surface is reflective, a laser may not be
appropriate as the measurement results may be incorrect as a result of light scattering.
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Selecting the Right Dimensional Inspection Equipment
§ Does the object have internal geometry that cannot be seen? If the object has
cavities or passageways, specialized equipment that incrementally slices the object—or
can see through it using computed tomography—may be needed to measure these
surfaces.
Tolerance Requirements
Equally important as selecting the right sensor type is ensuring that you understand and meet
your tolerance requirements. In dimensional measurement, tolerance refers to the acceptable
deviation from the desired outcome. For example, a medical device may need to be within one
or two microns of the required length in order to pass an inspection. On the other hand, a toy
part may have a higher tolerance in the range of millimeters.
Understanding the required tolerance levels will help you select the right type of dimensional
inspection equipment. Think about the difference between measuring with a ruler versus
calipers. You can achieve a much higher degree of accuracy and precision with calipers. Now
think about measuring with calipers versus an indicating micrometer with even higher accuracy
and precision. While an indicating micrometer might be able to achieve the highest level of
accuracy and precision, calipers may suffice (and will be more affordable) if your tolerance
level is not so tight.
Portability
This is typically an easier question to answer, but it does narrow the type of equipment you
need to purchase. Will you be taking measurements in the field or at a single location where
the equipment can remain stationary? Most of the time the choice will be obvious. However,
if you are uncertain, think carefully about how you will use the equipment in the future. While it
might be tempting to purchase portable equipment to have more flexibility, if you truly do not
require portability, you may be sacrificing other features that you could get with stationary
equipment.
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Selecting the Right Dimensional Inspection Equipment
You can put a turbofan blade into a machine to analyze its contours, but you cannot do the
same with an entire aircraft. Dimensional inspection equipment can also be used to determine
metrics such as the space between bolt holes, but only if you use a probe small enough to
enter the holes. Knowing the size of all the objects you intend to measure will help you select
the right equipment and accessories.
Objects that have internal geometry require different measuring methods than those that do
not. You may need to purchase accessories that enable internal measurements or use
specialized equipment dedicated to that purpose. The shape of the object can also impact the
type of equipment you purchase. For example, if you need to measure the form of a small
screw thread you will either need a contact sensor that has a small enough tip to reach all the
geometry, or a noncontact optical sensor with sufficient magnification.
Speed
Do you need to get immediate pass/fail (attribute) quality control results as objects come off a
manufacturing line? Or do you require variable data results with more comprehensive data
that allows you to understand by how much an object did not pass inspection and possibly
why? Of course, there are countless other scenarios, but as with other factors, understanding
your requirements will help you make the right choice. If you don’t need real-time results, you
can often get all the information you need with less expensive equipment.
Automatic or Manual
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Selecting the Right Dimensional Inspection Equipment
Ease of Use
Maintenance Requirements
How often does the equipment need to be calibrated? Can your staff maintain it or will you
need to call a qualified technician? What type of support does the manufacturer or reseller
provide?
Ongoing cost and time commitments should be carefully considered before you decide which
equipment to buy, as it can have a long-term impact on your operating budget.
Whether you need dimensional inspection equipment for a continuous quality control process,
as part of first article inspection, an inspection sampling plan, or a research and development
project, you want to be confident that the equipment will function properly every time you use
it.
Even if you know exactly what type of equipment you need, you still have to choose between
various manufacturers. How will you know which one provides the best quality and value?
Unless you are experienced in purchasing and using this type of equipment, you will likely
need some guidance from an expert.
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Selecting the Right Dimensional Inspection Equipment
Budget
Last, but certainly not least, you must consider your budget. As mentioned throughout this list,
the purchase price is not the only factor that impacts the budget for dimensional inspection
equipment. You must also consider the costs of:
All of the above factors also impact the total cost of ownership. Equipment that has higher
precision and provides faster results will typically cost more, so if you don’t need a high degree
of precision or speed, you may be able to save on the cost of equipment while still achieving
the results you desire.
Portable and generally easy to use, precision hand tools are often capable of providing all the
information you need.
