bowers in automotive

our expertise in your industry ISSUE 01

BOWERS IN AUTOMOTIVE • OUR EXPERTISE IN YOUR INDUSTRY Partners in Precision

Welcome toBowers inAutomotiveIn this edition of Bowers in Automotive,

leading bore gauge manufacturer,

Bowers brings you up-to-date with all

the latest developments in metrology

for your industry. Take a look at how

some of the solutions from Bowers

have helped revolutionise the working

practices of these organisations:

Carlisle Brake Products (UK) Ltdimproves the in-process measurement of

critical bores thanks to the Bowers XT

Analogue bore gauge. pg 1

Alcon Components Ltdlooks to specialised digital bore gauging

for the precise measurement of caliper

bore grooves. pg 2

Manuli Hydraulics UKturns to Bowers to help develop a

fail-safe, hose connection inspection

routine. pg 3

Musashi Auto Parts UK Ltdsuccessfully utilise a Bowers PC-2200

Air Gauging System to accurately

measure difficult-to-access camshaft

features. pg 4

David William investigated the available

alternative bore gauges. David explained, “As

we wanted to purchase a robust range of

internal gauges with a common operating

system that could be used on all of our many

bore sizes across the site, by both Production

Operatives and Quality Control personnel, we

needed to find a flexible, easy to use range of

internal micrometers. I found the answer to our

internal gauging needs in Bowers’ XT Analogue

range. Our new Bowers gauges are now in use

across the plant, helping to ensure the

dimensional integrity of our brake products.

Although relatively inexpensive, we have found

Bowers’ XT Analogue Bore Gauges to be easy to

use and extremely accurate.”

XT Analogue Bore Gauges are the 4th

generation of analogue internal micrometers

from Bowers. Through constant development

and enhancement the XT Analogue range has

evolved and improved and remains a global top

selling bore gauge. With the ability to measure

bores from 2 – 300mm (0.080” – 12”), length

extensions also enable the gauges to perform

precise deep-hole measurement. Manufactured

according to Din 863 part 4, Bowers XT

Analogue Gauges boast hard wearing, Tungsten

Carbide measuring faces on all 3-point

measuring heads larger than 12.5mm,

high visibility easy-to-read scales and

advanced ratchet stops to ensure consistently

accurate readings.

Boasting a long heritage of manufacturing

high-quality brake components in South

Wales, under the names of the company’s

well-known previous owners, ArvinMeritor,

Lucas Girling and Girling, Carlisle BrakeProducts was created in 2005 when

Carlisle Inc. acquired the Off-Highway

braking division of ArvinMeritor. To help

increase capacity and efficiency, the new

business was soon moved in its entirety,

including all employees, to a brand new

high-tech manufacturing and development

facility in Pontypool. Specialising in the design

and manufacture of ball-ramp brake assemblies

and hydraulic actuator products, ranging from

basic master cylinders to customised and

multi-functional boosted master cylinders,

Carlisle Brake Products (UK) Ltd can truly be

described as a full service provider – offering

complete technical support from initial concept

through to serial production.

An acknowledged global leader in the field,

with manufacturing sites in the USA, Europe

and Asia, the renowned Carlisle Industrial Brake

and Friction Group has earned an enviable

reputation for the high-quality of its products.

Reflecting the parent company’s ethos, the

impressive Pontypool site has invested heavily

in premium quality control equipment.

Having recently identified a need to improve the

in-process measurements of critical bores

located on the company’s boosted master

cylinders, Carlisle Brake’s Quality Manager,

Bowers Bore Gauges Won’t‘Brake’ The Bank

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109326_8pp_Automotive_Newsletter:Layout 1 23/6/09 14:54

BOWERS IN AUTOMOTIVE • OUR EXPERTISE IN YOUR INDUSTRY Partners in Precision22

company’s products means that bespoke

solutions to some of Alcon’s more unusual

measuring applications have to be sought. A

perfect illustration of the ingenious solutions

Alcon applies to difficult gauging problems is

the custom-built bore gauge system recently

supplied by Bowers Metrology UK.

Having sought an easy to use, ‘off the shelf’

solution to the precise measurement of a

pressure seal groove and a wiper seal groove,

located in the piston bore of a high

performance brake caliper, Carl Evans, Alcon’s

Quality Engineer was unable to find a standard

gauge that would match the company’s

demanding accuracy specification.

