THE HELMUT FISCHER CUSTOMER MAGAZINE OF MEASUREMENT TECHNOLOGY

01/2017

INDUSTRY 4.0 QUALITY ASSURANCE FOR MODERN INDUSTRY

ALSO AVAILABLE AS E-MAGAZIN ON:

HELMUT-FISCHER.COM/FSM

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BETWEEN GINKGO, GAUSS AND GOETHE | The story of a companyCALIBRATING CORRECTLY

INDUSTRY 4.0 | Quality assurance for modern industryTERAHERTZ | A revolution in measurement

WHAT’S NEW IN MEASUREMENT TECHNOLOGY

SWISS | Where clocks keep up with the times

Editorial staffPlease send questions, critique or comments to Maria Moskaleva, Tel. +49 (0) 7031 303-562maria.moskaleva@helmut-fischer.de

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CONTENTS

PROGRESS

TECHNOLOGY

ON SITE BACKSTAGE

INFO-POINT

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DEAR READER,

In your hands is the newly-designed Fischerscope. You may even be reading this on your smartphone or laptop – as the lines between the digital and physical worlds continue to blur.

This also applies to the measurement technology used in modern ma-nufacturing, where factories must respond ever more quickly to mar-ket demands. That’s why this issue revolves around automation.

These days, the planning for quality testing starts with the very first digital sketches of any new production plant. Right from the start, measuring systems for layer thickness or material analysis are seam-lessly integrated into the manufacturing process, whether that be for microchip production, electroplating or automotive engineering.

For decades, we have worked with our customers to automate their quality monitoring. Now we again raise the bar and connect our test technology to your control systems, process control and ERP. ­Because ­Industry­4.0­needs­Quality­4.0!

As the market leader in instruments for non-destructive coating thick-ness measurement, Fischer is continually developing new technologies to fulfill industry requirements. The next step in this pursuit is tera-hertz technology, which will finally enable non-destructive measure-ment of multiple layers of paint coatings on plastic substrates.

I hope you enjoy reading the new Fischerscope.

Dr. Wolfgang BabelCEO / Managing Director

EDITORIAL

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Trade fairs provide a good opportunity to exchange ideas about the needs that different industries have for measurement technology.

This is why Fischer takes part in more than 60 trade fairs every year worldwide. And since automation is playing an increasingly important role in measurement techno-logy, we have added two new trade fairs this year: the Automotive Engineering Expo (‘AEE’ for short) and the SPS IPC Drives.

The AEE in Nuremberg (30 & 31 May) is all about auto-mation in the manufacturing of car bodies. Long before a modern production line can be set up and com mis-sioned, the planning and construction phases must take the quality assurance approach into account. Will there be random-sample checks or 100% monitoring? At-line testing or integration into the process stream? Here, Fischer always offers customized solutions.

Likewise, at the SPS IPC Drives (28 – 30 November), the topic is also automation. From providers of ERP systems and operation panels through to sensors, all the major manufacturers are represented – and – starting this year, Fischer will also be present as a supplier of automated measuring systems.

Two new trade fairs on the Fischer calendar

Going from Cr(VI) to Cr(III) How will things change for the electroplating industry?

Whether for consulting on an instrument or a measurement task: our experts at the show will be glad to help you. Please see our event calendar on helmut-fischer.com

From­the­classic­radiator­grille­to­bathroom­fittings­and­even high-tech injection nozzles for diesel engines – for decades,­ chrome­finishes­ have­ served­ their­many­ and­diverse functions reliably well. However, many chromi-um compounds are poisonous, especially chromium(VI) oxide, which is a by-product of some electroplating pro-cesses.

This is why chromium(VI) oxide has been included in the EU list of registered substances under the REACH regulation. That means, starting in late 2017, chromi-um(VI) oxide may only be used with special approval.

For this reason, many electroplating companies have recently switched to using chromium(III) or eliminated chromium from their production altogether. Although chromium(III) electrolytes are much safer, they do have their weaknesses. They are more sensitive to contamina-tion by other metals – even very small amounts of cop-per or zinc are enough to discolor the chrome layer.

Irrespective of the electrolytes, Fischer instruments can still accurately measure chrome coatings down to the nanometer. This also applies to analyzing galvanic baths with our X-RAY devices.

