temperature compensated gaging

Temperature Compensation of Shop Floor Gages:

From Albion Devices, Inc. www.AlbionDevices.com Presented by Paul Sagar President Temperature Compensation of Shop Floor Gages

About Albion:

About Albion Albion Devices, Inc., was founded in 1988. Albion was first to make a concerted effort to address the problem of thermal expansion as it affects shop floor gages We have developed many products, software programs and custom sensors for temperature compensation applications. We have had hundreds of successful applications. Customers include all Big Three auto companies, major railroads, GE, bearing companies (SKF), printers, auto industry suppliers, etc. Albion Devices, Inc.

Why Compensate for Temperature? :

Why Compensate for Temperature? Albion Devices, Inc. Because variations in temperature during the production process cause measurement errors. Particularly when close to tolerance limits. Correction improves customer acceptance, product performance and correlation. 60 measurements taken of the same feature on the same part on the same shop floor gage over a period of 2 weeks. Measurements varied by approx. 100% of tolerance due almost entirely to varying ambient temperatures.

Benefits of Eliminating Thermal Errors:

Benefits of Eliminating Thermal Errors Consistent Accuracy (rather than precision) Maintains Gage R&R on shop floor. Gives Dimension at the International Standard 68  F / 20  C, (or other specified nominal temperature). Albion Devices, Inc.

Product History:

Product History Snap gages Tcomp (“tee-comp”) GageComp Sensors MicroComp Tcomp II Albion Devices, Inc.

Latest Development:

Latest Development Fireball Digital Temperature Sensors (and Measurement Probes). DigiGage software. Albion Devices, Inc.

Applications:

Applications Albion’s systems have been used to compensate a wide range of gages. Albion Devices, Inc.

Temperature Compensation System Components:

Temperature Compensation System Components Albion Devices, Inc. Combined Workpiece /Master Temperature Sensor, for OD or ID. Gage Temperature Sensor. Connecting cables. Controller or PC.

Sensor Configuration:

Sensor Configuration Workpiece sensor positioned to pick up temperature of workpiece and master. