Computer Aided Quality

Control

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Prof. Janakarajan Ramkumar
Professor
Department of Mechanical Engineering
IIT Kanpur, India.
 Computer Aided Quality Control (CAQC)
 Inspection Metrology

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 Conventional Measuring and Gaging Techniques
 Coordinate Measuring Machines
 Surface Measurement
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Machine Vision
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Other Optical Inspection Techniques
Noncontact Nonoptical Inspection Technologies
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 Control Charts
Computer-aided quality Control (CAQC) is the engineering application of
computers and computer-controlled machines for the definition and

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inspection of the quality of products.

This includes:
• Measuring equipment management

• Vendor rating
• Attribute chart
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• Goods inward inspection
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• Statistical process control (SPC)
• Documentation
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TMH, New Delhi, CAD/CAM Principles and Applications by P N Rao, 3rd Ed

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 Measurement - a procedure in which an unknown quantity is
compared to a known standard, using an accepted and consistent
system of units

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• The means by which inspection by variables is accomplished

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Metrology – the science of measurement
• Concerned with seven basic quantities: length, mass, electric
current, temperature, luminous intensity, time, and matter
• From these basic quantities, other physical quantities are derived
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 Accuracy – how closely the measured value agrees with the true value

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 Precision – a measure of the repeatability of the measurement process
• Rule of 10 – the measuring instrument must be ten time more
precise than the specified tolerance

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 Resolution – the smallest variation of the variable that can be detected
 Speed of response – how long the instrument takes to measure the
variable
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 Others: operating range, reliability, cost
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(a) High accuracy but low precision, (b) low accuracy but high precision, and
(c) high accuracy and high precision

Automation, Production Systems, and Computer-Integrated Manufacturing. Mikell P. Groover

 Analog measuring instrument – output signal varies continuously with the
variable being measured

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• Output signal can take on any of an infinite number of possible values
over its operating range

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Digital measuring instrument – can assume any of a discrete number of
incremental values corresponding to the variable being measured
• Number of possible output values is finite
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• Advantages:
• Ease of reading the instrument
• Ease of interfacing to a computer
1 Contact inspection

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• Makes contact with object being inspected

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2 Noncontact inspection
• Does not make contact with object being inspected
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Uses a mechanical probe that makes contact with the object being measured or
gaged

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 Principal techniques:

• Conventional measuring and gaging instruments, manual and automated

• Coordinate measuring machines

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• Stylus type surface texture measuring machines
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Uses a sensor or probe located a certain distance away from the object being
measured or gaged
 Two categories:

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• Optical – uses light to accomplish the inspection
• Non optical - uses energy form other than light

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Advantages of noncontact inspection:
• Avoids possible damage to surface of object
• Inherently faster than contact inspection
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• Can often be accomplished in production without additional part handling
• Increased opportunity for 100% inspection
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Automation, Production Systems, and Computer-Integrated Manufacturing. Mikell P. Groover

 Measuring instruments - provide a quantitative value of the part feature of

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interest
• Examples:
• Steel rules, calipers, micrometer, dial indicator, protractor

range
• Examples:
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 Gages - determines whether a part feature falls within a certain acceptable
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• Snap gages for external dimensions, plug gages for hole diameters,
thread gages
• Concerned with the measurement of the actual shape and dimensions
of an object and comparing these with the desired shape and dimensions
specified on a part drawing

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• Coordinate measuring machine (CMM) – an electromechanical system
designed to perform coordinate metrology

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A CMM consists of a contact probe that can be positioned in 3-D space
relative to workpart features, and the x-y-z coordinates can be displayed
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and recorded to obtain dimensional data about geometry
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Automation, Production Systems, and Computer-Integrated Manufacturing. Mikell P. Groover

CMM is a flexible measuring device capable of providing a highly accurate
dimensional position along three mutually perpendicular axes.

