Renishaw CMM Retrofit Increases Verus Capacity

March 30, 2021

Renishaw CMM Retrofit Increases Verus Capacity

March 30, 2021

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Renishaw CMM Retrofit - Increasing Metrology Inspection Capacity At Verus' Irish Facility

Metrology inspection and quality assurance (QA) testing is part and parcel of almost every industry today. Organisations situated in sectors like MedTech and Pharmaceutical, FMCG, Engineering and Manufacturing all rely on strict metrology and QA processes. This ensures each product component meets predetermined dimensional requirements, certifying its fit for purpose. To determine this, many organisations have inhouse QA systems to certify their product components meet metrological and other QA requirements. However, several rely on sub-contract inspection experts such as Verus Metrology to conduct metrological and QA services for them.

The Importance of Modernised Technology in Metrology

When utilising sub-contract inspection services, clients expect providers to have the best technology in place. Specific to metrology, this means having up-to-date, highly sophisticated and innovative technology and equipment to hand when conducting measurement activities. As metrology experts will know, the technology used during measurement will have an outright effect on the measurement results attained. The same technology will affect the level of measurement uncertainty also. Therefore, the more sophisticated the technology, the more desirable the inspection results will be. Hence, metrology service providers utilising the most up-to-date technology will have a more streamlined and reliable measurement process in place. This is in comparison to similar service providers operating measurement systems with lesser technical capability or outdated software.

Keeping this in mind, we know the importance of continued investment in the technology currently in use across our facilities. To cater to the many different client challenges we encounter, our facilities offer a wide range of metrology platforms. Our measurement capacity utilises cutting-edge metrology inspection systems from Mitutoyo, Hexagon, OGP, Renishaw and IMS. Boasting this diversity of machine types means we respond to individual metrology requirements with a solution unique to each client.

Taking this into consideration, we recently recognised that our metrology lab in Ireland needed streamlining from a CMM platform perspective. We found that our facility was becoming outdated due to the obsoletion of IMS systems software. Consequently, we have since made some heavy investments into our CMM and measurement technology capacity at our Irish facility.

The addition of a Renishaw CMM Retrofit to Verus Ireland

We want to remain at the forefront of technology in terms of metrology applications and programming. Hence, when searching for a replacement for our IMS systems, we wanted a CMM solution that would provide capability for a range of client requirements. We needed a measuring platform that would cater for clients utilising different metrology software and probing systems. The successful integration of such would bring our Irish metrological offering on par with Verus UK’s diverse range of metrology systems. Thus, creating like-for-like metrology capability across all our facilities.

The Apex Metrology Touch

To ensure this concept came to fruition, we requested the expertise of Trusted Metrology Partner Apex Metrology. We knew that we would benefit from using one machine that operated several measurement platforms. Therefore, the challenge was to create a multi-platform CMM that incorporated Virtual DMIS, Hexagon PCDMIS and Renishaw MODUS. Having previous experience in the development of multi-platform metrology systems, CMM specialists Apex Metrology were the top choice in sourcing a solution.

To facilitate a multitude of metrology platforms, a Renishaw UCC Controller was installed onto the CMM Retrofit. Alongside enabling our engineers to work across Virtual DMIS, PCDMIS and Renishaw MODUS, the addition of the universal controller provides advanced touch-trigger capabilities. Not only does this allow for fast, reliable and adaptable part measurement, but it also guarantees confidence in the metrology data through equivalency. As a result, our superior metrology services ensure maximisation of client’s production efficiencies through the application of equivalent metrology platforms and software.

Discussing Verus’ need for a multi-platform measuring machine, Verus COO Michael Nugent says:

An Apex applications engineer delivering remote training to a Verus expert metrologist.

“The Renishaw CMM Retrofit allows for a situation where our engineers are cross-trained on multiple metrology platforms.”

Further streamlining Verus’ in-house metrology activities, the addition of a CMM retrofit delivers increased productivity here at Verus Ireland. An example of this would be where one client requires programming with PCDMIS while another client has a Renishaw Equator. The CMM Retrofit can cater to both requirements. This speeds up internal processes by reducing metrology inspection lead time.

Renishaw MODUS Capabilities

In terms of the Renishaw Equator, those familiar with the system will know that it is not best practice to programme the equator on the actual equator system itself. Rather, the programme should be created on a CMM that utilises Renishaw MODUS and then transferred over to the equator. MODUS is the software that creates a link between the CMM and the equator. Henceforth, the CMM Retrofit will enable Verus to provide metrology programmes for clients that have the Renishaw Equator platform.