§ Bore and ID gages measure the internal diameter of an object, either by indicating the
deviation from a predetermined standard or by providing an actual measurement.
§ Calipers provide inside, outside, depth, length, or step measurements using various
technologies. Certain types can also be used to compare or transfer dimensions from
one object to another, or to precisely mark a measurement.
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Selecting the Right Dimensional Inspection Equipment
§ Micrometers are used for precision dimensional gaging and may use mechanical,
digital, dial, scale, and laser technology. Micrometers can be used to measure the
thickness, length, depth, internal diameter, outer diameter, height, roundness, or bore of
an object.
§ Protractors and angle gages measure the angle between two surfaces. They can be
fixed or variable depending on the intended use, and may be designed to provide other
functions such as simultaneous depth measurements.
§ Indicators and comparators amplify the movement of a precision spindle or probe and
display the results on a dial, digital display, or column. Different levels of precision are
available for a range of applications.
§ Air metrology instruments use changes in pressure and flow rates to measure
parameters such as thickness, depth, internal diameter, outer diameter, bore, taper and
roundness.
§ Ring gages provide a pass/fail assessment for shafts, pins, or threaded studs based on
specified dimensional tolerances. Depending on the application, ring gages may be
tapered, cylindrical, threaded, or smooth.
§ Rules and length gages are used for length measurement, and much like a measuring
tape or a ruler, have a flat, graduated surface. Linear scales and length gages can also
be used for higher precision and remote displays.
§ Thread gages measure and/or verify thread size, spacing, shape, geometry, or other
parameters.
Contact Sensors
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Selecting the Right Dimensional Inspection Equipment
§ Articulating arms are another type of CMM that use rotary encoders on multiple axes
of rotation. Instead of linear scales, articulating arms determine the position in space of
the hard probe or touch probe (laser probes are a common accessory). Such systems
are manual in nature but are portable and able to reach around or into geometry in a
way that cannot be accomplished with a conventional CMM.
§ Form and contour tracers are purpose-specific devices that use high accuracy
continuous contact sensors with varied styli to obtain small part geometry such as fillet
radii and chamfers or that measure roundness, cylinidricity, and other geometric
tolerances.
While this is not a complete list of the types of contact sensors available, it does cover the
major categories that you are likely to encounter.
In many cases, the object being measured cannot or should not be touched by a probe or any
other part of the measurement device. In these cases, visual inspection equipment may be
most appropriate.
§ Optical comparators use light projected upon a screen to obtain a magnified silhouette
or shadow of the object of interest. Measurements can be made by articulating the table
axes to obtain width and height. Physical overlays are commonly used for complex
shapes and quick-checks. Modern systems can employ fiber optic edge detection as
well as automated movement and measurement.
§ Vision systems are similar to optical comparators, but instead project light directly onto
a screen while a camera with interchangeable objective lenses and/or zoom optics
relays images to a display. Most systems have edge detection and other sophisticated
capabilities. Automation via a computer and controller is common, and some systems
even come with multiple sensors including laser and touch probes.
o Structured light scanners – Sometimes also called white light scanners, these
devices use light from halogen or LED lights to project a pattern of pixels onto the
object. The pixels are distorted by the surface of the object and measurements
of the light pattern can be used to reconstruct a 3D image.
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Selecting the Right Dimensional Inspection Equipment
The type of 3D scanning you should use will depend on ambient light conditions, the
surface characteristics of the object, and the degree of speed and accuracy required.
§ Help from the beginning – Selecting the right dimensional inspection equipment
requires evaluating many variables to ensure that the specifications of the equipment
you select will adequately meet your needs. You could try wading through these
complicated decisions on your own, or you could work with a reseller that is an expert in
such matters.
§ More equipment options – Individual manufacturers sell only their own equipment,
which typically means you will have only one or a few models from which to choose.
While you might be able to find the right equipment to match your needs, you won’t be
able to compare costs or weigh the many other factors that contribute to your
purchasing decision.
§ Lease or buy – Purchasing dimensional inspection equipment is not always the best
financial decision for your company. You may not have the cash flow to make an
outright purchase, or you may only need the equipment for a limited period of time.
