Instrument trio raises component testing to a new level

Until recently, Geissel 's production department mainly used manual measuring equipment to inspect workpieces. Gages were predominantly used for this purpose. The regular calibration of the measuring and testing equipment was associated with high personnel and financial costs. For this reason, Geissel Managing Director Marc Seidel decided to upgrade the metrology last year. The good reputation that Mahr has, especially in the testing of contours and mold positions, therefore also convinced Seidel to seek advice from Mahr when it came to measuring technology. To equip the newly designed measuring room, which already has a 3D measuring machine in operation, the company purchased a package of three measuring devices: These include the MarShaft Scope optical shaft measuring system, the MarSurf CD 140 contour measuring device, and the Precimar ULM 300 calibration device. With this trio, all measuring tasks on the precision turned parts and cable glands at Geissel can be performed.

120 images per second

The MarShaft SCOPE plus is a fully automatic, optical shaft measuring system for inspecting rotationally symmetrical workpieces. It features a high-precision roundness measuring axis as well as a vertical and horizontal measuring axis. The measuring sequences are fully automatic and free from operator influence. Zoom functions allow measurement of the smallest details that are difficult or impossible to inspect with conventional measuring methods. "At the heart of the system is the modern, high-resolution CMOS matrix camera with an image field of 1,088 x 2,048 pixels," explains Antje Zapfe, Global Account Manager Automotive at Mahr. "The very high recording rate of over 120 images per second enables the shortest measurement times." And so 30 to 40 measurements can be taken with the Scope within just 15 to 20 seconds, "otherwise an employee would be busy with this for half to three quarters of an hour – an enormous time saving with super accuracy and storage," as Evelin Kobiljar, Quality Assurance Team Leader at Geissel, points out. The documentation is also very important for the customers who install the parts, so there is a double benefit here. The documentation is done with the Mahr software platform MarWin, which bundles many years of experience in length, form, position and contour measurement and makes it usable.

Contour measurement with 140 mm scanning distance

In order to precisely measure the contours of cable glands and turned parts, the Mühlacker plant opted for a MarSurf CD 140. The device has a fully CNC-capable Z-axis for automated operation. The probe system can be changed quickly and without tools thanks to the magnetic suspension and without recalibration. In addition, automatic probe recognition speeds up measuring sequences and prevents incorrect measurements. With its optional probes – also with double tip – the quality assurance specialists at Geissel can also measure threads and surfaces directly. The MarSurf CD 140 scores with shorter measuring times thanks to high positioning and measuring speeds, flexible application options and easy handling. "The standard for the measuring range is 70 millimeters, but can be extended to a maximum of 100 millimeters by using extra-long probe arms," explains Mahr product manager Martin Adler. Maximum flexibility in handling is ensured by the mounting plate with 50 millimeter bore dimension and pluggable guide stops.

Calibration of plug gages, ring gages & Co.

With the Precimar ULM 300-E calibration measuring device from Mahr, Geissel wants to calibrate the test equipment itself in the futurewith the aim of delivering better quality including a calibration certificate. The Precimar ULM-E universal length measuring instruments are comparators with a horizontal base bed made of hard stone with high homogeneity and rigidity. This makes it possible to calibrate smooth plug gages and rings, setting rings, snap gages, ball gages, thread gages and much more. The X-axis measuring system features a high-precision Heidenhain length measuring system with a length of 100 millimeters. The measuring system of the Z axis is a Renishaw length measuring system with a length of 80 millimeters. It stands for high measuring accuracy with 100 percent compliance with the comparator principle according to Ernst Abbe. The measuring spindle is operated manually; the measuring element and counter bearing can be positioned very smoothly thanks to the air bearing.

Maximum cost-effectiveness right from the start

Until now, around 7,000 calibrations per year were necessary at Geissel to provide customers with the desired component precision. Thanks to the new type of measurement technology of the Precimar ULM 300, manual measurements can now be significantly reduced. This, as well as the enormous cost-effectiveness, convinced Geissel's Managing Director Marc Seidel of the value of this device. The metrology newcomers are operated by experienced measuring technicians. However, as QA team leader Kobiljar notes, "metrology technician" is still a profession without regulated apprenticeship training. "Yet it is definitely one of the most important professions in the industry – you need a lot of experience and you have to continuously train yourself, such as in the Mahr Academy," he says. The measurement specialist has acquired all certificates up to AUKOM III here. With the new technology and the experience of his employees, Geissel can permanently guarantee absolute high-end precision components for his customers from various industries and standardize a wide range of industrial processes.