NEWS

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Correctly measuring fire protection coatings

Steel beams and steel structures form the basic frame-work­of­many­buildings.­In­the­event­of­a­fire,­they­can­be exposed to extreme heat and quickly become unsta-ble.

Therefore, many of these constructions are coated with intumescent materials that swell up when heated, for-ming a thick, foamy layer that insulates the underlying structure­and­increases­its­ability­to­withstand­fire.­

Internationally, there are several different minimum re-quirements­ that­apply­ to­such­fire­protection­coatings.­Usually, the layers are 6 – 7 mm in thickness, although they can even be as thick as 20 mm.

Because human health and safety depend on how relia-bly these protective coatings work, their quality must be controlled meticulously. With the DUALSCOPE® FMP40 and the FA70 probe, Fischer offers the ideal solution for accurately measuring unusually thick coatings on rough surfaces like those on steel beams.

Fire protection coatings can mean the difference between life and death. They improve the heat resistance of steel beams, thus provi-ding the extra time needed to evacuate a building

XAN®500 – Flexible RFA measurement technology for modern industry

With its updated X-RAY XAN®500, Fischer brings a unique­device­to­market.­The­XAN500­is­the­world’s­first­mobile­ X-ray­ fluorescence­ instrument,­ that­ measures­metal-alloy coatings, e.g. zinc and nickel reliably and accurately.

Increasingly­ flexible­ manufacturing­ processes­ require­highly adaptable measuring technologies. The versatile XAN500 can be used as a handheld device, as a desktop unit, or inline, as an integral part of an automated quali-ty assurance system.

Features▶ X-ray­fluorescence­instrument­for­mobile­use▶ Optimized for coating thickness measurement and

alloy analysis▶ 3-point support for correct placement – every time▶ Measurement box and tablet computer with

­WinFTM®­software

Benefits▶ One instrument, three ways to use it: handheld,

desktop, inline▶ Precise coating thickness measurement in running

production (e.g. Zn, ZnNi, Ag, Au)▶ Measure bulky parts like car fenders, pipes and

turbine blades with good repeatability▶ Placed into its measurement box, the XAN500 turns

into a full-function desktop unit▶ As part of the control system of a production line,

the XAN500 enables 100% monitoring

Industry 4.0 Quality assurance for modern industryThe future belongs to automation. When Hen-ry Ford first outfitted his factory with con-veyor-belts over 100 years ago in the USA, he could not possibly have imagined that, only a few generations later, there would be indi-vidually-configured cars rolling off assembly lines – entirely automated. This progress is in part based on ever-improving measurement technology, as the fourth industrial revolu-tion (Industry 4.0) demands measuring inst-ruments that can do more than just measure.

Whether in the automotive, electronics or elec-troplating industry, robots are increasingly being utilized in areas where repetitive sequences must be carried out with precision and speed. Not only does this raise the quality, it also reduces costs, since the processes can be continually optimized under constant conditions. The same applies to quality control: as cycle rates go up and manu-facturing plants become more networked, mea-surement technology must keep pace with better performance and integration capabilities.

TECHNOLOGY

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High-tech strategyIndustry 4.0 also means increasing interlinkage between production processes and information technology: in the ‘smart factory’, the Internet of Things connects machines, measurement systems, components and products. At every step in the value chain, robots are communicating with mea-suring devices, and products. The German federal govern-ment is supporting such developments through its high-tech strategy. In 2014, it declared the digitization of the economy a high-priority task for the future.

Batch size: 1 One­of­the­defining­characteristics­of­Industry­4.0­is­decen-tralization. Through the Internet of Things, each unit has access to all the data on a given workpiece. That enables decentralized decision making, and the production process becomes modularized.

In an ideal world, this would allow a customer to tailor his product. For example, a mobile phone could be painted in the customer’s desired color and engraved individually – just as a normal step in the production line. Yet, despite the greater product and process diversity, any single piece would still cost no more than mass-produced ones.

Quality assurance in real timeIndividualized manufacturing would enable a completely transparent production: when comprehensive data is availab-le­at­each­step,­the­finished­product­can­be­traced­all­the­way­back to the raw materials, if necessary.

For this vision to become reality, it requires a powerful and fully integrated testing system with interfaces to all control units. Quality assurance must be carried out in real time with-out holding up the process; sensors and measuring systems become the eyes and ears of the smart factory.

