measureupp o r t a b l e C M M N e w s l e t t e r H e x a g o N M e t r o l o g y 0 3 / 2 0 0 6

December 2006 edition www.portable-cmm.com

portable CMM “the Missing evolutionary link” at airbus pages 4 − 5

romer turns 20: Interview with romain granger, Company Founder pages 8 − 9Midsize Company thrives Under globalization pages 10 − 11

Happy Birthday!

Dear reader,

The synergy effects of the new Portable CMM group within Hexa-gon Metrology are starting to bear fruit. If you recently contacted your Hexagon sales person, you were surely pleasantly surprised by the addition of some friendly new faces, who are armed with practical knowledge about different measure-ment technologies and can help you decide how to provide the most optimal solution for your specific measurement needs.

Romer has turned 20 in October, and we’ve decided to commemo-rate this proud milestone in this issue of measureup by giving you yet another Romer case study il-lustrating the vast array of possible applications for Romer articulated arms. In addition, we interviewed Romain Granger, General Direc-tor and founder of Romer. On the other hand, Leica Geosystems was awarded the 2006 Frost & Sullivan Market Leadership Award in the laser tracking segment.

If you have any comments or sug-gestions on how to make measureup even more to your liking, please don’t hesitate to contact us. So without further ado, enjoy your reading.

Best regards,

Your measureup Editorial Team

exhibitions January - March 2007 Index

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editorial

AutosportJanuary 11-14, 2007U.K., Birminghamwww.autosport-international.com

ImtexJanuary 18-24, 2007India, Bangalorewww.imtex.in

Southern ManufacturingFebruary 7-8, 2007U.K., Thorpe Park-Surreywww.industry.co.uk

KaliteFebruary 16-18, 2007Turkey, Istanbulwww.kalitefuari.com

Houstex Advanced Productivity ExpositionMarch 6-8, 2007USA, Houston TXwww.sme.org/houstex

Elmia QualitecMarch 6-8, 2007Sweden, Jönköpingwww.elmia.se/qualitec

Industrie Lyon 2007March 6-9, 2007France, Lyonwww.industrie-expo.com

Metrologia & QualitàMarch 14-16, 2007Italy, Turinwww.qualitaly.com

MaquitecMarch 20-24, 2007Spain, Barcelonawww.maquitec.com

IntermoldMarch 21-25, 2007Korea, Seoulwww.koreamold.com

WestecMarch 26-29, 2007USA, Los Angeles CAwww.sme.org/westec

TimtosMarch 28-31, 2007Taiwan, Tapeiwww.timtos.com.tw

The 8th China Shenzhen International Machinery & Moulds Industry ExhibitionMarch 28-31, 2007China, Shenzhenwww.chinaszma.com

MTA Metal AsiaMarch 28-31, 2007Singaporewww.mta-asia.com

portable CMM “the Missing evolutionary link” at airbuspages 4 − 5Featured product: Hexagon Metrology software solutionspages 6 − 7romer turns 20:Q&a with romain granger, Company Founderpage 8 − 9Midsize Company thrives Under globalizationpages 10 − 11Featured product: leica Industrial theodolites and total stationspage 12Focus on technologypages 13 − 14precision Centers in europepage 14

exhibitions January - March 2007 Index

Leica Geosystems Re-ceives Frost & Sullivan Market Leadership Award

Frost & Sullivan, a New York-based consultancy firm, con-ferred in London its coveted Market Leadership Award in the Laser Tracker Segment on Leica Geosystems. Already the recipient of the 2004 Frost & Sullivan “Industrial Automation Product Innova-tion of the Year” award for its Portable CMM line of prod-ucts, Leica Geosystems was selected in 2006 for its strong sales growth and its lasting commitment to emerging technologies. “Our custom-ers choose our laser trackers because of their long-term reliability, superior thermal stability and the substan-tially less frequent need for calibration when compared to our competitors. With the Frost & Sullivan award, what we already know from our customers is now given the official stamp of approval,” said Laser Tracker Product Line General Manager Duncan Redgewell.