Verus’ Bespoke Metrology Inspection Fixtures on a Renishaw Equator System

Apex’s Brian Young highlighted the benefits of utilising a multi-platform system when discussing the recent development of the CMM Retrofit:

By supplying the CMM with the Renishaw UCC Controller installed, we were able to offer the industry recognised I++ interface that allows any I++ compatible metrology software to operate. In this case Renishaw Modus, Hexagon PCDMIS and Virtual DMIS with the ability to add other software as and when demand presents itself.

While many clients rely on traditional touch probing technology to capture features, there is a growing number who also now utilise scanning probes as the technology can improve the data quality and utilise different stylus configurations.

The CMM supplied to Verus provides a universal metrology solution that we are confident will allow them to develop solutions closer to their client’s needs by using equivalent configurations.


The Verus Metrology + Renishaw Partnership

We only partner with the best in the business at Verus Metrology. Through our collaborative network, we bring together industry leaders who share the same passion and enthusiasm for metrology as we do and strive for metrology service excellence.

But, what is a true partnership?

A true partnership is choosing partners who are as dedicated as we are to providing clients with bespoke metrology solutions. A solution that is unique to their individual requirements. Through our trusted partnerships, we work closely with other like-minded experts to deliver an additional level of measurement proficiency, allowing them to gain confidence in knowing they are choosing the right metrology solution for them.

Hence, we are delighted to announce our latest addition to our Trusted Metrology Partners Programme, Renishaw. Renishaw has an excellent reputation for transforming measurement performance with its innovative metrology systems. Therefore, we look forward to working with them in our quest to push the boundaries of measurement and evolve the technologies used in measurement inspection. Renishaw joins existing Verus partners, Mick Smith CMM Consultancy, OGP UK and Apex Metrology.

The Verus Metrology and Renishaw Trusted Metrology Partnership

On the latest Verus Metrology partnership, Verus CEO Andrew Hodson says:

Our partnerships demonstrate the Verus Metrology ethos of Trust and Partnership as the foundation for business development and provision of an unrivalled service to our clients.

The recent CMM retrofit is only the first in a number of exciting innovations we are currently developing as a result of the Verus Metrology/Renishaw partnership.

You can check out our full list of Trusted Metrology Partners and the services they provide here.

To learn more about our Trusted Metrology Partners and how to become a member, contact Verus CEO Andrew Hodson on +353 (0)71 91 43506 (ext. 204). Moreover, be sure to subscribe to our NEWSLETTER to receive our technical blogs, customer updates, and all the latest developments.

Introduction 

As 2024 unfolds, the field of metrology is witnessing transformative changes. At Verus Metrology, we recognize the importance of keeping pace with technological advancements and new trends in the science of measurement. In this rapidly evolving landscape, innovations in metrology are not just about achieving precision; they are about meeting the evolving challenges of industries like medical devices, where accuracy is critical for ensuring safety and quality. This article explores the emerging trends and technological breakthroughs shaping metrology’s future. 

As 2024 unfolds, the field of metrology is witnessing transformative changes. At Verus Metrology, we recognize the importance of keeping pace with technological advancements and new trends in the science of measurement. In this rapidly evolving landscape, innovations in metrology are not just about achieving precision; they are about meeting the evolving challenges of industries like medical devices, where accuracy is critical for ensuring safety and quality. This article explores the emerging trends and technological breakthroughs shaping metrology’s future. 

Metrology Fixture Types – What’s Available, and Which is Best?

9 February 2023

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Fixture type and use cases

Metrology fixturing technologies continue to develop at a rapid pace, offering manufacturers in the medical device industry new and innovative solutions. Those solutions don’t just meet inspection and quality process requirements, but they also deliver efficiency savings and productivity gains. How do you know what metrology fixture types are available and which is best for your application? In this blog, we’ll outline the main options, their underlying technologies, and the use cases they are best suited for. 

However, it is also important to point out that the fixture types described in this blog represent broad categories. Within those categories, there is an infinite number of ways that a fixturing solution can be developed to meet your specific needs, reduce risk, and take advantage of opportunity

While there are metrology fixture types that we can explore, every fixture solution that we develop here at Verus Metrology is completely unique. In other words, fully customised for the product or component being measured, as well as the inspection machine, quality department workflows, production processes, and any other influencing factor. 

Metrology Fixture Types 

There are six main metrology fixture types: 

  • Auto rotational 
  • Manual rotator 
  • Multi-station
  • Proof of Principle (POP) 
  • Vision system 
  • Docking station 

 

Auto-Rotational Fixtures

Isometric view of an auto rotational metrology checking fixture, the automatic part of the fixture is the turning of the rail by a motor. The fixture has white plastic components held in place using brown clips

 

At a fundamental level, the job of a metrology fixture is to hold a product or component securely in place so it can be effectively inspected and measured. However, there are situations where the inspection process requires the part to be presented at different orientations to enable all the relevant measurements to be taken. This requirement for measurement in multiple orientations is increasing as medical device products become more complex and intricate. 