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• High precision mechanical structure
• Probing System
• Machine Control Unit

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• CMM Software
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Optional components (on many CMMs):
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• Drive system and control unit to move each axis
• Digital computer system with application software
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http://machine-drawing.blogspot.com/2018/03/coordinate-measuring-machine-throttle.html
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(a) Single tip and (b) multiple tip probes

Automation, Production Systems, and Computer-Integrated Manufacturing. Mikell P. Groover

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https://gfycat.com/totalrevolvingaracari
 Six common types of CMM mechanical structures:
1. Cantilever

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2. Moving bridge
3. Fixed bridge
4. Horizontal arm
5. Gantry
6. Column PT
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(a) Cantilever and (b) moving bridge structure

Automation, Production Systems, and Computer-Integrated Manufacturing. Mikell P. Groover

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(c) Fixed bridge and (d) horizontal arm (moving ram type)
Automation, Production Systems, and Computer-Integrated Manufacturing. Mikell P. Groover
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(e) Gantry and (f) column

Automation, Production Systems, and Computer-Integrated Manufacturing. Mikell P. Groover

 Four categories:
1. Manual drive CMM – human operator physically moves the probe and
records x-y-z- data

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2. Manual drive and computer-assisted data processing – can perform
calculations to assess part features

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3. Motor-driven CMM with computer-assisted data processing – uses
joystick to actuate electric motors to drive probe
4. Direct computer control (DCC) – operates like a CNC machine tool and
requires part program
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 Manual leadthrough
• Operator leads the CMM probe through the various motions in the

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inspection sequence, indicating points and surfaces to be measured and
recording these into control memory
 Off-line programming

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• Program includes motion commands, measurement commands, and report
formatting commands and is prepared off-line
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The set of programs and procedures used to operate the CMM and its
associated equipment

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 Example: part programming software for DCC machines
 Other software divide into following categories:
1. Core software other than DCC programming

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2. Post-inspection software
3. Reverse engineering and application-specific software
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Minimum basic programs for the CMM to function, which applies only to DCC
machines
Examples:
• Probe calibration – defines probe parameters so that CMM can

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automatically compensate for probe dimensions
• Part coordinate system definition – instead of aligning the part with the
CMM axes, axes are aligned to part
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• Geometric feature construction – e.g., hole center
• Tolerance analysis – compares measurements with part drawing
dimensions and tolerance
 Programs applied after the inspection procedure
 Statistical analysis – used to accomplish various statistical analyses

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• Process capability
• Statistical process control

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Graphical data representation – displays data collected during CMM
inspection in a graphical or pictorial way, permitting easier visualization of
form errors and other data
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 Reverse engineering
• CMM explores part surface and constructs 3-D model

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 Application-specific software:
• Gear checking
• Thread checking
• Cam checking
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• Automobile body checking
 When the touch trigger probe moves along a direction and touches a
surface, the elastic connection deflects and triggers the measuring system.

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 The trigger is basically an omni-directional switch capable of detecting
deflections in any direction.
 From that the physical position of the surface where the probe contacts
gets recorded.
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 Since the probe tip is spherical, the contact between the probe and the
measured surface is a point contact.
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 The controller automatically compensates for the radius of the probe.

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TMH, New Delhi, CAD/CAM Principles and Applications by P N Rao, 3rd Ed

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 Reduced inspection cycle time – translates to higher throughput rate

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• Especially with DCC, approximately 90% reduction in certain tasks
 Flexibility – CMMs are general-purpose machines

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 Reduced operator errors in measurement and setup
 Greater inherent accuracy and precision
 Avoidance of multiple setups – in general all measurements of a given part
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can be made in one setup
 Mounted on tool holders
 Stored in the tool drum

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 Handled by the automatic tool-changer the same way cutting tools are
handled
 Inserted into the machine tool spindle by the automatic tool-changer

a CMM
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• When mounted in the spindle the machine tool is controlled very much like

