MODULE 5

MCE 411: CAD/CAM

COMPUTER AIDED QUALITY CONTROL (CAQC)

INTRODUCTION

Quality control (QC) is a process through which product quality is maintained or improved.
Quality control involves testing units and determining if they are within the specifications for the
final product.

The quality control (QC) function has traditionally been performed using manual inspection
methods and statistical sampling procedures.

INSPECTION AND TESTING: Inspection is normally used to examine whether a product

conforms to the design standards specified for it. For a mechanical component, this would be
probably concerned with the dimensions, surface texture and tolerances specified for the part. Non-
conforming goods result in scrap, rework, and the loss of customer good-will. Various categories
of tests used for final product evaluation are:

 Functional tests under normal or simulated operating conditions.

 Fatigue or wear tests to determine the product’s life function until failure.
 Overload tests to determine the level of safety factor built into the product.
 Environmental testing to determine how well the product will perform under different
environments (e.g. humidity, temperature, vibration).

OBJECTIVES OF CAQC:-

i. Improve product quality

ii. Increase productivity

iii. Reduce lead-time

iv. Reduce wastage due to scrap/rework

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ROLE OF COMPUTER IN QC

Computer-aided inspection (CAI) and computer aided testing (CAT) are the two major segments
of computer-aided quality control. Whereas these activities have been traditionally performed
manually (with the help of gauges, measuring devices and testing apparatus), CAI and CAT are
performed automatically using computer and sensor technology. Today, CAI and CAT can be well
integrated into the overall CIM system.

With Computer aided inspection and computer aided testing, inspection and testing will typically
be done on a 100% basis rather by the sampling procedures normally used in traditional QC.
Inspection is integrated into the manufacturing process. This will help to reduce the lead-time to
complete the parts.

The use of non-contact sensors is recommended for computer aided inspection and CIM. With
contact inspection devices, the part must be stopped and often repositioned to allow the inspection
device to be applied properly. These activities take time. With non-contact sensing devices the
parts can be inspected while in operation. The inspection can thus be completed in a fraction of a
second.

Sensor technology will not be the only manifestation of automation in CAQC. Intelligent robots
fitted with computer vision and other sensors, as an integral part of completely automated test cells
is also a feature of CIM. An important feature of QC in a CIM environment is that the CAD/CAM
database will be used to develop inspection plan.

Inspection methods

1. Contact method

2. Non-contact method

1. Contact method: In contact inspection, physical contact is made between the object to be
inspected, and the measurement device. Typically contact is achieved using a mechanical probe or
other device that touches the item, and allows the inspection procedure to occur. By its nature,
contact inspection is concerned with some physical dimension of the part, and so contact methods
are widely used in manufacturing and production industries to assess metal parts, and for electrical

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circuit testing. Instrument used are: Conventional instruments, Coordinate measuring machine,
and Stylus measuring system

Conventional measuring instruments: scale gauge bars slip gauges, Vernier calipers, screw
gauge

Coordinate Measuring Machine: The coordinate measuring machine (CMM) is the most
prominent example of the equipment used for contact inspection of parts. When used for CIM,
these machines are controlled by CNC. A typical three-dimensional measuring machine consists
of a table, which holds the part in a fixed, position, and movable head, which holds a sensing
probe. The probe can be moved in three directions corresponding to the X, Y and Z Coordinates.
For manual operation, the control unit is provided with joysticks, or other devices which drive X,
Y and Z servo motors (AC/DC).Typical accuracies of these machines are in the neighborhood of
mm which are solution of mm. The measuring accuracy of a typical CMM is quoted 2.6 +L/300
micrometers, where L is the measured length in mm

CMM consists of main structure: The machine incorporates the basic concept of three coordinate
axes so that precise movement in x, y, and z directions is possible. Each axis is fitted with a linear
measurement transducer. The transducers sense the direction of movement and gives digital
display. Accordingly, there may be four types of arrangement:

(a) Cantilever: The cantilever construction combines easy access and relatively small floor space
requirements. It is typically limited to small and medium sized machines. Parts larger than the
machine table can be inserted into the open side without inhibiting full machine travel.