Many resellers give you the option to lease equipment, freeing up more cash in the
short term and giving you the flexibility to return the equipment when you’re finished
with it.
§ Unbiased advice – An individual manufacturer will naturally tell you that their
equipment is the best. While this may be true in many cases, you can hardly say that
this is an unbiased opinion. Individual manufacturers or distributors who carry a limited
number of brands also might not know if there is another solution that will better meet
your needs. A qualified reseller can provide unbiased recommendations based on your
requirements, not just an effort to close a sale.
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Selecting the Right Dimensional Inspection Equipment
§ Validation – After your equipment has been set up and you begin operating it, you
need to be sure that it is functioning properly. Getting consistent results does not
always mean that you are getting accurate results. Some resellers provide validation
services to confirm that the results you are getting are indeed correct.
§ Collaborative process – Look for a reseller that will work closely with you to find the
best possible solution. They should ask a series of questions about application,
tolerance requirements, speed, accuracy, how you intend to use the equipment, human
resources you have available, and your budget. You
should feel like the reseller is your partner, not a
salesperson!
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Selecting the Right Dimensional Inspection Equipment
§ Various purchasing options – Maybe you don’t need to purchase new equipment
outright. Perhaps pre-owned equipment will meet your needs and be better for your
budget. Or maybe you just need equipment to support a limited R&D phase. Look for a
reseller that has flexible purchasing options and other alternatives so you can get
exactly what you need without over-spending or making a long-term commitment.
§ Unbiased advice – Just as an individual manufacturer will promote only their own
models, a reseller that sells only a handful of brands will be naturally biased toward
those brands. A diverse product line helps ensure that the reseller can offer truly
unbiased recommendations. Your reseller should provide several options with clear
information about the advantages and disadvantages of each, so you can make an
informed decision about which dimensional inspection equipment to purchase.
§ Dimensional inspection expertise – Look for resellers that also offer dimensional
measurement services and use dimensional inspection equipment in their own labs. A
reseller that also provides consulting or outsourced measurement services will have a
deeper knowledge base than a company that only sells equipment. They will also be
more informed about the latest technology because they have to stay on the cutting
edge to provide the best services to their clients.
§ Equipment setup and validation – Obtaining the equipment is just the first step in the
implementation process. If your reseller does not provide setup and programming
services, you’ll have to take the time and expense to find another service provider that
does. Look for a reseller that provides full-service integration so you can purchase and
implement your equipment in one smooth process.
§ Flexible training options – Not every application is the same. In some cases you may
need to be trained on-site or in the field. In other cases a group training session at the
reseller’s facility may be appropriate. If you are installing dimensional inspection
equipment on a manufacturing line that runs constantly you may need to train
employees outside of normal business hours. Look for a reseller that offers flexible
training solutions that will best meet your needs.
§ Ongoing support – How often does your equipment need to be calibrated? Does the
manufacturer require a certified technician to do repairs? What maintenance schedule
do you need to uphold in order to keep the warranty valid? Look for a reseller who will
not only answer all of these questions, but who can also help you maintain the
recommended calibration and maintenance schedule.
Remember, you want a reseller that feels like a partner, not like a salesperson. This means
working with you through the entire equipment acquisition process, not just helping you buy the
equipment.
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Selecting the Right Dimensional Inspection Equipment
4. Programming – You can’t be expected to know how to program your equipment the
first time you use it. That’s why we do it for you. As you learn the nuances of
programming and operation, you can use our expertise to help you become more
knowledgeable. We can also help you with first article inspections and gage
repeatability and reproducibility, or run capability studies.
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Selecting the Right Dimensional Inspection Equipment
5. Validation – You can’t be sure your tests are completely accurate unless the results are
verified independently. We’ll run the same dimensional measurements in our lab to
confirm that your equipment is functioning properly and operating correctly.
Q-PLUS is the partner you need from beginning to end when purchasing dimensional
inspection equipment. We’ll help you select the equipment that best matches your specific
needs, taking into account a range of factors to determine the optimum solution.
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