Hexagon accelerates large-scale aerospace inspection

As aerospace manufacturers race to ramp up production amid labour shortages and rising costs, Hexagon’s Manufacturing Intelligence division has launched the Leica Absolute Tracker ATS800, a next-generation laser tracker for high-mix, large-structure production environments. The system represents an entirely new quality inspection solution in large-scale manufacturing areas such as aerospace and wind energy, delivering direct scanning accuracy comparable to reflector measurement systems, packaged in a portable lightweight design.

With integration into digital and robotic automation workflows, the ATS800 reduces inspection time while enabling real-time measurement and process alignment. A key innovation is FeatureDetect, an automatic feature recognition capability that identifies important part geometries without the need for manual programming. By reducing operator workload, FeatureDetect unlocks productivity gains in both automated and manual inspection processes.

FeatureDetect operates from CAD data or independently, using the ATS800’s built in high-resolution panoramic camera. This wide-aspect live image feed allows the system to recognise features directly from the physical part, accelerating set-up and streamlining inspection.

With set-up times reduced from hours to minutes, Hexagon says the ATS800 supports unattended or in-process inspection – from fuselage alignment to composite lay-ups – without compromising on accuracy or traceability.

“Today’s manufacturers are under immense pressure to increase output while maintaining the highest quality standards, and traditional labour-intensive processes can’t keep pace,” states Rodrigo Alfaia, laser tracker product director at Hexagon. “The ATS800 eliminates hours of set up and ‘boots-on-the-ground’ measurement activity without sacrificing precision.”

He adds: “We’re physically and digitally automating large-scale inspection by bringing data-driven processes to the operational level, whether scanning a full fuselage overnight or guiding critical assembly processes in real time without the need for complex operator training.”

More information www.bit.ly/408wLA8

Measurement probe improves dry room control  

Vaisala has launched its DMP1 dew point and temperature probe to monitor environmental conditions in critical manufacturing rooms and spaces. With dew point measurement capability down to -70°C and rapid response capabilities that the company says is hundreds of times faster than competing measurement technologies, the new compact DMP1 is highly suited to dry rooms. 

The new Vaisala DMP1 probe provides precise measurements in demanding dry processing applications that include lithium-ion battery production, where humidity control is critical to manufactured battery performance. Employing advanced measurement technology, the DMP1 ensures dew point conditions stay as specified in all areas of a manufacturing dry room, helping to maintain both product quality and manufacturing safety. The DMP1 offers easy integration into centralised production, safety and quality monitoring systems.  

“The fast response of the new probe means that customers’ control systems are able to respond quickly, in a timely manner, ensuring the protection of product quality and safety,” says Juhani Lehto, product manager for precision instruments. “This means that customers can efficiently control any deviations in the dry room dew point. Quick reaction times translate into improved workplace safety in battery manufacturing, maintaining high product quality and avoiding waste in the production process.” 

The DMP1 is a part of the modular Vaisala Indigo measurement ecosystem, offering plug-and-play compatibility with connected smart devices. For example, it can be connected to an Indigo300 transmitter to display data locally and transmit measurement values to automation and control systems. The probe can also be connected to an Indigo80 handheld device for maintenance work, where interchangeable probes mean that downtime is minimised and service work is simplified. 

More information www.vaisala.com

£250,000 investment enhances quality control

Basildon-based Rodwell Powell, a specialist in precision machining for the aerospace, defence, marine, construction and other industries, has invested £250,000 in a renovation of its inspection department. The centrepiece of the upgrade was the acquisition of two CMMs manufactured by LK Metrology at its Castle Donington factory. The CMMs are delivering high levels of accuracy and efficiency to support increasingly complex quality control requirements for Rodwell Powell’s clients, which include Rolls-Royce Aerospace and Caterpillar.

The two next-generation LK Metrology Altera C CMMs are enabling the subcontractor to handle larger, more intricate parts with greater accuracy and efficiency. One of the new machines is an LK Altera C 10.7.5 equipped with a Renishaw PH10M Plus motorised indexing head deploying an SP25M probe with an SH25-2 stylus holder, which can perform scanning for form measurement and reverse engineering, as well as touch-trigger probing for accurate geometrical measurements. Featured also is a six-port stylus change rack to enable unattended completion of complex inspection routines.

