Measurement Strategies and Standardization in Manufacturing

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Open AccessArticle

Validation of a Manual Methodology for Measuring Roundness and Cylindricity Tolerances

Enrique García-Martínez

Narciso García-González

María Carmen Manjabacas

and

Valentín Miguel

Appl. Sci. 2023, 13(17), 9702; https://doi.org/10.3390/app13179702 - 28 Aug 2023

Viewed by 277

Abstract

This paper describes a practice-based methodology applied to roundness and cylindricity concepts. Traditionally, technicians encounter difficulties in understanding this topic, especially when they analyze the tolerances involved due to the complexity of their graphic interpretation. Additionally, it is mandatory for industrial engineers to acquire competencies that allow them to validate form and make decisions in this field. With the goal of enhancing the handling of measurement techniques involved in this topic and analyzing the results obtained, a methodology has been designed to address the roundness and cylindricity tolerance evaluation from different perspectives. Firstly, based on a conceptual analysis, an analytical procedure is introduced. Secondly, an engaging manual practice is implemented by using simple measuring instruments that allow the user to be involved in the development of the procedure applied. The conditions that tried to optimize the manual procedure to get good results were analyzed. Moreover, the results obtained under this perspective allow us to ensure that better skills can be acquired regarding the typical method based on the coordinate measuring machines. This experience has been validated based on the practice with ongoing users under a training period. Full article

(This article belongs to the Topic Measurement Strategies and Standardization in Manufacturing)

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Open AccessArticle

Metrics Related to Confusion Matrix as Tools for Conformity Assessment Decisions

and

Appl. Sci. 2023, 13(14), 8187; https://doi.org/10.3390/app13148187 - 14 Jul 2023

Viewed by 504

Abstract

Conformity assessment refers to activities undertaken to check whether some product, service or process meets certain criteria and specifications given by internationally accepted standards. The decision on whether a property of interest is aligned with the set standards is made based on measurement. However, uncertainty associated with the measurement results may lead to incorrect decisions. Measurement results may be falsely rejected as non-conforming, although they meet specifications. This is referred to as the producer’s risk. If the measurement result that does not meet the required specifications is accepted as conforming, this is referred to as the consumer’s risk. This paper covers calculations of global consumer's and producer's risk using the Bayesian approach and deals with the application of metrics related to confusion matrices in conformity assessments. These techniques have been used to assess the conformity of the bearing ring diameter with the given specifications. Based on the behavior of these metrics, the optimal length of the guard band was determined with the aim of minimizing the global consumer’s and producer’s risk. Full article

(This article belongs to the Topic Measurement Strategies and Standardization in Manufacturing)

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Open AccessArticle

An Efficient Improved Harris Hawks Optimizer and Its Application to Form Deviation-Zone Evaluation

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Sensors 2023, 23(13), 6046; https://doi.org/10.3390/s23136046 - 29 Jun 2023

Viewed by 428

Abstract

Evaluation of the deviation zone based on discrete measured points is crucial for quality control in manufacturing and metrology. However, deviation-zone evaluation is a highly nonlinear problem that is difficult to solve using traditional numerical optimization methods. Swarm intelligence has many advantages in solving this problem: it produces gradient-free, high-quality solutions and is characterized by its ease of implementation. Therefore, this study applies an improved Harris hawks algorithm (HHO) to tackle the problem. The average fitness is applied to replace the random operator in the exploration phase to solve the problem of conflicting exploration strategies due to randomness. In addition, the salp swarm algorithm (SSA) with a nonlinear inertia weight is embedded into the HHO, such that the superior explorative ability of SSA can fill the gap in the exploration of HHO. Finally, the optimal solution is greedily selected between SSA-based individuals and HHO-based individuals. The effectiveness of the proposed improved HHO optimizer is checked through a comparison with other swarm intelligence methods in typical benchmark problems. Moreover, the experimental results of form deviation-zone evaluation on primitive geometries show that the improved method can accurately solve various form deviations, providing an effective general solution for primitive geometries in the manufacturing and metrology fields. Full article

