The Hexagon Manufacturing Intelligence Division demonstrates at this year's EMO how reliable and user-friendly quality assurance can tackle challenges in metalworking – whether for individual parts, in processes, or across industries.
Quality assurance in metalworking faces similar challenges as other industries, but under particularly high demands for precision and efficiency: Companies must increase productivity and flexibility, compensate for acute skilled labor shortages, and simultaneously ensure consistently high quality standards. The pressure is growing as more and more highly complex metal components with tight tolerances need to be tested, often in significantly shortened development cycles and under high time and cost pressure.
New coordinate measuring machine MAESTRO combines speed, digitalization, networking, and ease of use
In developing the new coordinate measuring machine MAESTRO, Hexagon therefore united four principles: speed, user-friendliness, digital networking, and scalability. The digital-first architecture of the CMM enables users to perform quick measurement routines, intuitive operation without prior programming knowledge, and seamless integration of data into their system.
MAESTRO is also fully digitized, accompanied by a digital twin, and equipped with a digital rack for storing sensors. This allows the machine to know at all times which sensor is in use where, and enables users to digitally track and simulate their measurements. The fully digital system also facilitates easy integration into automation and IT systems and simplifies subsequent system expansions. A combination of synchronized multi-axis movements and 360° rotations of the B-axis, along with improved calibration routines, reduces positioning times and makes re-tracking unnecessary. In motion, the machine achieves speeds of up to 6500 mm/s², and in measurement, it reaches up to 1100 mm/s. This allows MAESTRO to flexibly adapt to changing production needs.
New Autonomous Metrology Suite reduces CMM programming time
The newly released Autonomous Metrology Suite also provides support for CMM programming and rapidly changing products: A digital twin of each connected CMM seamlessly synchronizes with its physical counterpart, ensuring that the correct test program reaches the right machine. All collected quality, usage, and environmental information can then flow directly into the cloud-based dashboard if desired.
The Metrology Suite integrates three applications, all built on Hexagon's Nexus platform: Metrology Mentor ensures that users employ consistent measurement methods for the same workpiece by automatically creating ISO and ASME-compliant test programs from CAD. Metrology Reporting consolidates the data from the measurement and tomography systems in use, analyzes batch quality, and creates comprehensive part histories. The Metrology Asset Manager ensures that machines are functional and measurements are reliable by monitoring calibration status, machine operation, errors, and environmental factors such as temperature, humidity, and vibration. With the suite, users can also perform reliable measurements without in-depth programming knowledge, generate the required protocols, and minimize bottlenecks – even with a large number of different workpieces.
Geomagic Suite demonstrates possibilities of reverse engineering, inspection, and organic design
At EMO, Hexagon Manufacturing Intelligence also showcases the possibilities of reverse engineering, inspection, and organic design for the industry with the Geomagic Suite: The software supports reverse engineering, inspection, and measurement workflows with 3D scanners from a wide range of optical, laser, and LiDAR scanners from all manufacturers.
The included software Geomagic Design X allows users to trace data from any scanner with guided workflows and enables accurate conversion and restoration of parametric CAD data. This allows for the creation of models of parts that were previously difficult to model. The Geomagic Control X solution further simplifies the interpretation and inspection of scan data as well as report generation. The software automates workflows and offers validated accuracy according to the standards of NIST, PBT, and NPL. Finally, Geomagic Freeform enables the intuitive creation and shaping of organic models that would be too complex for conventional CAD systems. During this process, STL, CAD, scan, and other 3D data can be imported for faster processing, while extensive automated and manual tools provide maximum modeling flexibility.
Laser tracker ATS800 allows precise inspection of large parts
The Leica Absolute Tracker ATS800 is designed as a next-generation laser tracker for complex production environments with high variability and large-format components, without requiring special skills. The system combines high-precision, direct scanning with reflector tracking, providing direct measurement accuracy comparable to reflector measurement systems in a portable, lightweight system. Setup takes only a few minutes, allowing for unattended or process-accompanying inspections without compromising accuracy or traceability. When integrated into digital and robot-based automation processes, the ATS800 additionally reduces inspection times and allows for real-time measurement and process adjustments.
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