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[ ENG ] KOCOS AUTOMATION KOCOS - THE TECHNOLOGY GROUP | WHERE PRECISION MEETS QUALITY Optical 3D measuring systems LOTOS

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[ ENG ]K O C O S A U T O M A T I O N

KO C O S - T H E T E C H N O L O G Y G R O U P | W H E R E P R E C I S I O N M E E T S Q UA L I T Y

Optical 3D measuring systemsLOTOS

Three-dimensional measurement with LOTOS

LOTOS automatic measuring systems can measure the full outer contours or individual areas of any measurement object quickly and precisely, irrespective of the shape. The three-dimensional, non-contact measurement is carried out using optical measurement sensors with accuracy in the µm range.

The  result  is  a  representation  of  the  measurement  object  as  a  3D  model. Powerful,  intuitive  software  allows  the measurement  results  to  be  assessed extremely quickly. 

Easy  integration  into  any  data  environment  as  well  as  traceability  and reprocessing for all measurements make these measuring systems suitable for an extremely wide range of applications.

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LOTOSLOTOS

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Measuring system for a wide range of applications

LOTOS systems make it possible to make a three-dimensional measurement of the entire contour or of a freely definable section of any measurement object. The object is turned on a rotary stage for the measurement. At the same time, a high-precision vertical measuring stage is used to move a multi-dimensional laser sensor along the measurement object to measure its entire outer contour. This contour can then be tested fully automatically for pre-defined geometrical properties.  Because  of  the wide  range  of  possible  uses,  applications  for  in-process  testing  and  for  quality  testing  exist  in  many  areas,  including  the following:

  Machine / plant engineering

  Automotive / automotive parts industry

  Metal construction

  Metalforming industry

  Hardening plants or thermal processing industry

  Medical engineering

  Dental industry

  Plastics industry

  Electronics / electrical engineering 

  Aerospace industry

  Watchmaking industry

  Hydraulics / pneumatics

  Ceramics industry

  Packaging industry

Beverage industry

  Food industry

Household goods industry

Office equipment

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Cost-effective solution for development and production

LOTOS  is  extremely  cost-effective  because  of  the  wide  range  of  possible applications.  Whether  required  for  tasks  connected  with  development  and optimisation  or  for  in-process  testing  and  process  control:  a wide  variety  of measuring tasks can be carried out flexibly and efficiently with just one LOTOS measuring system.Flexible holding fixtures completely eliminate changeover times or keep them very short  for  tests on a wide  range of different products. Coupled with the large measuring range, this means that these systems can measure everything from very small parts to heavy machine components.

LOTOS  measuring  systems  offer  a  wide  range  of  functions  for  performing myriad tasks, such as

 geometrical measurements

 tolerance tests

 shape and position tests

 determination of change in shape and size

 volume determination

 defect identification

 surface inspection

 generation of a CAD model of the measurement object (reverse engineering)

The LOTOS software modules also offer

  software and hardware interfaces for integration in any   manufacturing environment

 direct in-line production monitoring and statistical functions   for process monitoring and control

  synchronous remote administration and monitoring of   all measuring systems in use

  interfaces for manual, semi-automatic and automatic   measurement (e.g. PLC-controlled)

 automatic data export to various formats

  self-monitoring functions and temperature compensation

 poka-yoke functions which prevent any operator errors

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Datum Name BenennungName 28-Sep-10 B. Gey

AuflagetellerGepr.NormZei.-Nr.: 014005-660-10-01

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Extremely high accuracy over a wide measuring range

The  use  of  high-precision  mechanical  and  optical  components  guarantees high measurement accuracy  in  the μm  range.  The measurement  sensor has a  high  resolution  and  its  functioning  is  not  affected  by  the  surface  of  the measurement  object.  The  use  of  low-maintenance,  durable  hardware  from leading manufacturers and the enormous measuring range for measurement objects up to 400 mm in diameter guarantee excellent measurement capability to ensure optimum quality and process monitoring.

Fast, maintenance-free stages

Fast,  high-accuracy positioning and  the direct  response  characteristic  of  the stepper motors  are  key  features  of  the  stages.  The  rotary  stage with  direct coupling  guarantees  precise  positioning  even  with  heavy  measurement objects.  In  combination with  the  lifetime  lubrication,  this makes  the  stages maintenance-free.

High productivity due to automated measurements

Fast  stages  for  positioning  the measurement  object  and  sensor,  a  powerful internal evaluation and control processor and an additional real-time processor allow fast, fluent operation because processes run in parallel.It takes less than 10 seconds to complete a full measurement and assessment of a component. Test plans can be chosen in a matter of seconds or can be read in automatically to perform a wide range of measurement tasks efficiently. 