Hexagon Metrology UK Heralds Arrival of Dedicated Portable CMM Team

The Hexagon Metrology sales and support organization in the UK now has a dedicated Portable CMM team made of seasoned professionals with long-standing experience. The team is lead by Steve Shickell in the dual role of team and product manager for the Leica Geosystems products, with Martin Bishop as manager of the Romer product portfolio. With the new Portable CMM team, Hexagon Metrology is able to devote the necessary attention to the growing por-table business. The customers will receive knowledgeable, custom-made sales support structure that best suits their individual needs.

Red Bull F1 Fully On Track With Leica T-Probe System

Red Bull F1 Racing Team has recently joined Renault F1 Racing in the ranks of major teams relying on the Leica T-Probe for quality control. Red Bull uses the “Walk-Around” wireless probing system in their Inspection Department. “Everyone on our team who is using the Leica T-Probe system is really impressed, and they go use the equipment whenever they can, which is a big indicator of the effectiveness of the kit. I’m chuffed to bits with it and look forward to seeing it used more in the future,” says Chris Charnley, Red Bull F1 Quality Manager.

Newsticker

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Case study

The Airbus site in Broughton near Chester, UK, manufactures every single wing variant in the Airbus product line, including the mother of all flagships, the new A380. Providing work for more than 7,000 people, Airbus is the largest employer in town. Over 100 Leica Laser Trackers are used by the 16 production facilities in France, Germany, Italy, Spain and the UK, and the Broughton site alone relies on 7 Leica Laser Trackers to perform recerti-fication and modification jobs.

The newest addition to their Leica Metrolo-gy arsenal is the Leica T-Probe, the wireless hand-held “Walk-Around” portable CMM. However, technology aside, it is the Leica Ge-osystems unparalleled quality of service and support that has made all the difference to day-to-day sustainability of Airbus operations.

Few things arouse as much awe and admirati-on as flying does. Nothing captures our love affair with airplanes better than the brand-new A380, the largest passenger aircraft ever built. With 73m in length, a wingspan of 80m and a height of more than 24m, its sheer size instantly earns both respect and affection. When it goes into service in 2008, the A380 is poised to redefine long-distance air travel as we know it.

A perfect fitThe wings on any aircraft are probably the single most complex and crucial element in the entire construction. Not only the number of complex parts going into the assembly of a wing but also the need to maintain unforgi-

portable CMM “the Missing evolutionary link” In tooling operations at airbus

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vingly tight tolerances of about 0.25mm (one tenthousandth of an inch) over the entire length of the wing put tremendous require-ments on the tooling. The assembly takes place in large jigs that may reach the height of several stories. Individual jigs may have hundreds of tooling points that have to be in perfect alignment with each other.

Saving time, saving moneyGraham Tudor, Tooling Operations Manager at Airbus, explains: “Leica equipment has taken us away from the conventional tooling business and has made recertifications and modifications our core competence. We are using Leica Laser Trackers plus the new Leica T-Probe for that innovation and are registe-ring saving in the region of 30 to 50 percent in both time and money.”“Recently, we had to rework an A340 wing. We were requested to move the wing back into the jigs to repair the fault, which had never been done before. We had recertified the jigs using the Leica laser technology and were able to put the wing into a different jig other than the one in which it was originally built. Bringing the wing into a different jig with absolutely no modifications or adjustments was only possible because of the tolerances we had achieved when we did the recertifi-cation.”

Proximity is everythingRelying on dependable service and support is another element of the Leica experience. “What I get from Leica Geosystems is a true turnkey package. Leica’s Technical Sales Engineer Steve Shickell lives locally and is al-ways on hand to offer support and expertise. There is always an instant, rapid response because Steve and his team understand the implications of not delivering. I receive regular updates on products, launches and new tech-

nologies that allows me to view your latest products first hand. For example, we were one of the first companies in the UK to start using the Leica T-Probe.”

Leave nothing to chance“When I want a laser tracker, I think of Leica Geosystems above anyone else because of the package I receive and not just because of the price of the product. Sure, I might save money somewhere else, but when it breaks down, where do I go for help? How long is it before that help gets to me? In this business, the risk of failure is simply too high to leave anything to chance. With Leica Geosystems, there are no open questions.”