Fischer has been developing and producing highly advanced measurement instruments for over 60 years. Now, we are using our experience in measurement technology in the area of automation. With more than 300 installed inline systems worldwide, we offer sophisticated, automated measurement technology – from the standard unit to customized solutions.

Tactile coating thickness measurementEspecially in the automotive industry, quality management is already highly automated. With the FISCHERSCOPE MMS PC2,­Fischer­offers­a­very­flexible­system­that­employs­diverse­measuring methods for use at various stages of production.

For testing bulky parts, the measuring process can be automa-ted with the help of a multi-axis robot arm. For example, the thickness of galvanic coatings on car bodies can be determined quickly and precisely using the phase-sensitive method. Using a probe, the robot quickly scans a sequence of points, locating the correct position via image recognition.

In contrast to manual testing, the robot will always place the probe perfectly vertically, even on curved parts like fenders. These constant measuring conditions make it possible to un-cover­very­fine­differences­in­the­coating­quality­and­thus­im-prove the painting process.

Automation in the electronics industryNot­all­industrial­robots­are­big­and­orange!­In­the­electronics­industry,­ automated­ sleds­ and­ handling­ systems­ are­ often­used to protect fragile parts such as wafers from undue en-vironmental­influences.­

Even though making wafers is vastly different from making cars:­ the­ quality­ assurance­ systems­ still­must­ fit­ seamlessly­

TECHNOLOGY

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1.0 At the beginning of the 18th century, Tho-mas­Newcomen­installed­the­first­commer-cially-used steam engine to pump water from­ a­ mine­ shaft.­ His­ invention­ laid­ the­foundation­ for­ the­ first­ industrial­ revolu-tion, which took Europe by storm in 1784 with the advent of the mechanical loom.

2.0 Then, in 1913, Henry Ford had the famous Model T built in assembly-line production. Over the years, manufacturing continually picked up speed until it took only 93 min-utes to manufacture a Model T.

3.0 With the launch of the microchip, the wor-king world was once again reinvented. Sud-denly, in the factories of the 1970s, it was no longer technicians but programmers who were the most prominent professional group.

4.0 The internet is the birthplace of the fourth industrial revolution. In today’s smart fac-tory, all the pieces of the value chain are linked together in the Internet of Things.

INDUSTRY 1.0INDUSTRY 2.0

INDUSTRY 3.0INDUSTRY 4.0

70‘s Today

into­ the­production­process.­This­ is­why­we­also­equip­our­X-ray­fluore-scence devices with data interfaces for connecting to the PLC.

Fischer’s­ X-RAY­ XDV-µ­ SEMI­ is­ designed­ specifically­ to­ operate­ under­clean room conditions in wafer production. A robot automatically transfers the wafers from the cassette into the encapsulated interior of the measu-rement instrument with the utmost care and precision. Equipped with a high-­performance­ detector­ and­ microcapillary­ tubes,­ the­ X-ray­ fluores-cence­device­can­perform­very­fine­analyses­like­determining­the­materi-al composition of solder caps or the thickness of the gold coating on plug contacts.

Efficient use of gold in electroplatingMany­of­ the­plugs­used­ in­modern­electronics­have­an­electroplated­fin-ishing. In general, the high-value connectors are coated with gold, making them particularly corrosion-resistant.

To prevent the waste of expensive materials such as gold, one must closely monitor the thickness of the coating during the strip electroplating pro-cess. Fischer has more than 30 years of experience in this area of automa-tion and, in the FISCHERSCOPE X-RAY 4000, it has created a system that is perfectly suited to this industry. For instance, we are the only manufactu-rer­to­offer­a­variety­of­statistical­evaluation­features­that­can­significantly­reduce the amount of gold consumed while ensuring the same quality of coating. That is unique in the market.

From the first discussion through to the phasing-outIn addition to these examples, Fischer serves many other industries with its automated measurement solutions. We place a great emphasis on service over the entire course of an inline measuring system’s life cycle. From the very­first­sales­call­ through­to­ the­phasing-out­of­an­ instrument,­Fischer­service is tailored exactly to the needs of the customer. This makes it pos-sible for modern factories to produce individual products around the clock while continuously monitoring quality.