A chance conversation with a Bowers’ Sales

Engineer resulted in Bowers manufacturing a

specialised digital bore gauge. Carl Evans

enthused, “Based on Bowers’ XT Xtreme Pistol

Grip Digital Bore Gauge, our new measuring kit

has measuring anvils that match the profiles of

our caliper bore grooves. By pulling the gauge’s

trigger, the instrument’s anvils retract allowing

entry into the bore, releasing the trigger enables

the contacts to locate accurately into our

difficult to access grooves. The resulting

diameter measurement is then instantly

displayed on the gauges digital output.”

“The micron capableBowers gauges areextremely repeatable,they have speeded-upa previously timeconsuming inspectionroutine and haveproven very popularwith our machineoperators.”

“Although we normally employ our new gauges

on brake calipers post production, it is useful

that, due to their impressive fluid resistance, we

are able to measure components that remain

located in our machine tools. The higher

magnitude of dimensional measuring accuracy

the Bowers kit has delivered, enabled us to

Established in 1984 by engineer and sports

car racer John Moore, the well-known

brake and clutch product manufacturer,

Alcon Components Ltd now employs

more than 80 staff at its global

headquarters and impressive manufacturing

facility based in Tamworth, Staffordshire.

Complementing the work of technical sales

personnel located in the UK, the USA and

France, Alcon has a network of distributors

situated throughout Europe, Africa and

Australasia. Alcon’s comprehensive range of

brake and clutch products are able to satisfy an

extremely wide spectrum of customers, from an

F1 designer seeking a bespoke solution, to an

enthusiast building a race car on a tight budget.

Equally an OEM project engineer with a new

performance car programme to support is able

to find all of the help he needs.

Within the challenging world of motorsport, as

well as enjoying official Technical Partner status

with the Honda F1 Racing Team for the past 7

years, Alcon’s advanced brake hardware is also

used by a number of other prominent F1 teams.

Alcon’s advanced brake hardware is also

supplied to Citroën, helping Sebastien Loeb to

dominate the demanding World Rally

Championship [WRC] in recent years.

Reflecting the global popularity of the

company’s products, the motorsport

departments of Audi, BMW, Ford, Peugeot,

Renault and Volkswagen are all valued Alcon

customers. Whilst In the USA, every IRL title

since 2003 has been won using Alcon brakes.

Well-known, front-running NASCAR customers

include the famous Penske, Joe Gibbs Racing

and Richard Petty Motorsports teams.

In the field of specialist and performance road

cars, Alcon serves an impressive list of

prestigious road car manufacturers, including

Audi, Bentley, Brabus, Jaguar and Land Rover.

The company’s reputation for technical

innovation is illustrated by the advanced brake

calipers it supplies for the Bentley Continental

Supersports and Audi RS6.

The safety critical nature of Alcon’s products

dictates that the company runs an extremely

stringent quality control regime. In addition to

employing a full range of high-tech inspection

equipment, the specialised nature of the

BOWERS ‘BRAKE’ THROUGHIN MEASUREMENT

recently undertake a rigorous process

capability study. The result of this exercise has

delivered considerable process improvements

and a reduction in the purchase of

consumable tooling.“

Bradford based Bowers describes its

state-of-the-art XT Xtreme range as the ideal

solution to bore gauging within hostile

measuring environments, such as in close

proximity to Machine Tools. The impressive, XT

Xtreme Bore Gauging range has advanced new

electronics boasting a very impressive IP65

rating, rendering them resistant to coolant and

water. Amongst a long list of useful features

incorporated into these radical, tough

instruments are: a clear digital display,

metric/inch conversion, RS 232 output and

hardwearing extended travel carbide measuring

anvils. Available to measure diameters up to

300mm, as with Alcon, Bowers is able to

manufacture affordable ‘one-off’ XT

instruments to cater for many none standard

internal measuring applications, such as

threads, grooves and splines.