Charting the change togetherOver the past decade most of the Airbus tooling has been designed using a 3D CAD package. This has allowed the company to go gaugeless and recertify these tools using a non-contact measurement systems like the Leica Laser Tracker. Alan Minshul, Airbus Tool Engineer, provides the final food for thought: “One of the frustrations has been that our legacy tooling still has to be checked using conventional methods. With the introduction of the Leica T-Probe, we can go gaugeless the-re as well, thus allowing us to recertify these tools up to 50 percent quicker. In a way, the Leica T-Probe is the evolutionary missing link that we have been waiting for all along.”

Contacts

Full version of this case study available opon request using the feedback form in the back.

For further information, please contact your closest Hexagon Metrology Precision Center (see list on page 14) www.portable-cmm.comwww.airbus.com

articulated arm software

Articulated Arm SoftwareThe ROMER software suite is a complete range of solutions to satisfy the needs of several metrology applications: geometric and surface inspection, scanning and tube inspection. They are specifically designed for 3D portable measuring arms and run on standard PC hardware. Thanks to their user-friendliness, a maximum of 2-3 days training is required. It includes the following:

G-ScanReverse engineering softwareG-Scan software is a reverse engineering package able to generate surfaces and sections from digitized point

clouds. Thanks to efficient and fast surface calculation, reverse engineering times can be dramatically improved.

G-TubeNon-contact tube mea-surement softwareG-Tube is the latest technol-ogy in non-contact tube measurement: automatic tube-bending machine ad-justment is included, as well

as spring-back calculation and customized interfaces to the most common pipe-bending machines. G-Tube reduces bending machine setup times and tube manufacturing costs.

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G-PadGeometric measurement softwareG-Pad is the basic, user-friendly geometric mea-surement package for the ROMER arms. An efficient and quick menu access makes G-Pad easy and intuitive to use. In addition to the basic interface, the package offers advanced inspection functions, automatic and guided measurement procedures, data export and 3D part display.

G-SurfGeometric and surface inspec-tion softwareG-Surf is the mea-surement package for inspection and verification of geometric elements and surfac-es, based on a CAD model of the part. The program is compatible with all common CAD formats and features 3D part presentation in both wire-frame and shaded view mode. Graphic and numeric output is available for immediate analysis of inspection data.

PC-DMIS3D inspection, measurement and reverse engineeringWith PC-DMIS, you can perform your mea-surements with speed, efficiency and accuracy. This comprehensive software features an easy-to-use operator interface that guides you through part programming, setup and inspection routine execution. Plus, with its integrated graphics function, you can cre-ate reports that put a fresh perspective on dimensional data.

Metrolog XG for LeicaGlobal 3D inspection softwareMetrolog XG for Leica interfaces to the Leica PCMM Laser Tracker and the “Walk-Around” Leica T-Probe. In addi-tion, more than 50 interfaces for CMMs and PCMMs are available. The graphical visualiza-tion provides direct interfaces for virtual any neutral and native CAD format. A powerful feature based measurement tool, a complete GD&T engine, the customizable reporting and a simple, fast programming language all support and simplify your sophisticated as-sembly and inspection processes.

PolyWorksIndustrial Measure-ment SoftwareWhether you are cast-ing, milling, molding or stamping, you can rely on PolyWorks to provide a complete solution for your process. The PolyWorks software suite is available as a complete package or – with regard to the two main applications – as a point cloud inspection or reverse engineering pack-age. Use high-density point clouds of digitized prototype parts & assemblies to quickly iden-tify deformations and to fix problems in the earlier stage of the manufacturing process or approve your manufacturing process by fully inspecting your first-assembled products.

laser tracking/wireless probing/Hand-scanning software

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AxyzModular software for Leica Laser Trackers and TheodolitesAxyz is a modular Windows based soft-

ware that adapts ideally to all metrology tasks and Leica instruments. It has been designed for easy, everyday applications in build and inspect use that require online measure-ment and analysis. Axyz is based on Leica Geosystems’ knowledge of local conditions and requirements on the shop floor. This has helped very much in developing a software that is proven worldwide with a couple of thousands of sold seats. Axyz is approved by major companies such as Boeing and Airbus and tested on the mathematical algorithms by the Physikalisch Technische Bundesanstalt PTB in Braunschweig/Germany.