Silicon wafers are manu-factured under cleanroom conditions. The X-RAY XDV-µ SEMI is a fully automatic test station in which these sensitive wafers can be measured precisely – and safely

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Terahertz: A revolution in thickness measurementFischer is developing a technology for the non-destructive measurement of multiplex coatings on plastic

[A]utomotive paint has to withstand a lot: stone-chips, frost or heat. This is why the coatings have become so elaborate. Today at least four different layers are applied to car bodies. However, many car parts are made of plastic, and until now, the paint in these areas could only be tes-ted using destructive methods. With its terahertz techno-logy, Fischer finally makes it possible to measure multiple layers of paint on either metal or plastic substrates – non- destructively.

To­ ensure­ that­ a­ coating­will­ properly­ fulfill­ its­ function,­ it­must be tested carefully. Only then can an automotive manu-facturer,­for­example,­guarantee­that­the­paint­finish­will­last­for the entire life of the car while only expending as much ma-terial as really necessary. Modern quality assurance is there-fore faced with the task of precisely measuring multiple layers of paint.

In addition to metal, however, other substrates are also used: from your toaster to the medical devices found in operating rooms, many plastic parts are coated with multiplex paints. To­date,­it­has­only­been­possible­to­analyze­such­finishes­des-troying them with a wedge cut.

But­ Fischer­ is­ developing­ a­ technology­ to­finally­ close­ this­gap.­ For­ the­ first­ time­ ever,­ terahertz­ (THz)­ radiation­ will­make it possible to inspect multi-layer coating systems with-out damaging them – even when they are on plastic subst-rates. This method is called terahertz TDS (Time Domain Spectroscopy).

Measuring with terahertz – how does it work?The terahertz radiation in use here is made up of electromag-netic waves with frequencies ranging between 100 GHz and 4 THz. That means: shorter than microwaves but longer than light­waves.­Only­recently­efficient­emitters­and­detectors­for­this frequency range have become available.

The special feature of THz radiation is that it penetrates many kinds of paints and coatings. Fischer harnesses this transpa-rency to measure the thickness of the layers. Similar to measu-ring thickness with ultrasound, the THz radiation is partially reflected­at­the­transitions­between­layers:­the­"echoes"­arrive­at­the­detector­with­a­slight­delay.­From­this,­the­Fischer­soft-ware can determine the thickness of up to four layers – the measurement itself takes only a second.

How does terahertz compare?[ Excellent repeatability ] Even now, though still in develop-ment, the accuracy of the terahertz method is impressive: on a measuring spot of less than 2 mm, it is possible to measure layer thicknesses of 5-10 μm. In contrast to magnetic induc-tion, which has a similar resolution, terahertz offers 10 times better repeatability, or 1‰.

[ Non-destructive ] Since the paint layers are transparent to the­THz­radiation,­the­rays­do­not­influence­the­coating.­This­makes the measurement entirely non-destructive.

[ Non-ionizing ] Terahertz is much less energy-intensive than X-radiation and therefore harmless. THz devices can thus be used in the open and require no radiation protection.

PROGRESS

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[ Contactless ] Unlike magnetic induction and ultrasound, terahertz is non-contact, so it is even possible to measure wet paint.

[ No calibration needed ] While thickness mea-surement with ultrasound is based on a principle similar to terahertz, it requires complex calibra-tion. Fischer's THz system, on the other hand, can be used on simple coatings without any cali-bration at all. All the requisite readings are taken in a single step.

Before­ analyzing­multiplex­ paint­ finishes,­ each­layer is measured individually. The device saves all the relevant values. Should the same paint be­ encountered­ again,­ there­ is­ no­ need­ to­ "re-­­calibrate"­it.

Terahertz – method of the futureThe­first­THz­ system­ is­ being­ designed­ specifi-cally to measure multiple layers. Together with automakers and lacquer manufacturers, we are developing solutions for integrating this techno-logy into production processes.

But that does not come close to exhausting the method’s­potential!­Many­substances­absorb­THz­radiation in ways that are characteristic for them alone. This opens up a wide variety of other pos-sible applications in the future.