Auto-rotational fixtures enable the inspection of products and components in multiple orientations with minimal operator intervention. An auto-rotational fixture can be a single-station set-up, but they more commonly come in multi-station designs to minimise the time it takes to achieve your required sample rate. 

The most important feature of an auto-rotational fixture is that you can measure multiple components in multiple orientations in a single setup. 

Manual Rotator Fixtures

Manual Rotator Metrology Fixtures by Verus Metrology

Manual rotator fixtures offer similar benefits to auto-rotational fixtures. The obvious main difference is that operators manually rotate components once they are loaded into the fixture. 

Manual rotator fixtures can be multi-station. They are also designed so that all measurements in all orientations can be taken in one set-up. So, while the operator will need to manually control the rotation mechanism, there is no requirement to touch or adjust the components as the fixture holds them securely in place during rotation. 

The benefits of manual rotator fixtures include: 

  • Significantly reduced operator intervention 
  • Improved measurement accuracy 
  • Elimination of errors 
  • Faster and more efficient metrology processes 

Furthermore, we can design your manual rotator fixture so it can be loaded with components away from your CMM. This improves CMM availability as the machine doesn’t have to sit idle while components are being loaded onto the fixture. 

Multi-Station Fixtures 

multi station rotator

According to FDA regulations and ISO 13485, it is essential that you can statistically justify sampling rates in your quality procedures using a risk-based approach. The operational part of this requirement isn’t covered in the guidelines, but it is an important business consideration. How do you efficiently, accurately, and cost-effectively inspect the number of products or components that are required to hit your sampling rate target? 

Multi-station fixtures are a common solution. We can design multi-station fixtures in any configuration. This could be a large cavity multi-station fixture, a fixture to inspect very small and complex medical devices, or solutions for products or components of any size, geometry, or characteristic. 

The benefits of multi-station fixtures include: 

  • Operator intervention is greatly reduced 
  • Fixtures only need to be loaded once before full inspection routines can take place on multiple products at the same time 
  • Reduce human error 
  • Speed up inspection processes while achieving your sampling rate target 
  • Reducing the cost of inspections 

 

Proof of Principle Multi-station Prototype Fixtures 

proof of principle

 

In many product development and process change situations, it is beneficial to have a POP fixture that can be used for verification and validation purposes. The approach we typically take at Verus Metrology is to design a multi-station fixture to deliver on your requirements. 

However, before this multi-station fixture design goes into manufacturing, we design and produce a single-station POP prototype fixture. This POP prototype can be manufactured quickly in our advanced manufacturing facility. We’ll then put it through a gage R&R study to give you confidence in its repeatability and reproducibility, before sending it to you for evaluation and testing. 

POP prototype fixtures offer a range of benefits: 

  • Facilitates design for inspection during the product development process 
  • Minimises delays in process verification 
  • Enhances and speeds up the design transfer process 
  • Reduces time to market in line with regulatory requirements 

 

Vision System Solutions

We also design and manufacture fixturing solutions for vision systems in addition to the fixtures we design for use on CMMs. Fixturing solutions that are optimised for vision systems have a number of specific and differentiating features, including ensuring there is a clean and clear view of the part. 

Vision system solutions can also allow for backlighting where necessary. Furthermore, a single set-up is all that is required for the full inspection routine to take place, with parts securely held with as little force as possible. 

 

Docking Systems 

Docking System Verus Metrolody

Docking systems enhance the efficiency of quality departments that use multiple fixtures and/or have high sampling rates. Docking systems are securely fixed to CMMs to make it quick and easy for technicians to load fixtures that are fully set up with components ready for inspection. Once the inspection routine for a fixture is complete, it can be quickly and easily removed from the docking system ready for the next fixture to be loaded. 

With a custom-designed docking system, you can have confidence that each changeover results in precisely secured fixtures for repeatable and reproduceable inspections. 

Choosing the Right Fixture for Your Requirements

There are many factors to consider when choosing the best type of metrology fixture for your requirements. Your budget is an important consideration, as are your ROI goals, quality processes, quality resources, and future requirements. 

The best approach is to speak to a fixture design expert to explore the options and get an understanding of what is possible. Contact us today to find out more. 

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About Verus Metrology Partners

Verus is committed to the enhancement of our client’s metrology laboratories, machine efficiencies, and inspection processes. Since our beginning, our expert metrology engineering team has partnered with some of the world’s largest MedTech multinationals.

 

We specialize in high quantity, difficult to measure, yet critically important, medical device parts. As well as working in the MedTech, Pharmaceutical and Personal Care industry, we also work with metrology departments in the FMCG and Aerospace industry.