The second CMM is a smaller LK Altera C 7.7.5 with PH10M Plus and SH25-2, and additionally equipped with a Renishaw TM25-20 touch-trigger probe module, allowing the continued use of legacy CMM Manager software alongside LK’s latest CAMIO 2024 R2. The latter is CAD-based metrology software that underpins the use of multiple sensors, intuitive programming, simulation, results analysis, GD&T, reporting and automation.

Andrew Rodwell, managing director, says: “Our investment in LK Metrology’s cutting-edge CMM technology is a game-changer for us. The CMMs allow for increased accuracy, greater throughput and reduced lead times, reinforcing our reputation for uncompromising quality in these highly demanding industries.”

More information www.lkmetrology.com

Multi-purpose measuring device from Blum-Novotest

Blum-Novotest presented it new MG81 multi-purpose measuring device at the Control 2025 exhibition in Stuttgart earlier this month. The compact device, which is the size of a bank card, has been specially developed for sensor-based status assessment of clamping systems. The recorded values are transmitted wirelessly to the machine tool control system in real time, meaning they can be incorporated directly into the process.

Winfried Weiland, head of marketing at Blum-Novotest explains: “The aim of an automated machining process in the spirit of Industry 4.0 is to record all relevant influences and come up with appropriate actions. With the new MG81, we’re integrating the transmission system and sensor technology directly into the clamping systems, making it is possible to record important process data in real time during machining. This includes the current workpiece temperature, the clamping pressure, the presence of the workpiece and the clamping jaw position. As a result, the machining centre can access and react to the process-relevant data of the clamping device at any time.”

For instance, the MG81 is used in automated processes in which workpieces with strongly fluctuating input temperatures undergo machining. Sensors integrated into the clamping jaws record the temperature of the current part, which is then transmitted to the control system, where it can be immediately evaluated in the process.

The system is also used to monitor the clamping pressure. This is how corresponding sensors can detect whether a workpiece is being clamped securely and with constant force. Another example is automatic pre-positioning of the clamping jaws according to the current workpiece size that will be machined: if workpieces with different dimensions are to be automatically fed to the clamping device, the process is supported by integrated position measuring sensors.

More information www.blum-novotest.com

Hexagon launches Maestro next-generation CMM

Hexagon’s Manufacturing Intelligence division has launched Maestro, an all-new, next-generation CMM engineered from the ground up to meet the rising productivity demands of modern manufacturing. Designed to combat global skills shortages and increasing quality requirements, Hexagon says that Maestro sets a new standard for speed, simplicity and digital integration.

Maestro is built upon four principles: to be fast, easy to use, connected and scalable. Its digital-first architecture offers the industry rapid measurement routines, an intuitive user experience and seamless data integration. With modular software and hardware, it is designed to scale with evolving production needs, making it suitable for aerospace, automotive and high-precision manufacturing environments where there is a high demand for accuracy to deliver safety, compliance and performance.

The CMM’s newly-developed digital architecture incorporates digital sensors, a single cable system and a completely new controller. Together, these capabilities increase throughput, streamline the complete measurement operation and ensure future-ready connectivity for modern production environments.

According to Hexagon, Maestro delivers industry-leading throughput through high-speed motion while maintaining exceptional precision. Synchronised axis movements, rapid calibration and cloud-connected software significantly accelerate set-up, programming, execution and reporting.

“Manufacturers told us they needed a next-generation system that tackles rising quality demands and skills shortages,” says Jörg Deller, general manager of stationary metrology devices at Hexagon. “By rethinking our hardware and software from the ground up, rather than iterating on existing systems, we’ve had the freedom to create a high-accuracy inspection solution which is so intuitive that anyone from experts to new hires become significantly more productive.”

Pilot users report dramatic productivity gains and reduced inspection lead times, helping to avoid production bottlenecks and to keep pace with fast-changing customer requirements.

More information www.bit.ly/4mcLOC0