For more information visit www.bowers.co.uk Partners in Precision 3

Bowers Quality Takes The PressureWith manufacturing anddistribution facilities in most ofthe world’s industrialisedcountries, the renowned ManuliRubber Industries Group isregarded as one of the globalleaders involved in themanufacturing and sale ofhydraulic hoses and connectors.As failure in the field of any ofthe company’s comprehensiverange of products could havedisastrous safety consequences,in addition to severe financialimplications, Manuli ensuresthat quality is at the core of allof the company’s activities.Based in Patricroft, Manchester,Manuli Hydraulics UK (part of MRIGroup) pursues a philosophy ofconstantly upgrading and improvingthe company’s quality systems andinspection routines. A study of themethods used to measure theeffectiveness of the hi-pressurecrimping process, used to secureconnectors to the company’s hoses,resulted in the creation of animaginative new measuring system.

In search of a fail-safe, hoseconnection inspection routine,Manuli Hydraulics UK contactedBowers Metrology. In cooperationwith Manuli Hydraulics UK, Bowerswas able to develop a range of

specialised bore gauging heads.When fitted to Bowers XT digitalpistol-grip gauges, the ingeniousbore gauging heads are able toaccess the critical internal areas ofhose connectors and measure thediameter of an assembly prior to itbeing pressure crimped on to thehose, and then again after thecritical crimping process takes place.The post crimping, reduced diameteror ‘collapse’ of the assembly has adirect bearing on how securely thehose and connector are joined,and by extension the assembly’sperformance in the field.

By collecting data, via the newBowers digital bore gauging system,Manuli Hydraulics UK is able tocontinuingly monitor its crimpingprocesses across the company’sentire range of hoses. The gathereddimensional information allows thecompany to make minor changes totheir presses, enabling them to applythe optimal amount of pressure toensure the ideal ‘collapse’ diameterof connectors to be achieved.

Richard Walker of Manuli HydraulicsUK explained, “Mindful of the factthat our hydraulic hoses can besubjected to pressures exceeding420bar, the reliability of ourconnector to hose crimping process

is of vital importance to us. As ourBowers bore gauging systems haveclear digital displays and areactuated by simple triggers, theyhave proven to be very popular withour operators.”

“We are able to gather

data from the gauges

without the need for

cumbersome cables, due

to the gauges’ advanced

Wi-Fi capability.”

“I am pleased to report that theBowers gauging system has enabledus to achieve zero defects within thisimportant company process.”

KEEPING YOU IN THE KNOWBowers Metrology has been manufacturing high quality bore gauging

systems for over 50 years and the demand for ‘special’ gauging systems

to suit our customers’ specific requirements has never been greater.

To help keep you up-to-date with all our latest Special Applications, a new

brochure has been released. With the use of simple line drawings, the brochure

describes some of the most popular applications based around our standard

range of flexible gauging systems. By changing either the measuring anvils or the

measuring head, our products can be converted economically into ‘special’

gauges to solve our customers’ specific problems.

To request your copy of the brochure, simply email your details to:

[email protected]

Special ApplicationsFabrications SpécialesSonderanfertigungen



When faced with the need to find an

extremely accurate way of measuring critical

camshaft features, David Moore contacted

Bowers UK and related his extremely

demanding gauging requirements to their

technical staff. David explains “In addition to

investing in state of the art CNC Machine Tools

to help uphold the Company’s reputation for

the quality of our output, Musashi regularly

invests in equipment that ensures our valued

customers continue to receive Automotive

products of the highest possible standard.

Having identified the need for an advanced

Air-Gauging system that could accurately

measure difficult to access camshaft bearing

journal diameters, within Machine-Tool cycle

times, I undertook a web-search in order to

compile a list of potential suppliers. Having

examined the merits of several alternative

Air-Gauging providers, the ease of use,

accuracy, repeatability and not least the price of

the Bowers system convinced me to choose the

Bowers option. Bowers designed and delivered

a range of easy to use Air Snap-Gauges linked

to Bowers PC2200 Air Columns. The great

success of the first Bowers Air-Gauging

measuring station installation convinced me to

extend the scheme into several other areas of

our busy Camshaft manufacturing facility. The

significant contribution our Bowers Air-Gauging

has made to the continued quality of our

output and the enthusiasm for the system

shown by our operators means that our

Air-Gauging programme will soon be rolled-out

to other areas.”