(This article belongs to the Topic Measurement Strategies and Standardization in Manufacturing)

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Open AccessArticle

Geometric Error Parameterization of a CMM via Calibrated Hole Plate Archived Utilizing DCC Formatting

Ming-Xian Lin

and

Tsung-Han Hsieh

Appl. Sci. 2023, 13(10), 6344; https://doi.org/10.3390/app13106344 - 22 May 2023

Viewed by 705

Abstract

This study implemented the measurement results and administrative information obtained from the hole plate into the Digital Calibration Certificate (DCC). The DCC comprises three parts: Norms and Standards, Hierarchical Structure, and XML as Exchange Format. DCCs play a significant role in the field of metrology and statistics by ensuring data interoperability, correctness, and traceability during the conversion and transmission process. The hole plate is a length standard used for two-dimensional geometric error measurements. We evaluated the accuracy of the high-precision coordinate measuring machine (CMM) in measuring a hole plate and compared the measurement error results obtained from the hole plate with those of the laser interferometer, autocollimator, and angle square. The results show that the maximum difference in linear error is −0.30 μm, the maximum difference in angle error is −0.78″, and the maximum difference in squareness error is 4.54″. The XML is designed for machine-readability and is modeled and edited using the XMLSpy 2022 software, which is based on information published by PTB. The administrative management and measurement results tasks are presented in PDF format, which is designed for human-readability and ease of use. Overall, we implemented the measurement results and information obtained from the hole plate into the DCC. Full article

(This article belongs to the Topic Measurement Strategies and Standardization in Manufacturing)

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Open AccessArticle

Thermal Calibration of Triaxial Accelerometer for Tilt Measurement

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Sensors 2023, 23(4), 2105; https://doi.org/10.3390/s23042105 - 13 Feb 2023

Cited by 1 | Viewed by 1409

Abstract

The application of MEMS accelerometers used to measure inclination is constrained by their temperature dependence, and each accelerometer needs to be calibrated individually to increase stability and accuracy. This paper presents a calibration and thermal compensation method for triaxial accelerometers that aims to minimize cost and processing time while maintaining high accuracy. First, the number of positions to perform the calibration procedure is optimized based on the Levenberg-Marquardt algorithm, and then, based on this optimized calibration number, thermal compensation is performed based on the least squares method, which is necessary for environments with large temperature variations, since calibration parameters change at different temperatures. The calibration procedures and algorithms were experimentally validated on marketed accelerometers. Based on the optimized calibration method, the calibrated results achieved nearly 100 times improvement. Thermal drift calibration experiments on the triaxial accelerometer show that the thermal compensation scheme in this paper can effectively reduce drift in the temperature range of −40 °C to 60 °C. The temperature drifts of x- and y-axes are reduced from −13.2 and 11.8 mg to −0.9 and −1.1 mg, respectively. The z-axis temperature drift is reduced from −17.9 to 1.8 mg. We have conducted various experiments on the proposed calibration method and demonstrated its capacity to calibrate the sensor frame error model (SFEM) parameters. This research proposes a new low-cost and efficient strategy for increasing the practical applicability of triaxial accelerometers. Full article

(This article belongs to the Topic Measurement Strategies and Standardization in Manufacturing)

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Open AccessArticle

Research on Image Measurement Method of Flat Parts Based on the Adaptive Chord Inclination Angle Algorithm

Tao Liu

Xingchen Lv

and

Min Jin

Appl. Sci. 2023, 13(3), 1641; https://doi.org/10.3390/app13031641 - 27 Jan 2023

Viewed by 645

Abstract

To accurately measure the critical dimensions of flat parts using machine vision, an inspection method based on the adaptive chord inclination angle progressively screening the segmentation points of graphic elements was proposed in this study. The method doubled the size of the part image using bicubic interpolation, extracted the single-pixel contour with more detailed information, and designed an adaptive step size to obtain the front and back chord inclination angles of the contour. The method of complementing the front and back chord inclination angles was employed to avoid the negative effects of contour jaggedness, thereby obtaining the contour segmentation points after the initial screening. The segmentation points obtained in the initial sieving were divided into different point clusters according to the distance, and the contour, which was segmented by two segmentation points in different point clusters, was fitted using the least squares. The fitting results were evaluated, and all the fitting results were selected using the improved non-maximum suppression (NMS) algorithm to obtain the precisely selected segmentation points of the graphic elements. Consequently, the segmented individual graphic elements were fitted with the segmentation points as constraints to obtain the key dimensions of the closed part. The developed method could accurately find the contour segmentation points, and the relative error was less than 0.6%. Full article