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to complete frames. With articulated arms weighing only 7kg, 3D CMM became portable and was brought to the part being measured. Making computer process-ing mobile was imperative for the arms’ development. To put things into perspec-tive, keep in mind that early PCs ran at 4.77MHz. Today’s processors run at speeds well in excess of 3GHz.

measureup How did Romer, situated in a small French city in the Loir region, become a big multinational company?

romain granger: Romer was created with an American associate. In fact, only an inter-national approach from the beginning could guarantee continuous product development in the long term. The fist arms were sold in France to Renault and Peugeot, and in the USA to Ford and Boeing.

measureup Could you please talk some about the different products over the years.

romain granger: The first arm series, “System 6 2000,” that had remained in production until the end of 2003, was made

measureup Mr. Granger, Romer is turning 20 in October 2006. Could you tell us a little about how it all got started?

romain granger: Romer’s history is tightly linked with the articulated arm history as well with the development of microcom-puters. The company where I used to work before starting Romer sold machine tools for bending tubes. A measuring machine was used to inspect the tubes in 5 axes. This machine, stationary and very heavy, worked together with a small computer. Creating a portable measurement tool was finally possible in 1986, with the advent of first microcomputers. Moreover, 3D measurement needs were real, especially in the automotive industry and the assembly tools. So in October 1986, in a rented space of just 100m2, Romer was born.

measureup In which industries was Romer specialized in the beginning?

romain granger: Our first jobs involved machine tools on automotive assembly lines. The arms were used to inspect dif-ferent parts, from simple measurements

Celebrating romer’s 20th birthday Interview with romain granger, general Director and founder of romer

stability and a constant focus. New product development is done in-house by our R&D, with production, testing and validations also done internally. We are offering our clients products with state-of-the-art technol-ogy, providing solutions to their specific needs. We also offer excellent after-sale service. The development of new products at Romer got a fresh boost in 2005 with the introduction of Romocut, a mobile NC modeler that has already found many applications in the automotive sector. The Romer integration into Hexagon Metrol-ogy has streamlined product development and optimized responsiveness to market impulses. Today, these two factors allow us to expand the production facilities in Mon-toire by an additional 1,000m2. The work on the expansion will start at the beginning of 2007, and will represent an important milestone for our company.

measureup How about a little parting anecdote?

romain granger: I had the opportunity to measure the last solid booster stage on the engine of the Ariane rocket, which is around for only 30 seconds. The day after, I was at a hydroelectric plant, measuring the blade of a alternator weighing 400 tons, located in a tube that was 10m in diameter. The alternator will be around for 30 years. Our articulated arms are made to fit practi-cally any kind of customer application.

of carbon fiber and anodized aluminum, with the accuracy of 0.15mm in a 2m volume. Arms in different lengths, up to 3.6m, soon followed. The second arm was “Romer 100,” weighing just 4kg, offering a fixed length and volume, while “Harmony” offered variable arm lengths. The range was then expanded with “Sigma,” the first arm featuring limitless rotation. Its modular concept has the advantage of changing arm lengths in the Flex configuration, with lengths of up to 5.2m. G-Scan was launched in 2004. Equipped with a rotation axis, G-Scan can be used on a 6-axis arm, giv-ing it 7-axis capabilities. Of course, in the meantime, accessories were developed for different products, for example mobile supports, horizontal rails, vertical rails (to elevate the volume) or floor position recognition systems with intelligent targets containing identification numbers.

measureup How did Romer join the Hexagon Metrology group? What are the benefits for Romer?

romain granger: Romer wanted to join a larger organization to manage the growth of the arm business and to be more efficient in the international market. In fact, automotive producers in different countries were asking for direct local service, something that Romer was not able to offer alone. For Hexagon, articu-lated arms were an ideal addition to their product range. Both companies had a common interest, and we are now very proud to be part of such an extensive organization. Hexagon has under its roof several prestigious brands, all supporting a common software platform, PC-DMIS. The latest integration of Leica Geosystems into the Hexagon Metrology group has allowed us to expand into the laser tracker sector, thus creating a “Portable CMM Business Unit,” which is consolidating our market presence and commercial strength in different countries and creating uniform strategies and marketing tools.