• Sensors in the probe determine when contact is made with part surface so
that required data processing is performed to interpret the sensor signal
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 In the conventional application of a CMM, parts must be removed from the
production machine and taken to the inspection department where the CMM is

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located
 New coordinate measuring devices allow the inspection procedures to be
performed at the site where the parts are made

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 Example: Faro gage, a.k.a. Personal CMM, is a six-jointed articulated arm
 At the end of the arm is a touch probe to perform coordinate
measurements, similar to a CMM
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Automation, Production Systems, and Computer-Integrated Manufacturing. Mikell P. Groover

 Necessity to move parts from the machine tool to the CMM and back is
eliminated
• Material handling is reduced

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 Inspection results are immediately known
 The machinist who makes the part performs the inspection

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 Because part is still attached to machine tool during inspection, any datum
reference locations established during machining are not lost
• Any further machining uses the same references without the need to
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refixture the part
 Most surface measuring devices use a contacting stylus
• Therefore, classified as contact inspection

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 Cone-shaped diamond stylus with point radius = 0.005 mm (0.0002 in) and
90 degree tip angle
• As stylus is traversed across surface, tip also moves vertically to follow

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the surface topography
• Movement is converted to electronic signal that can be displayed as
either
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• Profile of the surface
• Average roughness value of the surface
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Automation, Production Systems, and Computer-Integrated Manufacturing. Mikell P. Groover

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Surface measurement can be displayed as the profile of the surface as
indicated by the stylus trace or the average of the surface deviations during
the trace

Automation, Production Systems, and Computer-Integrated Manufacturing. Mikell P. Groover

Acquisition of image data, followed by the processing and interpretation of
these data by computer for some useful application, also called “computer

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vision”
 2-D vs. 3-D vision systems:
• 2-D – two-dimensional image – adequate for many applications (e.g.,

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inspecting flat surfaces, presence or absence of components)
• 3-D – three-dimensional image – requires structured light or two
cameras
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 Image acquisition: The actual images of the parts are acquired in digital
form through cameras, digitisers, etc.

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 Image processing: These acquired images are filtered to remove
background noise or unwanted reflections from the illumination system.

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Feature extraction: The next step is to extract the features from the image.

Decision-making: From all the features found in the previous step, combine
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the features that are relevant for the given application. The reduced feature
set is processed further as to reach a decision based on the type of
application.

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Automation, Production Systems, and Computer-Integrated Manufacturing. Mikell P. Groover

 With camera focused on subject, viewing area is divided into a matrix
of picture elements (“pixels”)
• Each pixel takes on a value proportional to the light intensity of that

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portion of the scene and is converted to its digital equivalent by ADC
• In a binary system, the light intensity is reduced to either of two

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values, white or black
• In a gray-scale system, multiple light intensities can be
distinguished
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• Each frame is stored in a frame buffer (computer memory),
refreshed 30 times per second
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(a) The scene
(b) 12 x 12 matrix superimposed on
the scene

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(c) Pixel intensity values, either black
or white, in the scene
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Automation, Production Systems, and Computer-Integrated Manufacturing. Mikell P. Groover

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(a) Front lighting, (b) back lighting, (c) side lighting

Automation, Production Systems, and Computer-Integrated Manufacturing. Mikell P. Groover

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(d) Structured lighting using a planar sheet of light

Automation, Production Systems, and Computer-Integrated Manufacturing. Mikell P. Groover

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(e) Strobe lighting

Automation, Production Systems, and Computer-Integrated Manufacturing. Mikell P. Groover
 Segmentation – techniques to define and separate regions of interest
in the image
• Thresholding – converts each pixel to a binary value (white or black)

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by comparing the intensity level to a defined threshold value
• Edge detection – determines location of boundaries between an
object and its background, using the contrast in light intensity

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between adjacent pixels at the boundary of an object
 Feature extraction – determines an object’s features such as length,
area, aspect ratio
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 For a given application, the image must be interpreted based on
extracted features

