Information Technology Tools for Metrology J. Raja Center for Precision Metrology University of North Carolina at Charlotte
Information Technology Tools for Metrology
J. Raja
Center for Precision Metrology
University of North Carolina at Charlotte
Outline• Manufacturing in the global age• IT tools in metrology - Efforts at UNCC
– Internet based Analysis software– Surface texture Database– Information system– Peer-to-peer file sharing– Tool boxes for process and function– Uncertainty and gage R&R– Gage management software
• Future directions• Conclusions
Business models in manufacturing industries
• Traditional Model– Vertically integrated– Design, Manufacturing and Assembly
• Distributed Manufacturing Model– Design and Assembly– Manufacturing of key components (3Cs, 5Cs)
• Virtual model– Some design and assembly– Emphasis on brand (Marketing, Distribution and
services)
Henry Ford’s vertically integrated facility
Ford River Rouge Complex
The complex included dock facilities, blast furnaces, open-hearth steel mills, foundries, a rolling mill, metal stamping facilities, an engine plant, a glass manufacturing building, a tire plant, and its own power house supplying steam and electricity.
IRON ORE
Manufacturing in the global age
• Remarkable progress in IT in the last decade
• Manufacturing goes global• Need for sharing information
across geographical boundaries
• Monitor data real time for diagnostics
• Quickly deploy solutions to the industry
• Share documents, data and results between academia and industry
Crankshaft
Engine
Bearing
Made in USA!
IT in Metrology – the last 30 years
Src: Taylor Hobson and Mahr-federal web sites
Historical Surface Metrology Measurement Spectrum
Micro-burrs &Torn Material
Roughness Straightness Dimension(Size & Position)
Microscopy(Visual Assessment)
Sharp-Stylus(Roughness)Instruments
Special PurposeInstruments
Surface Plate(layout) Instruments& Gauges
Current Metrology Measurement spectrum
Micro-burrs &Torn Material
Roughness Straightness Dimension(Size & Position)
Microscopy(Visual & Digital Assessment)
Sharp-Stylus(Roughness)Instruments
Waviness
Roundness &CylindricityInstruments
CoordinateMeasuringMachines(CMM's)
Efforts at UNCC
IT Tools for Metrology
Internet based Analysis software
Database
Peer-to-peer file sharing
Information System
Toolboxes
Process specific
Functional toolbox
Uncertainty(GUM)
Gage management software
Visualization tool using VRML
Visualization controls for viewing profiles
Internet based Surface Texture Analysis Software
Internet based analysis software
• A surface texture analysis system capable of accessing data from a database over the Internet
• Comprehensive set of filters and user defined filtering schemes for surface profile diagnostics
• Collection of advanced tools for surface texture analysis
• Tools for comparing profiles
• Visualization tools for multiple profiles
• Tools for process specific analysis
• Providing a common analysis package for data from different sources
• A template for the development of recipes for detailed analysis
Analysis Tools Developed• Filters
– Gaussian
– TwoRC
– BandPass
– RKFilter
– Functional Filtering
• Curvature removal• Amplitude Dist.• Power Spectrum• Parameters (ISO)
• Compare Two Profiles• Correlation Function
– Auto, Cross
• Multiple File Analysis• Multiple File Formats
– Mahr, Talysurf, Federal, SDF
• Special Tools– Generate and Analyze turned
profiles
– Multiple Cutoffs
– Removing Asperity
– Wavelet Analysis
Internet based software – raw data & slope removed profile
Roughness, waviness and form
Multiple cutoffs
Surface Texture Database
Surface Texture Database
• Organize surface texture data for analysis
• Process mapping: collect comprehensive data long period of time
• Use data over extended time to develop process knowledge
Entity Relationship Diagram
MEASUREMENT
InstrumentName TraceLength
DriveSpeed TipRadius TipForce
ToolFeed
MeasureNo
MeasurementDate
Additional_ Information
MeasurementTime
Temperature
ProbeRange
Resolution
Range
GENERATES
PART
PartNo
Company
PartDate Additional_ Information
PartTime
PartName
PRODUCES
N
M 1
1
N
Additional_ Information
SURFACE_FUNCTION
Description
Symbol SurfaceNo
1
Pa ANALYSIS_
DATA Pz
Psk
Pku
Rms_Slope
Sm
Pv
Pp
Pt
Pq
1
HAS N
PROCESS
1
Process_Name
Depth _Cut
Tool Speed
ToolRadius
ToolFeed
ToolLife
ToolChange
Temperature
Machine_Tool_ FileName
ProcessNo
DATA_FILE
Format
Spacing
DataNo
FileName
NumberPoint
CONTAINS INCLUDES
MACHINE_TOOL
MachineNo
Additional_Information 1
N
Filename
Features• Remote and local data upload to the database• Upload data to surface analysis program• User privilege and Password protected storage
space• Customized Database fields• Ability to read commercial data formats• Extensive query capability• Data file management
Component Interaction
Database
Surface Analyzer
Application
Instrument B
Web Browser
The User
Client
Instrument C ..n..