measureup What are Romer’s strengths today? What are the next steps you see coming?

romain granger: Above all, ROMER is a team, a team of young people, offering

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“above all, roMer is a team, a team of young people,

offering stability and a constant focus.”romain granger, Founder of roMer

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Case study

The picturesque Lake Constance, located near the rim of the Alpine region of Germany, Austria and Swit-zerland, is home to Krayer GmbH, a middle-sized company of about 50 employees specializing in the produc-tion of 3D forming parts. The com-pany has a rich history, dating back to 1884, when Franz-Joseph Krayer founded a modest fabrication shop in the lakeside town of Langenargen. The business has weathered two world wars and the turbulent hyper-inflation times in-between, only to see its pressing equipment com pletely confiscated by the allied occupying forces right after the end of WWII. However, the company rose from the ashes and expanded, quickly making up the losses.

The product offerings are mind-boggling. Over 1,000 tons of rolled and cut sheet-metal in all grades, shapes and thicknesses are kept in stock at any one time. Tens of thousands of tools are stored in the base-ment, utilizing a modern motorized storage system for quick access. The customers are primarily subcontractors to the commercial vehicle sector, many of which have been cooperating with Krayer for decades, such as world-famous ZF from Friedrichshafen, who are known for their high-performance gearboxes found in the world’s fastest production sedans and sports cars. But

Krayer also produces a plethora of pressed sheetmetal parts varying from large-sized sinks for the gastronomy industry to the “indestructible” keyboards found at public internet access booths.

Managing Director Cristoph Brugger points out: “We specialize in fabricating small and medium-sized runs of pressed and perfo-rated sheet metal parts, with series running anywhere from just one part to tens, hundreds or thousands of parts. For smaller runs, we rely on old-fashioned manpower. Larger runs are automated, and we use industrial robots to free up our workforce for those tasks for which programming a robot would be too time-intensive relative to the time savings resulting from automa-tion. Our extensive collection of tools lets us quickly alter production runs, and we can also rapidly manufacture new tools, which is very important for the development of pro-totypes. Within a very short period of time, we are able to produce sample parts based on test tools, letting us keep pace with the ever-changing needs of our customers.”

Keeping up with the changing times has also meant acquiring ISO9001 certification. Depending on the specifics of a particular production run, representative samples need to be compared against part drawings. Checking part dimensions has the potential for slowing down the production: parts need to be taken into the metrology lab,

Mid-size enterprise with Century-old tradition thrives In times of globalization

where their actual dimensions are com-pared to the target values. This is especially troublesome if parts are large, heavy or difficult to handle.

This is why Krayer was looking for a more contemporary solution to this measure-ment task. After seeing a Romer Omega articulated arm in action at an industrial trade show, the management organized a product demonstration on the premises and was quickly convinced of the arm‘s ben-efits. Krayer has been relying on a Romer Omega articulated arm for over a year to streamline and expedite its metrology tasks as part of ISO9001 compliance.

“The main benefit of the Romer articulated arm is its portability,” Brugger continues. “As you can see, we have mounted it on a mobile cart work station, so we can take it directly to any machine located in our factory. While one worker is producing parts, a metrology technician can perform the necessary measurements right there on the spot. In addition, the Romer Omega articulated arm is much faster than the conventional measurement methods, letting us perform the required measurements in a fraction of the time previously required for the same task.”

Production Manager Michael Banhardt expands: “The arm is very easy to use, and the workflow can be quickly learned by practically any employee. That way, the production process does not need to be interrupted, the machine operator does not need to leave his station to bring the part to the stationary CMM. The evaluation is done in the PC-DMIS software, and we have documentable results to show to the customer.” Another reason for purchasing the Romer arm was to have it as an alterna-tive to a contourograph. With the arm, Krayer can check the contours of even the smallest parts, something that was not pos-sible with a classical contourograph.

Today, Krayer is still true to its roots, being run by a closely knit family of long-time associates. Over the years, the company has been able to expand its business to include not just the German and the greater EU market, they also have customers from the Far East and beyond. What all these cus-tomers have in common is that they have all heard of Krayer by word of mouth: the company is proud to emphasize that they invest no money whatsoever in any form of marketing or advertising; the quality of their products speaks for itself.