Designed to withstand the rigours of a harsh

shop-floor environment, Bowers advanced PC

2200 Air/Electronic Measuring columns

can be linked to a PLC or Logic controller

and boast a multitude of features

including metric/imperial conversions,

3 colour LED display, status indicator,

2-4 probe input, probe mixing (A+B),

(A-B), static/dynamic mode –

Max –Min -TIR, Tolerance limit

setting, approach limit setting,

calibration Max/Min, accuracy

0.5% full scale +/- resolution,

RS-232 output.

Bowers Metrology UK has earned a

reputation second to none for providing

cost-effective, innovative Air-Gauging

solutions to the measuring needs of the

UK’s Automotive Industry. The considerable

experience gained by Bowers within this

demanding field enables it to provide a large

range of ‘off-the-shelf’ Air-Gauging solutions

and also to design and deliver cost-effective

bespoke fixtures and accessories, enabling the

most demanding of Air-Gauging measuring

applications to be undertaken.

Typical of Bowers many satisfied customers is

David Moore, Quality Manager at the high-tech

Musashi Auto Parts UK Ltd manufacturing

plant based in Blackwood, South Wales.

Boasting an impressive 70-year history of

manufacturing a wide range of automotive

parts in its manufacturing plants situated in

North and South America, Asia and Europe,

the multinational Musashi Corporation’s

customer base reads like a ‘who’s-who’ of the

automotive world, demonstrating Musashi’s

enviable reputation for the high quality of

its wide range of Automotive products.

BOWERS ‘AIR TIGHT’ CASEFOR QUALITY



BOWERS SMARTPLUGSThe robust, easy to use SmartPlug range is designed to give the operator greater speed of use, unmatched measuring

accuracy and superb repeatability, especially in harsh shop-floor environments. Advanced hand held ergonomics allied to

an ingenious mechanical / electronic system render SmartPlugs the easiest to operate Bowers bore gauging system to

date. The flexible nature of Bowers SmartPlugs range means that they can be supplied fitted with easy to read electronic

indicators (ideal for automatic data collection), conventional analogue indicators, or transducer probes linked to remote

digital readout units.

Features• Range 6 - 280mm

• Tough, robust construction

• High accuracy dedicated plug-gauges

• Hand-held measurement

• Protective indicator shroud (with some

indicators)

• Repeatability ≤1 µm

• 2 - point measurement as standard

• Depth-stops available

• Extensions available for deeper bores

• Guide chamfer for easy entry into bore

• Plug body coatings: Hard-chrome

(standard), T.i.N., Plain steelSmartPlug with TiN

coated body

SmartPlug with ceramic contacts

SmartPlug with

depth stop

SmartPlug with transducer holder

and standalone display

For more information on our range of SmartPlugs and Air Gauging productsEmail: [email protected]

BOWERS AIR PLUGS AND RINGS

Bowers offers the mostcomprehensive range ofstandard air plugs, rings,calipers, etc, currently available.To complement this service wealso produce bespoke air gaugingproducts to help solve customer’sspecific measuring problems.Our hi-tech manufacturing plantincorporates a first class UKAScalibration laboratory, ensuringthe quality and accuracy of ourair gauging products.

Features• High resolution

• 3mm to 150mm diameter

• High repeatability

• Non contact

• Static or dynamic measurement

• Multi parameter measurement

• Compatible with instruments from other sources

• Air plugs for internal measurement

• Air rings and calipers for external measurement

• In-cycle, in-process and post-process

Straightness

Parallelism of 2 Bores

Concentricity of 2Inside Diameters

Taper

Simultaneous Int/ExtMeasurement

Centre Distance of 2 Holes



IF YOU’RE BORING, WE’RE MEASURING:

BOWERS’ GUIDE TO BORE GAUGINGAs a general trend, it is safe to saythat engineering tolerances arebecoming tighter and parts morecomplex than ever before. This, initself, is not a problem for mostengineers, as generally the rightmeasuring instrument for the job isimmediately to hand. When chasingmicrons the gauge of choice couldbe a height gauge, an externalmicrometer, or any of a myriad ofstandard gauges. But what if thepart to be measured contains boresthat need to be sized? The obviousanswer to this problem is a boregauge — but which one? There arenumerous varieties of instrumentsavailable from many manufacturers,all of which have their own uses,characteristics and prices.