  

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Intuitive operation for safety and reliabilitySimple,  intuitive  operation  provides  safety  and  reliability.  This  means  that operators  require  very  little  training.  The ergonomic design of  the device  in accordance  with  current  safety  standards  keeps  downtimes  to  a  minimum, poka-yoke functions prevent any operator errors. Fully automatic measurement procedures can be organised quickly and simply in test plans for a wide range of different measurement tasks. One-touch operation and easy-to-understand assessment  with  visual  highlighting  of  tolerance  and  warning  threshold violations round off the operating concept.

Precise measurement for variable surfacesThe  measurement  sensor  has  a  high  resolution  and  its  functioning  is  not affected by the surface of the measurement object. Measurement objects with surface  variations  caused by welded  joints or  coatings,  for  example,  can be measured precisely without outliers too.

Temperature compensation and self-monitoringSeveral internal sensors and multi-level, decentralized temperature compensation guarantee  that precise measurement  results  are delivered  consistently,  even when  the ambient  temperature varies.  In addition,  self-monitoring  functions provide the ability to monitor machine capability continuously.

Poka-yoke for guaranteed process stabilityVarious  poka-yoke measures  are  available  for  the  immediate  detection  and prevention  of  errors  during  operation  of  the  measuring  systems.  Attempts to  manipulate  measurements  and  operator  errors  are  reliably  identified  by the software and a correction message is displayed. In order to continue the measurement process, only the erroneous step must be corrected and not the entire measurement.

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SPC concept for process reliabilityFor the purposes of statistical process control, the system requests a specific component  to  be  measured  at  defined  intervals  and  the  results  of  the measurement are compared with a  reference measurement.  If  the measured values lie within the permissible range, the current measurement process can be continued immediately. If the values lie outside the permissible tolerance, the  system automatically  issues a  request  for  calibration. Measurement and evaluation take only a few seconds. The SPC tests and results are recorded in the database. They are safe from any kind of manipulation and can be viewed and exported at any time.

Simple, reliable calibrationCalibration as may be required after an SPC measurement, for example, can be carried out quickly and easily. The use of just one calibration piece guarantees clear-cut results and drastically reduces the probability of calibration errors. If there are deviations, the adjustment is carried out automatically with no need for manual intervention or settings.

Codes for orientation and tracking Measurement  objects  can  be  identified  and  tracked  by  reading  in  different codes.  To  guarantee maximum flexibility within  the  production  process,  the functions for the code scanners can be freely assigned using the measurement recipe.  LOTOS  therefore  complies  with  the  requirements  stipulated  in  the  008-06-17 OEM standard.If codes are attached to the outer surface of the measurement objects, optional scanners can be used to read them in during the measurement process while the measurement objects are being rotated. In this way the scan can be used as a poka-yoke measure for checking the orientation of the measurement object and its correct positioning.If  components  are  delivered without  product  codes,  alternatively  box  codes such as batch and part numbers can be scanned. The part number, which may be included in the product code, can be used as a poka-yoke measure in order to check or automatically select the recipe.

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Comprehensive software solutions for all fields of applicationDepending  on  the  system model  and  the  field  of  application,  a  number  of different software versions are available for LOTOS measuring systems. LOTOS provides solutions for various fields of application, including the following: 

 Quality control in the production environment

 Production monitoring

 Process monitoring and optimisation

 Process analysis for development and prototype production

LOTOS-Vision: operation via touch screenLOTOS-Vision is optimised for operating and controlling the measuring systems via  touch  screen  and  is  specially  designed  for  use  in  production.  It  is  the standard operating software installed on the measuring systems.The  ergonomically  designed  user  interface  is  clearly  structured  and  easy  to understand,  enabling  operators  and  setters  alike  to  work  intuitively.  The touch  screen  is used  for  the  configuration of  the measuring  system and  for the creation of recipes for measurements. In addition to automatic tolerance testing, a graph comparing the nominal and the actual contour is displayed for the purposes of immediate assessment.

LOTOS-Automate: the solution for automated manufacturingLOTOS-Automate has been developed  in order  to  integrate the  full  range of features  of  the  LOTOS measuring  systems  in  an  automated manufacturing process.  LOTOS-Automate  makes  it  possible  to  use  external  automation systems, such as PLCs, to control the measurement process. The configuration of  the measuring  systems and  creation of  recipes  are  also performed using commands in the control protocol.