(b) Bridge Type: The bridge arrangement over the table carries the quill (z-axis) along the x-axis
and is sometimes referred to as a travelling bridge. It is claimed that the bridge construction
provides better accuracy, although it may be offset by difficulty in making two members track in
perfect alignment. This is by far the most popular CMM construction.

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(c) Column Type: The column type machine is commonly referred to as a universal measuring
machine rather than a CMM. These machines are usually considered gauge room instruments
rather than production floor machine. The constructional difference in column type with the
cantilever type is with x and y-axes movements.

(d) Gantry: In a gantry type arrangement, arms are held by two fixed supports. Other two arms are
capable of sliding over the supports. Movements of the x, y and z-axes. The gantry type
construction is particularly suited for very large components and allows the operator to remain
close to the area of inspection

(e) Horizontal: The open structure of this arrangement provides optimum accessibility for large
objects such as dies, models, and car bodies. Some horizontal arm machines are referred to as
layout machines. There are some horizontal machines where the probe arm can rotate like a spindle
to perform tramming operations. Tramming refers to accurate mechanical adjustment of
instrument or machine with the help of tram.

Stylus instrument: Stylus – type instruments are commercially available to measure surface
roughness. These electronic device have a cone shaped diamond stylus with point radius of about
0.005 mm and a 90° tip angle that is traversed across the test surface at a constant slow speed. As
the stylus head moves horizontally, it also moves vertically to follow the surface deviations. The
vertical movements are converted into an electronic signal that represents the topography of the
surface along the path taken by the stylus. This can be displayed as either profile of the surface or
average roughness value.

2. Non-contact method: Non-contact inspection methods utilize a sensor located at a certain

distance from the object to measure or gauge the desired features. The non-contact inspection
technologies can be classified into two categories: 1. optical 2. Non-optical.

Optical inspection technologies use light to accomplish the measurement or gauging cycle. Non-
optical inspection technologies utilize energy forms other than light to perform the inspection.

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These other energies include various electrical fields, radiation and ultrasonic. The main
advantages of non-contact inspection are:

 It eliminates the need to reposition the work-piece.

 Non-contact inspection is faster than contact inspection.
 There is no mechanical wear encountered in the contact inspection probe.
 The possibility of damage to the surface of a part due to measuring pressure is eliminated.

Machine Vision:

Machine vision is the creation of an image and the collection of data derived from the image, and
the subsequent processing and interpretation of the data by a computer from some useful
application. Machine vision is also known as computer vision, and its principal application is in
industrial inspection. Machine vision exists in two-dimensional (2D) and three-dimensional (3D)
formats, with 2D being most common in industrial applications. Examples of its usage include
dimensional measuring and gauging, verifying the presence of components, and checking for
features on a flat (or semi-flat) surface. 3D machine vision is used in applications where a 3D
analysis of the scene is required.

Here we focus on the simpler 2D machine vision system. The operation machine vision system
can be divided into the following three functions:

1. Image acquisition and digitization.

2. Image processing and analysis and

3. Interpretation

Image Acquisition and Digitization: Image acquisition and digitization is typically performed by
deploying a video camera to capture the image, and the use of a digitizing system to store the
image data for subsequent analysis. The camera is focused upon the surface of the item of interest,
and an image consisting of discrete pixel elements is captured in the viewing area; each pixel has

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a value proportional to the light intensity of that portion of the scene. The intensity value of each
pixel is converted into its equivalent digital value by an analogue- to-digital converter.

Image Processing and Analysis: A number of techniques have been developed so that data
produced during the first phase of machine vision may be processed and analyzed. These general
techniques are called segmentation (a technique intended to define and separate regions of interest
within the image), and feature extraction (which follows on from various segmentation processes).

Interpretation: The extracted features of the image are guide from which interpretation of the
image emerges; that is, interpretation is concerned with recognizing the object (object recognition),
and/or recognizing the major features of the object (pattern recognition). Predefined models or
standard values are used to identify the object in the image.

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