usesconnects
displays
insertsinserts
Instrument A
inserts
inserts
queriesreturns
InsertDeleteUpdate
Internet based Form analysis software
Roundness & Cylindricity
• Polar & Linear Roundness plot
• Filter– 2RC
– Gaussian
– Spline
– FFT
– FFT Bandpass
• LS, MI, MC & MZ Algorithms for Roundness
• LS Algorithm for Cylindricity
• Power Spectrum & harmonics
• Comparison of two different profiles
• Multi-filters using One Cutoff
• Multi cutoffs using One Filter
Roundness Analysis System
Filtering of Roundness Data
Cylindricity Analysis System
Straightness & Flatness
• Least Squares and Minimum Zone Straightness
• Display of Straightness Profile
• Least Squares & Minimum Zone Flatness
Issues with the Applet version
• Computing done on client machines
• Speed not satisfactory
• Firewall problem
• Database access slow
• System does not allow the creation of multiple DB user account
The servlet version• Three-tier architecture
– DB, application server and servlet
• Thin client• Run on firewall environment because client only
sees html pages• Support multiple user accounts• Speed issue resolved• Supports access to user log files for administration
purposes
The servlet software:3-tier architecture
User
Web Application (Metrology software
application) Database
HTTP JDBC
DatabaseServlet Application Server
The customizable database
• User can customize database fields based on specific application
• Can interface with analysis software
A milestone: A new server
• Spring 2001: Server installation
• The software can now be accessed at
http://www.sfmg.uncc.edu/metrology
The common interface to the software
Process and Functional Toolboxes
Toolboxes for process and function
Tool boxes for surface metrology
Generic Process Tool box
Turning toolbox
Plateau-honing toolbox
Grinding toolbox
Functional Tool box
Analyticaltools
Inferenceengine
DB
Analyticaltools
Statisticaltools
DB
Process specific toolboxes
• To build a process specific toolbox for diagnostic applications
• Toolbox will have a knowledge base and also have an inference engine to perform diagnostics like tool wear, feed changes etc.
• Build a toolbox for turning, grinding and plateau-honing
Turning Example
Effect
Parameters Ra, Rsk, Rku, RqPower SpectrumAutocorrelationEnvelop variations
Predictive logic
Cause
Tool wearFeed change
Monitor profile variations
Turning Example• Develop a model that describes cause-effect
relationship– The data for this model will come from many sources –
experiments, literature, industry etc– This data will serve as the knowledge base for the inference
engine
• Prototype model will be built in Matlab that implements the predictive logic
• Database design to handle large quantities of data• Final version of the software will be deployed over the
internet
Functional toolbox - Objective
• To build a toolbox with a collection of advanced analysis tools for functional correlation studies
• The toolbox will include statistical tools, analytical tools along with database support
Peer to peer file sharing
Peer-to-Peer file sharing
• Provide the users a mechanism to share data file between peers in a network
• Provide the users a search engine where they can search data files from other peers on the network based on surface parameters and instrument names
• Provide the users analysis tools and a data file library
Peer-to-Peer file sharing
Measurement in Germany
Measurement in India
Measurement in US
Peer to peer search engine interface
Downloading interface
Information System
Information System
• Content Management Process
• Editorial board to review and approve content
• Centralized web-based application approach
Surface Metrology Content• Instruments: information regarding instruments used to measure
surface texture• Parameters: definition of surface parameters• Filters: filter types and how they can be used• Standards: International standards• Process: relationship between process parameters and surface
and form parameters• Function: relationship between function and surface and form
parameters• Classic Papers• Case Studies• Other Links
Content ManagementContent provider uploads, edits or deletes content via web interface and submits update
Content provider sets a content type and applies attributes relative to this type and submits document
Content editor modifies document properties, as appropriate, and if necessary, approves content, which is then submitted
Site administrator submits site content to a stage server for review
Content is deployed, either automatically, or manually to production server(s)
Collaborative Filtering System
• Collaborative filtering systems make use of reaction and opinion of people that have already seen a piece of information to make predictions about the value of that piece of information for people who have not yet seen it.
• Collaborative filtering systems can guide the users to relevant resources or resources that have best quality in context.
Features
• Recommendation Engine• Top N List • Generalized and categorized Search• Information is put in categories
Uncertainty, Gage R&R and Gage Management tools
Uncertainty and Gage R&R
• Currently developing an Internet based uncertainty analysis tool based on GUM
• Also developing tools for performing gage R&R on the web
• These tools would allow a large manufacturing company to store and access uncertainty and gage repeatability data, thereby aiding the measurement assurance process
Gage Management software
• Currently in the process of designing a gage management tool for storing data related to gage calibration and maintenance
Technology Transfer
• In the process of transferring the servlet version of the software to Caterpillar’s Manufacturing and Logistics Division for use on their intranet
In Summary
IT Tools for Metrology
Internet based Analysis software
Database
Peer-to-peer file sharing
Information System
Toolboxes
Process specific
Functional toolbox
Uncertainty(GUM)
Gage management software
Future directions• Internet and web based technologies are becoming
increasingly popular.• They will become the medium of information
exchange in the coming years.• Transition from stand alone computing to local
intranet will be driven by economic and legal issues
• Commercial products are slowly in the process of supplying a server with instruments
• Communication between different databases and networks will become an issue and XML based languages will be necessary
Conclusions
• Presented the work done at UNC Charlotte over the last six years in the area of building a framework for doing remote metrology
• Built a platform to support distributed manufacturing and product development
• Information technology tools enable better communication between experts in academia and industry and provides access to experts anywhere in the world
Conclusions
• Change in the business models will influence manufacturing and metrology, requiring the use of such data sharing and analysis tools
• Internet based systems, client-server computing and peer-to-peer data sharing will be more common tools in the future