Un unico software per la misurazione 3D
Quando Bruno Presezzi SpA, specialista nelle lavorazioni meccaniche, ha voluto aggiungere la scansione 3D per il controllo dimensionale agli altri sistemi già in uso, ha scelto PolyWorks®. Perché? Per la praticità di avere un unico software per tutti gli strumenti di misura utilizzati.
Final inspection of a compressor disc for a gas turbine by probing with a COORD3 Kronos CMM.
Nata in Brianza circa settant’anni fa come una piccola officina meccanica, Bruno Presezzi è oggi una SpA che impiega circa 200 dipendenti. Arrivata alla sua seconda generazione con Alberto Presezzi, attuale proprietario, questa florida azienda di Burago Molgora opera nel settore metalmeccanico. Uno dei core business sono le lavorazioni meccaniche di componenti di grosse dimensioni, con tolleranze molto accurate. I campi applicativi sono i più svariati, anche se è quello energetico a spiccare. A fianco delle lavorazioni meccaniche c’è una divisione di carpenteria, dedicata sempre a pezzi di grandi dimensioni. A questi due ambiti si è aggiunta una divisione che progetta e realizza impianti per colate di alluminio. Infine, qualche anno fa Bruno Presezzi ha assunto il controllo di Franco Tosi Meccanica, storica impresa dedicata alla produzione di impianti per compressori, turbine a vapore e idroelettriche. Parliamo quindi di una realtà imponente e variegata, con al proprio interno strutture operative che seguono la progettazione, l’assemblaggio, la lavorazione meccanica e la carpenteria, e tutto quello che ruota attorno. Pensiamo in particolare ai controlli di qualità dimensionali, che l’azienda esegue sul 100% della produzione. Ed è proprio in questo ambito che un paio di anni fa è nata la collaborazione con PolyWorks Europa Italia, specialista nelle soluzioni software di metrologia 3D intelligente. Ne abbiamo parlato con Sem Fantauzzi, Responsabile del Controllo Qualità in Bruno Presezzi.
THE CHALLENGE
Bruno Presezzi represents an imposing and varied reality, with in-house operational structures that follow the design, assembly, mechanical machining, and carpentry activities, and everything that revolves around that. More specifically, it carries out dimensional quality controls on 100% of its production.
Quality requirements were growing, especially with regard to mechanical machining—clients were increasingly looking for detail and precision, particularly in terms of geometric, linear, and assembly tolerances.
So, their Quality Control department decided to purchase a MetraSCAN Black™|Elite optical CMM scanner from Creaform, a product on the frontier of technology with which they can acquire the complete form of the components they produce. The scanner takes millions of points and outputs a polygonal mesh accurately describing the measured surface.
The scanner, combined with a FARO laser tracker and a Kronos series CMM from COORD3, made for three measuring devices, each with its own native software. Over time, it became complicated for the operators to manage three different types of software, including even additional training. Bruno Presezzi went looking for a universal platform capable of managing all the measuring devices using a single software.
Sem Fantauzzi, Quality Control Manager at Bruno Presezzi.
THE SOLUTION
It was essential to be able to use the same software on all 3D measuring instruments. After extensive research, they decided to turn to PolyWorks® from InnovMetric, a Canadian company dedicated exclusively to intelligent 3D metrology software solutions, and to all satellite topics. And more specifically, PolyWorks|Inspector™, its module for dimensional analysis and quality control. And it is precisely in this context that a partnership was created with PolyWorks Europa Italia, a subsidiary of InnovMetric that sells PolyWorks and provides technical support to clients.
To use the software on three different devices Bruno Presezzi needed help, especially in the beginning, and PolyWorks Europa Italia came through for them by training every quality inspector who carries out dimensional checks. “Their support was essential for us,” comments Sem Fantauzzi, Quality Control Manager. “Indeed, it was, and still is. Their technical support is not just intended to maintain the software but also to find solutions. We appreciate this ongoing partnership with an expert in an accompanying journey to maximize the possibilities of PolyWorks for our processes.”
Final inspection with FARO laser tracker of a gas turbine exhaust case.
Immagino la formazione del personale abbia giocato un ruolo importante quando avete approcciato questa nuova tecnologia.
“Assolutamente sì, e lo riveste tuttora. Ogni ispettore di qualità che esegua controlli dimensionali viene formato dai tecnici PolyWorks Europa Italia. E quando assumiamo un nuovo addetto, prevediamo un corso iniziale per fornirgli subito la conoscenza di base del software. A questo poi si aggiunge il supporto tecnico, che non è finalizzato a una mera manutenzione del software, ma a trovare soluzioni. Una collaborazione continua con un esperto in un percorso di accompagnamento per massimizzare le possibilità. Impiegando il software su tre strumenti diversi, questo supporto è stato essenziale per noi, soprattutto all’inizio. E oltre alla praticità di cui possiamo godere ogni giorno, PolyWorks ha aperto le porte ad analisi e controlli che prima non eravamo in grado di fare. Il software infatti è completo in tutte le analisi e in tutte le strutture su cui andiamo ad agire. Ci ha quindi allargato gli orizzonti sul tipo di controllo richiesto e sui bisogni dei nostri clienti.”
THE BENEFITS
Says Fantauzzi, “The first benefit is using a single software to interface with our 3D measuring devices, which saves on training and brings a culture of shared knowledge within the quality control team. But there is even more. In addition to the practicality which we can enjoy every day using a single software, PolyWorks has opened the door to analyses and checks which we were not able to carry out before.”
He continues, “Another advantage is being able to use several measuring devices in the same inspection project. For instance, when a component has dimensions and features which can be checked with a scan, but a laser tracker is needed for a more accurate check on the inside, we can combine the measurements in the same project. The software actually works with all the measuring devices, and all the devices work in the same project, thanks to a series of customized measurements which can be added.”
Fantauzzi’s team has also benefited from PolyWorks’ multipiece inspection capabilities. “We always talk about the combination of data acquisition and data analysis, how one could not exist without the other. While we usually produce individual parts, one project involved the construction of 48 guide vanes for the Isola Serafini hydroelectric power station on the Po River. With the support of PolyWorks, we adapted the program to control the first piece, so that we could use it with all subsequent pieces. We thus avoided having to recreate a new program for each new piece, which greatly accelerated our processes.”
He also counts on PolyWorks’ powerful scripting capabilities to accelerate part inspection. “For a different client, we had to analyze geometric tolerances on turbine discs, which can have dozens and dozens of vane slots with particular shapes. With PolyWorks, we created macros: once the first slot was checked correctly, that could be repeated automatically for all the other slots. The possibility of creating macros is actually always envisaged, even in the basic versions of the software. They can be created either together with technical support, or independently if you have the necessary skills. A broad selection of helpful macros is available for download on the InnovMetric website according to your application needs. A versatility we greatly appreciate.”
In conclusion, Fantauzzi reflects on his experience with PolyWorks and his partnership with PolyWorks Europa Italia. “The software is indeed complete in all the analyses and all the structures on which we act. It has therefore broadened our horizons on the type of control required and the needs of our customers.”
PolyWorks|Inspector™