Clear coat ~ 40 μm

Base coat ~ 15 μm

Filler ~ 30 μm

CPD coat ~ 20 μm

Car body

THz-Source Detector

Substrate

Layer 2

Layer 1

Air

Reflection 2

Reflection 1

40035030025020015010050

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95Cross section / microscopy THz system

Magnetic inductive probe

Thic

knes

s [µ

m]

Position [mm]

The terahertz pulse pene-trates the coating and is reflected at the material boundaries. From the delay time of the various reflections, the software calculates the thickness of each layer

Typical auto paint finishes consist of several insulating layers, which as yet could only be measured indivi-dually using destructive methods

In measuring a wedge cut, terahertz compares favor-ably to established meth-ods such as micro scopy and magnetic induction

AT A GLANCE

▶ For measuring the thicknesses of mul-tiple layers

▶ Whether metal or plastic: the substrateplays no role in the measurement

▶ Non-ionizing▶ Contactless▶ Non-destructive▶ Little to no calibration needed

ON SITE

[ I ]n Northwest Switzerland, the Jura Mountains run along the border to France. This rural area has always been sparsely populated; in many places one still can find traditional far-ming culture where humans and livestock sha-re the same roof in whitewashed farmhouses. A perfect place for hikers to rest and to enjoy nature. And yet, this secluded area is also home to a world-famous industry: Swiss watches.

The meager Jurassic soil and the harsh moun-tain climate have never made agriculture easy here, so farmers from the region have always sought additional ways to make it through the long winter months. To this end, in the 18th century, peasants from the small village of La Chaux-de-Fonds started making clock parts in their­homes.­This­new­cottage­ industry­flouris-hed and quickly attracted more workers; the town subsequently grew – and adapted to the needs of the watchmakers. A new city plan was drawn up in 1794: the roads were made wide and ran in a south-westerly direction, in order to pro-vide as much sunlight as possible to the workers at their benches.

Due to this synthesis of urban planning and the needs of the watch industry, today La Chaux-de-Fonds is a UNESCO World Heritage Site. Some of the world's most renowned watchmakers have emerged from this small, remote village and come to dominate the luxury watch market.

Elegant shine:from the hands to the bandTo be worthy of a luxury watch, not only does a clockwork have to be precise, it also has to look valuable and exude quality. This is why many watch components require functional coatings that are also decorative.

Thus, alongside the watchmakers, several elec-troplating companies also call the Jura Moun-tains home. Saulcy Traitement de Surface SA (STS) is one such company that has located a branch in La Chaux-de Fonds. Founded in 2006, for the past 10 years STS has been a preferred partner­when­it­comes­to­fine­coatings­on­watch­components. With its rack plating and bulk pro-cessing techniques, STS has made a name for itself among watch manufacturers. So that it can respond quickly to customer requests, besides its subsidiary in La Chaux-de-Fonds, STS also has operations in two other centers of watchmaking: Le Sentier and Develier.

Swiss: Where clocks keep up with the times

Because it enables automated serial testing, the XDAL can also be used to analyze batches of samples with high precision

In modern clockworks, not only does precision count but also their aesthetics

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From­the­watch­plates­to­the­hands,­STS­finishes­a­wide­variety­of watch components; the orders are correspondingly diverse. To meet these requirements, not only must the electroplating itself be extremely versatile, but also the quality assurance processes.­"At­STS,­we­galvanize­components­for­the­very­best­watchmakers­in­the­world,"­said­Frédéric­Saulcy,­CEO­of­STS:­"The­quality­demands­are­commensurately­high.­For­carrying­out the 80 to 90 different measuring tasks that we’re always faced­with,­we­find­the­flexible­Fischer­instruments­to­be­the­ideal­solution.­"

Quality assurance:from the electrolyte to the finished partThe biggest challenge in coating watch components are the tight production tolerances on already very thin layers. Espe-cially­in­the­movement,­the­delicate­pieces­have­to­fit­together­absolutely perfectly. Too-thick layers would generate more friction and make the watch inaccurate.

Plus, expensive raw materials such as gold and rhodium must be­ used­ as­ efficiently­ as­ possible.­ Therefore,­ STS­ often­ ap-plies multi-layer coatings with a total thickness of less than a micrometer, for example, 0.05 μm rhodium on 0.1 μm gold and 0.5 μm nickel. The base material of the parts is frequently a copper alloy such as brass.

At all three locations, STS analyzes these sophisticated coat-ings with the FISCHERSCOPE XDAL 237 devices. Because the­ flexible­ X-ray­ fluorescence­ systems­ are­ equipped­ with­silicon PIN detectors, they can measure very thin layers. Besides producing a good resolution of the thicknesses, the PIN detector can also reliably distinguish between very si-milar­elements.­Using­ the­WinFTM­software,­ the­XDAL­237­dependably differentiates between the copper signal coming

from the base material and the nickel signal in the coating system.