LOTOS-Expert: detailed analyses and evaluationsThe Expert software features comprehensive analytical, statistical and graphical tools  and  is  recommended  for  use  in  development,  process  optimisation, quality  assurance  and  the  technological  preparation  of  the  manufacturing process.  The  software  can  be  installed  on  every  PC  if  required  in  order  to evaluate  measurement  data  on  screen  during  serial  production  or  create recipes during the work preparation process without tying up the measuring system, for example. The applications listed below are given as examples of the comprehensive possibilities afforded by the LOTOS-Expert software:

  Flexible measurements thanks to execution of individual   measurement steps

  Automated multiple measurements and recording of changes

  Detailed inspection of individual contours

  Determination of local measurement values or curvature in specific areas

Superimposition of contours from various measurements

  Statistical functions such as trend analysis and histograms

  Various export options ranging from single parts to large lots in   all common file formats with freely configurable content

  Use of measurement data from external sensors, such as   temperature and humidity 

  Direct display of all measurement values

  Generation of a CAD model of the measurement object   (reverse engineering)

Admin module for LOTOS-ExpertThe Admin module allows full administration of all LOTOS measuring systems from a central location using a network.This makes it ideal for operators with a number of measuring systems which may even be located at different sites. With LOTOS-Admin, these measuring systems can be configured for scheduled measurement tasks, serviced and monitored in various ways via remote access. This also  includes  the upload of updates and  recipes. Monitoring plant and production  parameters  provides  effective  support  for  the  preparation  of production reports and statistics as well as for direct production monitoring. 

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Intuitive user interfaceThe  intuitive  and  easy-to-understand  user  interface  of  all  software modules guarantees easy operation and minimizes the time it takes to become familiar with  the measuring  system. Guided  data  entry  in  the  recipe  generator  and data  plausibility  testing  ensure  reliable  configuration  and  automatic  fault detection. Nominal contours can be created directly or read in via CAD files. The measurement  procedure  is  fault-tolerant;  individual measurement  steps can be corrected at any time without the entire measurement process having to be carried out all over again. The results are displayed on the monitor clearly and appropriately for the specific application.

Reliable and comprehensive storage of resultsThe data is securely stored in a database which is insusceptible to manipulation. A  highly  efficient  database  system  allows  the  storage  of  at  least  2 million data sets in the measuring system with consistent access times. The data sets contain  the  complete  measurement  results,  including  the  plant  and  recipe parameters, enabling repeat measurements and further analyses to be carried out. Remote access for analysis and statistics is protected by a password and certificates.

In-process data interfaceAll measurement, adjustment and SPC data can be published  regularly and automatically  in  different  data  formats  and  using  different  interfaces.  This makes it possible for data to be imported and further processed as required by  the  customer  for  the  purposes  of  quality  management  and  mandatory documentation.

Measuring range Diameter Any cross-sections

LOTOS LS 10…110 mm infinitely variable up to 295…395 mm

Measurement object height Max. 500 mm

Power Measuring times < 5 seconds per 60 mm object height with a speed of rotation of 360°/s

Poka-yoke Prevention of manipulation and operator errors

Accuracy Radius 0.01 mm Standard deviation < 0.003 mm

Length (axial) 0.02 mm Standard deviation < 0.006 mm

Weight 0.2…7000 g Standard deviation < 0.05 g

SPC measurement Duration < 7 seconds

Recommended frequency 1x per shift

Sensor calibration Duration < 4 minutes

Recommended frequency After 90 days or 90,000 measurementsOn changes of temperature > 3° Optional: fully automatic temperaturemonitoring and compensation

Measurement sensor Laser class  Class II (FDA (CDRH) part 1040.10), class 2 (IEC 60825-1)

Positioning systems Maintenance-free stages with high-precision encoderRotary stage with a maximum load rating of 200 kgOptional: Measurement-object-specific support adapter for centric positioningHigh-precision quick-fix clamping device for holding the measurement object with many adapter options

Interfaces USB                            5x (1x freely accessible; 4x locked) 

Ethernet (RJ 45)          13x (1x for network connection; 12x for peripherals, locked)

Housing Table-top device

LOTOS LS Dimensions (W x H x D) mm 800 x 950 x 800

Weight 85 kg

Quality system Developed and manufactured to DIN ISO 9001:2000

Voltage supply Rated voltage: 88…264 V AC, 47…63 Hz

Environment Operating temperature range 5…40°C

Relative humidity 5…85%, non-condensing

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Technical data

KoCoS AutomationDöbereinerstr. 2299427 Weimar, GermanyTel.  +49 3643 [email protected] Su

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