(This article belongs to the Topic Measurement Strategies and Standardization in Manufacturing)

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Open AccessArticle

Calibration Procedure of a Multi-Camera System: Process Uncertainty Budget

Ibai Leizea

Imanol Herrera

and

Pablo Puerto

Sensors 2023, 23(2), 589; https://doi.org/10.3390/s23020589 - 04 Jan 2023

Cited by 2 | Viewed by 1705

Abstract

The Automated six Degrees of Freedom (DoF) definition of industrial components has become an added value in production processes as long as the required accuracy is guaranteed. This is where multi-camera systems are finding their niche in the market. These systems provide, among other things, the ease of automating tracking processes without human intervention and knowledge about vision and/or metrology. In addition, the cost of integrating a new sensor into the complete system is negligible compared to other multi-tracker systems. The increase in information from different points of view in multi-camera systems raises the accuracy, based on the premise that the more points of view, the lower the level of uncertainty. This work is devoted to the calibration procedures of multi-camera systems, which is decisive to achieve high performance, with a particular focus on the uncertainty budget. Moreover, an evaluation methodology has been carried out, which is key to determining the level of accuracy of the measurement system. Full article

(This article belongs to the Topic Measurement Strategies and Standardization in Manufacturing)

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Open AccessArticle

A Designed Calibration Approach for the Measurement-While-Drilling Instrument

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Appl. Sci. 2023, 13(1), 61; https://doi.org/10.3390/app13010061 - 21 Dec 2022

Viewed by 850

Abstract

The Measurement-While-Drilling (MWD) system, composed of a tri-axial magnetometer and a tri-axial accelerometer, is widely used in the Horizontal Directional Drilling machine in coal mines. This system can provide attitude information of each measuring point in the borehole, which will eventually allow the trajectory of the borehole to be drawn. The attitude information, however, showed a low-level accuracy, due to the sensor’s imperfection and mounting errors. The accuracy worsened when low-cost sensors were employed, as they had higher random noise. Therefore, an exploration of ways to eliminate the sensor imperfection and mounting tolerance as well as to suppress the noise is needed. In this paper, a feasible calibration approach was designed to address these issues. This new approach combined three foundational calibration algorithms, including the ellipsoidal fitting method, the planar fitting method, and the inner product invariance method. The traditional ellipsoidal fitting method and planar fitting method were optimized by using the recursive least square criterion and omitting the steps of sample data acquisition, respectively. In addition, the noise suppression method was involved in our approach to improve the calibration accuracy. The numerical simulation results showed that the number of sampling points decreased significantly, but the accuracy of the azimuthal angle and the pitch angle fully met the engineering requirements. The experimental results showed that the pitch angle error was reduced by less than 0.5°, and the azimuth error was also reduced by less than 2.5°. It should be noted that this new approach could be implemented without the help of other expensive auxiliary equipment. Full article

(This article belongs to the Topic Measurement Strategies and Standardization in Manufacturing)

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Journal Name	Impact Factor	CiteScore	Launched Year	First Decision (median)	APC
Applied Sciences applsci	2.7	4.5	2011	15.8 Days	CHF 2300	Submit
Journal of Manufacturing and Materials Processing jmmp	3.2	5.5	2017	15.6 Days	CHF 1600	Submit
Materials materials	3.4	5.2	2008	14.7 Days	CHF 2600	Submit
Metrology metrology	-	-	2021	18.9 Days	CHF 1000	Submit
Sensors sensors	3.9	6.8	2001	16.4 Days	CHF 2600	Submit
Standards standards	-	-	2021	27.7 Days	CHF 1000	Submit

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