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 Concerned with recognizing the object, called pattern recognition -
common techniques:
• Template matching – compares one or more features of the image

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object with a template (model) stored in memory
• Feature weighting – combines several features into one measure by
weighting each feature according to its relative importance in
identifying the object
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1 Inspection:
• Dimensional measurement

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• Dimensional gaging
• Verify presence or absence of components in an assembly (e.g.,
PCB)

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• Verify hole locations or number of holes
• Detection of flaws in printed labels
2 Identification – for parts sorting or counting
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3 Visual guidance and control – for bin picking, seam tracking in
continuous arc welding, part positioning
 Conventional optical instruments
• Optical comparator

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• Conventional microscope
 Scanning laser systems
 Linear array devices
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Optical triangulation techniques
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Automation, Production Systems, and Computer-Integrated Manufacturing. Mikell P. Groover

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Automation, Production Systems, and Computer-Integrated Manufacturing. Mikell P. Groover

 Range R is desired to be
measured

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 Length L and angle A are fixed
and known
 R can be determined from

follows:
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trigonometric relationships as

R = L cot A
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Automation, Production Systems, and Computer-Integrated Manufacturing. Mikell P. Groover

 Electrical field techniques

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• Reluctance, capacitance, inductance
 Radiation techniques
• X-ray radiation
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Ultrasonic inspection methods
• Reflected sound pattern from test part can be compared with standard
• Parts must always be presented in the same position and orientation
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relative to the probe
 Control charts are the most effective tools in SQC to determine the
variability of a given process.

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 The control chart will have a nominal value that the manager would like to
control with specified upper control limit (UCL) and lower control limit (LCL).

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Both the process variability (measured by the R-chart) and the process
average (measured by the X bar chart) must be in control before the process
can be said to be in control.
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 detects special causes of variation of the process,
 measures and monitors common causes of variation in the process,

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 identifies the time to look for problems and adjust, and
 identifies the time to make a fundamental change in the process.

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 R-Chart: A range chart or R-chart is used to monitor the variability of the
production process. Range is the difference between the highest and lowest
data points in a group.

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 X -Chart: is used to measure the mean values of the observations.

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 What is Computer Aided Quality Control (CAQC)?
 What is Inspection Metrology?

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 What is Coordinate Measuring Machines?
 Working of CMM?
Surface Measurement
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What is Machine Vision?
Various Optical Inspection Techniques
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 Various Noncontact Nonoptical Inspection Technologies
 Various Control Charts

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Thank You!
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3D measurements; Coordinate
Measuring Machine (CMM)

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Dr. Amandeep Singh
Imagineering Laboratory
Indian Institute of Technology Kanpur
Contents
• 3D Measurements
• Co-ordinate Measuring Machine (CMM)

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• Universal CMM Controller (UCC)
• Laboratory demonstration on using CMM

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3D Measurements

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Coordinate-measuring machine

• A coordinate measuring machine is a device for measuring the

physical geometrical characteristics of an object.

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• This machine may be manually controlled by an operator or it may be
computer controlled.

• Measurements are defined by a probe attached to the third moving

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axis of this machine.

• Probes may be mechanical, optical, laser, or white light, amongst

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others.

• A machine which takes readings in six degrees of freedom and

displays these readings in mathematical form is known as a CMM.
 Configuration of CMM
• Model: - Spectra 5.6.4. CNC
• Scale Regulation = 0.5 μm
• Machine accuracy = (± 2.5 + L/250) μm; (L: Standard length in mm)

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• Angular accuracy = 1” (One second)
• Granite flatness = 2 micron per meter square

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• Granite grade = zero grade
• Probing system = MS2DI
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• M/c version = CNC version
• M/c working volume = X = 500 mm; Y = 600 mm; Z = 400 mm
• Controller name = Renishaw UCC (Universal CMM Controller) lite-2
(U.K.)
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