Most bore gauges rely on the use ofring gauges or similar ‘masters’ as ameans of setting them, thesemasters also act as an occasionalreference check when in use. Somemanufacturer’s include ring gaugesas standard in their bore gaugingsets, indeed some also supplytraceable certification as part oftheir standard package, bare this inmind when comparing prices.

As the world’s largest bore gaugemanufacturer, Bowers Metrologyboasts the widest choice of internalmeasuring instruments. Here weexplore some of the more readilyavailable instruments, and hopefullyhelp you make an informed decisionon the most appropriate gauge forthe job in hand.

Bore Gauges: Analogue orDigital?

Universally perceived as the mostflexible of options, the internalmicrometer bore gauge such as theBowers XT Digital Xtreme or XTAnalogue has evolved over theyears into an internal measurementall-rounder. With each interchangeable

head covering a wide measuringrange and a systems capacity of over300mm, these affordable, simple tooperate gauges are perfectly suitedto most applications, whether in aninspection department or indeed onthe shop-floor.

The first decision to be made is aneasy one, digital or analogue? Whilstthe later is less expensive and stands-up well to the rigours of oil andcoolant, they can be more difficult toread. As analogue gauges cannottransmit their readings to externaldevices, they are not appropriate forconnection to printers or datacollection devices.

For a relatively small premium thepurchase of a digital micrometerbore gauge can be made, although

the early variants had a reputationfor being susceptible to coolant, themodern generation of advancedelectronic instruments are shop-floorproof in all but the harshest ofenvironments (Bowes XT Xtreme hasa high protection rating of IP65). Incommon with other digital gauges,these simple-to-operate bore gaugeshave an output allowing them to belinked to SPC devices, printers etc.

Digital bore gauges are available intwo basic formats; the traditionalinternal micrometer style, activatedby a ratchet, replicating theergonomics of the traditionalanalogue internal micrometer orelectronic pistol-grip gauges (such asthe Bowers XT Holematic).Characterised by applying their ownbuilt-in constant measuringpressure, these gauges require verylittle operator input in terms of skill,and can be operated with one hand,yet they retain remarkableconsistency. These two digitaloptions usually share the same levelof accuracy and repeatability and aresimilar in price. Bowers digital boregauges can also be fitted withspecialised heads; enabling theconvenient measurement of amultitude of internal features suchas splines, threads, grooves—furtherincreasing their usefulness and costeffectiveness by solving difficultmeasuring challenges.

The Bowers XTA Analogue Bore Gauge

The Bowers XTD Digital Bore Gauge

The Bowers XTH HolematicXtreme Bore Gauge



Two-Point or Three-Point?

Having resolved the analogue v.digital question, a further decisionmust be made; to purchase a boregauging system with two anvilcontacts or three? Two anvil gauges,although more difficult to use, areideal for checking the ovality of abore, whilst the more common threepoint bore gauge is easier to use, selfcentring and represents the perfectoption for an all-round, accurateshop-floor bore gauge.

Internal Caliper Gauges

A time honoured, traditionalsolution to the problems raised bythe measurement of plain bores andbores with features such as groovesetc, but generally only capable ofaccuracies of 0.01 mm. Calipergauges are readily available in awide selection of shapes and sizeswith long or short reach legs andvarious options for contact pointsetc. Bowers offers a wide range ofoff-the-shelf TGM caliper gauges,but will also produce inexpensiveone-off gauges in both internal andexternal formats to suit anyparticular application. Mostengineers will be familiar with thelong established analogue internalcaliper gauges, but as with mostareas of metrology, digital versionsof these instruments are nowgaining in popularity.

Split Collet Gauges

Consisting of a split collet connectedto a clamping device, which holdseither an analogue or digitalindicator, these durable instrumentscan be mounted on a stand for rapidgauging of batch parts, are easy touse, but are limited by the smallrange of sizes that can be measuredby each collet.

Indicating Plug Gauges

Indicating plug gauges, such as theBowers SmartPlug are ideal foruse within the harshest of measuringenvironments. Indicating plugs aremanufactured to a size just belowthat of the bore to be measured.These gauges are dedicated to one

size only, but are extremely simple touse. The operator simply inserts thegauge into the bore to be measuredfor an accurate and repeatablereading to be displayed via a digitalor analogue indicator.