"A­watch­has­a­lot­of­tiny­parts.­For­components­like­pinions,­we­like­to­use­Fischer's­XULM,"­Saulcy­confirms.­This­X-ray­sys-

Swiss watches, coatings from STS and Fischer measuring instruments are a perfect match because each one is focused on the best quality.

ON SITE

Frédéric Saulcy, CEO of Saulcy Traitement de Surface

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tem performs precise analyses of minuscule parts with mea-suring spots just 0.05 mm in size. Another one of its strengths lies in analyzing the contents of the galvanic bath. Besides the classic measurement functions, WinFTM also does funda-mental parameter analysis; that means it can determine the bath­composition­without­standards.­"The­XULM­saves­us­a­lot­of time on bath analyses because the device doesn’t have to be re-calibrated for every new bath,” says Saulcy.

From the Jura to the world"With­the­help­of­Fischer,­we’ve­enhanced­our­in-house­quality­assurance so much that we’ve even begun accepting orders to analyze­baths­ for­ other­ coaters,"­ Saulcy­ explains.­ STS­main-tains one of Switzerland’s leading laboratories for the analysis of­galvanic­baths.­In­addition­to­X-ray­fluorescence­measure-ments, STS also offers inspections of the coated parts: micro-scopic, chemical and mechanical.

However, the high quality assurance standards enable more than just optimization of existing processes; at STS, six che-mical engineers are also currently at work developing new baths and coatings. For example, treatments such as Rutheni-um­Noir­and­the­NAC­finish­were­both­developed­by­STS.­With­modern­surface­refinements­like­these,­STS­is­contributing­to­the unique reputation that Swiss watches enjoy worldwide.

All the clock components are bought together on the watch plate. Here, the tiny parts must fit perfectly so that the movement works smoothly

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BACKSTAGE

Between Ginkgo, Gauss and GoetheThe Helmut Fischer Museum presents an extraordinary corporate history

[N]ature and technology, art and science – Helmut Fischer’s perspective on life links these seeming contrasts with one another. At the Fischer Museum in the Sindelfin-gen headquarters, visitors can experience his life’s work, as well as our company's history and values.

The­ room­ is­ flooded­ with­ light.­ The­ sun­ plays­ on­ the­ glass­showcases and catches the light just like the leaves of the trees. When you enter the Helmut Fischer Museum, you feel as if you could still be in the garden just outside the window: visitors are welcomed with the sounds of nature and birdsong.

From chaos to orderThis closeness to nature strikes one as unusual for a technical museum. In biology, many things are chaotic: each leaf of the ginkgo tree has its own unique shape; no bird egg is the same size as any other. Technology, however, always strives for the highest order: every screw should look just like the next, every device deliver the same results.

Nevertheless, Helmut Fischer, an enthusiastic hobby botanist, has always found inspiration in nature for his work. Whether we consider the weight of a seed or the thickness of a coat of paint­–­there­are­always­fluctuations.­A­single­measuring­point­cannot completely represent reality. It is only through statistics that the measured values present an image of the greater whole.

The basis for modern statistics was laid down by the Ger-man mathematician Carl Friedrich Gauss. He described the standard distribution, which is still used today in science and technology. Studying the works of Gauss made a long-lasting impact on Fischer. Since 1984, Fischer devices have been equipped­with­powerful­analysis­software­to­ensure­that­sim-ple measured values produce reliable and correct results.

While the Helmut Fischer Foundation can be seen as the cul-mination of a life's work, in truth it is­a­gift­to­future­generations

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From improvisation to perfectionOne person who encouraged Fischer to look into the works of Gauss, and who exerted his own formative effect on the young man, was his physics teacher, Mr. Schuhmann. Together they founded­ Fischer’s­ first­ company­ in­ Stuttgart­ in­ 1953.­Quick-ly recognizing the needs of a burgeoning post-war industry, 22-year-old Fischer developed a device for measuring lacquer and chrome coatings – the Permaskop – and won over Bosch and­Daimler­as­some­of­his­first­customers.­

In post-war Germany, though, many materials were still hard to­find:­often,­one­simply­had­to­improvise.­From­a­common­nail, Helmut Fischer built a sensor that could measure coa-tings­less­than­5­µm­thick!­This­boldness­was­rewarded­as­just­a year later, in 1954, the company booked some DM 40,000 in sales.