Contacts

Full version of this case study available opon request using the feedback form in the back.

For further information, please contact your closest Hexagon Metrology Precision Center (see list on page 14) www.portable-cmm.comwww.krayer.com

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leica Industrial theodolites & total stations

Based on proven technology, unrivalled precision and optics, Leica Geosystems’ electro-optical Indus-trial Theodolites & Total Stations have set global standards in practically all industrial alignment applications.

TM5100AThe TM5100A is the world’s most accurate theodolite with the highest angular accuracy, panfocal telescope and autocollimation device. With unrivalled precision and superb optics, the TM5100A has become the standard instrument of choice in the aerospace industry for satel-lite alignment as well as for system and Heads Up Display alignment for combat aircraft. When the need arises, the system can be expanded to a multi-instrument system.

TDA5005The built-in precision distance meter and its ability to locate and track a target make the TDA5005 Total Station perform much like a stan-dard laser tracker. Additional tracker-like capabilities, such as fast and flexible one-man operation, remote control option, along with a mea-surement volume far above 500m, make the TDA5005 an ideal tool for extremely large part inspection and assembly. Expandable to a multi-instru-ment system configuration.

TDM5005By incorporating a precision distance meter and motor-ization features, the Total Station has spread into every industry as a truly large-scale PCMM solution for tooling, inspection and assembly in ship-building and other size-dominated industries. The TDM5005 Total Station brings precision on-site – no matter the environment. Expandable to a multi-instrument system configuration.

Focus on technology

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Focus on technology

a brief History of theodolites

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The word “theodolite” is derived from the arabic “alhidade” (meaning “ruler”) morphed with the definite English article, “the.” A theodolite is an instrument for measuring both horizontal and vertical angles and is an important metrological tool. A theodolite consists of a telescope mounted movably within two perpen-dicular axes. When the telescope is pointed at a desired object, the angle of each of these axes can be measured with great precision, typically on the scale of arcseconds (1 arcsecond = 1/3600th of one degree).

The history of theodolites dates back to the so-called plane table alhidades, devices al-lowing the graphical mapping of the terrain. These devices consisted of a plane table and a telescope mounted in a fork-like contrap-tion or alhidade, allowing it to be aimed out

continued on next page

of the horizontal plane. The whole assembly rested on a plane table, onto which graph-ing paper was attached; a ruler connected to the alhidade in such a way as to be always pointing in the same horizontal direction as the telescope, was then used to plot the direction to the target.

In today’s theodolites, the reading out of the horizontal and vertical circles is usually done electronically. The readout is done by a rotary encoder, which can be absolute, e.g., using Gray codes, or incremental, us-ing equidistant light and dark radial bands. In the latter case the circles spin rapidly, reducing angle measurement to electronic measurement of time differences. Addition-ally, lately CCD sensors have been added to the focal plane of the telescope allowing both auto-targeting and the automated measurement of residual target offset. All this is implemented in embedded software.

precision Centers in europe

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Today’s theodolites are usually equipped with integrated electro-optical distance measuring devices, allowing the measurement in one go of complete three-dimensional vectors – albeit in instrument-defined polar co-ordinates – which can then be transformed to a preexisting coordinate sys-tem in the area by means of a sufficient number of con-trol points. The technique is called free station position surveying and is widely used in mapping surveying. The instruments, ‘intelligent’ theodolites called self-reg-istering tachometers or ‘total stations’, perform the necessary operations, saving

data into internal registering units, or into external data storage devices. Typically, rugged laptops or PDAs are used for this purpose.

editorial measureup c/o Leica Geosystems AGMoenchmattweg 5CH-5035 UnterentfeldenSwitzerlandPhone +41 62 737 67 67 Fax +41 62 737 68 68www.portable-cmm.com

Lucia Drago, Publisherlucia.drago@hexagonmetrology.com

Neven Jeremić, Managing EditorAnne Willimann, Marketing CoordinatorLudwig Willimann, Creative & Productioncontact@portable-cmm.com

measureup was launched in 2006 and is published quarterly.

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continued from page 13

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