Cylinder Bore Gauges

Suitable for most environments andapplications, these well-proven,traditional gauges are self-centringand due to their shape are ideal formeasuring down deep cylindricalshapes. The two-point format of thecylinder bore gauge enables thegauge to detect ovality as well asgeneral diameter measurement.

Air Gauging

Air gauging, such as the Bowers2200 System offers a simple touse, maintenance free answer toshop-floor bore gauging. Capable ofmeasuring other parameters such as

slot widths, straightness, taper andconcentricity, as well as plain bores,this flexible alternative scores highlyon usability. Although relativelyexpensive, it’s hard wearingcharacteristics should ensure troublefree measuring and longevity of use.Its downside is its dedicated nature,as the measuring heads will onlymeasure over a limited range.Recommended for intensive use onthe shop floor where high accuracyreadings are required.

Go/No Go Plug Gauges

Traditionally the most basic form ofbore gauging has been the use ofGo/No Go plug gauges. Ease of useand ruggedness characterise thesesolid comparative gauges. Thedownside of plugs is their dedicatednature, covering only one specificsize, these gauges can be deemed tobe subjective, in that operator ‘feel’can influence the gauges findings.The result they give the user is asimple one, i.e. the measuredbore lies outside or withindrawing tolerances.

Specialised Large DiameterGauges

There is no catch-all, generic term todescribe this diverse grouping ofinstruments, but gauges such asBowers’ Universal Gauge hasmodular extensions to enable largediameters to be accommodated.Further flexibility is built in to thesemodular gauges by the wide rangeof retrofit-able accessories available,enabling a wide variety of featuressuch as grooves, threads, undercuts,etc to be measured. As the titlesuggests large bores are easilymeasured with these gauges, indeedbores of more than three meters canbe tackled with confidence.

[email protected] find out how Bowers can help yousolve your measuring challenge.

Bowers has available both digitaland analogue versions of its

Cylinder Bore Gauge



Product Focus: Intex - A Closer Look

THE NEW BOWERS

INTEX BEAM GAUGE

Features of the Intex Beam Gauge:• Lightweight and rigid - typically weighing

less than 2kg• Internal and external measurement• 2mm travel on moving contacts• Adjustable fixed contacts with a range of

adjustment up to 250mm• Digital or mechanical readout display• Hardened steel wear pads locate gauge

Developed to measure both internal andexternal diameters and lengths, theBowers Intex Beam Gauge’s aluminiumextrusion beam gives it a rigid, yetlightweight quality – making it ideal forshop-floor environments.

The simple release of a locking thumb screwenables the gauge’s measuring direction to bechanged easily and quickly. The four gauges inthe Intex range have been designed to measurecomponents from 200mm up to 1m long –extended lengths are available on request.

on to the component aiding accuracy,repeatability and prolonging the life ofthe instrument

For more information email [email protected].

Designed to accurately perform astaggering variety of measuringtasks, Bowers Metrology has launchedits UniCal multi-purpose digitalcaliper range.

Available in standard 300mm, 600mmand 1000mm capacities, with largerversions available upon request, Bowers’revolutionary new technology boasts tough,lightweight reinforced beams, givingthem incredible strength and anamazing weightlessness.

Bowers’ flexible UniCal’s advanced featuresinclude a large, easy to read digital display,a preset facility, a constant measuring force,a metric inch conversion and a RS232 dataoutput port.

Although a wide range of standard UniCalaccessories enable a multitude ofmeasuring tasks to be performed, for moreunusual applications Bowers willmanufacture ‘one-off’ adaptations allowingthe most difficult of gauging routines tobe undertaken.

For more information about theUniCal email [email protected]

Measuring contacts for face-groove and V-groove

ø measurement

Shoulder anvils Code: TGUA 011

Semi-cylindrical anvils Code: TGUA 012

Disc anvils Code: TGUA 013

Cylindrical measuring pins

Product Focus: UniCal – Flexibility at Your Fingertips

A TOTALLY NEW

SOLUTION FROM BOWERS


bowers in automotive

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