Then as now, quality was always Fischer’s top priority. Each and every device was individually calibrated: dozens of stan-dards were measured and the corresponding values marked in ink on the dial. This resulted in an individual scale for each in-strument that was as precise as any modern calibration curve.

From yesterday to tomorrowFor Helmut Fischer, it was important to build equipment that would last for many years – and the same goes for the com-pany itself. Five decades later, he transferred his company shares to a foundation, ensuring the purpose-bound and char-itable continuation of his work.

As versatile as Helmut Fischer the person is, so is his founda-tion: in addition to endowing professorships, it also has the mandate to support culture, because Helmut Fischer is an enthusiastic collector of literature as well. In 2009, he entrus-ted to the Deutsches Museum in Munich a library of histori-cal books that he had assembled over the years with love and expertise. Besides original editions of works by Newton and Einstein, the 5000 volumes also include artistically illustrated versions of Goethe's Faust.

But one of the most important goals of the Helmut Fischer Foundation is the sponsorship of young scientists. That is why interested young researchers and students are always wel-come­guests­at­the­Helmut­Fischer­Museum­in­the­Sindelfin-gen headquarters.

Helmut Fischer and his first X-ray fluorescence device. In 1983, the company revolutio-nized the practice of coating thickness measurement with these instruments

The future belongs to automated measurement systems. Used in conjunction with robots, Fischer's precise measurement technology can improve the coating while saving material costs

The exhibits lead visitors chronologically through the company's history. The oldest instrument in the museum bears the serial number ‘01’ and dates from 1953

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Calibrating correctly

INFO-POINT

[A] gauge can only deliver correct results if it has been scrupulously calibrated. This is why the ISO 9001 standard requires the calibration of measuring instruments. Here, we answer some questions about what you should consider when calibrating tactile gauges.

What does "calibration" mean? During calibration, the reading of a measuring device is compared with the actual property of the measured object (usually a standard with known values). Layer thickness is one such property. If the just-measured value deviates from the known value, the device must be adjusted. For all of Fischer's tactile coating thickness gauges, these two func-tions­are­combined­under­the­"Calibration­"­menu­item.­

How should one go about calibrating?The same conditions should prevail during calibration as would later, during the actual measurement. If the thickness of a coating is to be measured, the device should be calibra-ted on an uncoated original part. For calibration, use the same location on the uncoated workpiece as you will when measuring the coated part.

When should one recalibrate?In general, the instruments should be recalibrated whenever the measuring conditions change. For example, if the com-position­of­the­substrate­changes,­or­if­you­go­from­a­flat­part­to a curved one, it may be necessary to recalibrate, depen-ding on the measuring method used.

Quick or extensive calibration?On most devices, you can choose between a fast, single-point calibration and a comprehensive, multi-point calibration. The­quick­variant­will­usually­suffice­if­the­values­you­want­to measure are very close. For example, if the thickness of the coating varies between 10 and 15 μm, it is enough to cali-brate the device with a single 13 μm standard. If the range of thicknesses is larger, a multi-point calibration is recommen-ded; the target values should bookend the expected range of coating thicknesses.

AT A GLANCE

Common factors that can affect the results of a measurement If­one­of­these­factors­changes­significantly,­the­device­should be recalibrated:

▶ Curvature of the measuring surface ▶ For thin specimens: thickness of the base material ▶ For small specimens: dimensions of the piece ▶ Roughness ▶ Composition and magnetizability of the substrate or

coating materials ▶ For conductivity measurements: temperature

Robust Fischer MP0R gauges are purpose-built to perform in the world of corrosion protection.• Accurate Dry Film Thickness measurements –

no calibration needed• Sturdy construction outside, high-tech inside• Easy to use, versatile, reaches into the tightest spots• Pivoting and illuminated display for quick and

convenient reading of results• Lighweight and pocket-sized• Measure according to standards, special modes for

IMO PSPC and SSPC-PA2

helmut-fischer.com

Compact gauges for big jobs

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Helmut Fischer GmbH Institut für Elektronik und Messtechnik Industriestrasse 21 71069­Sindelfingen

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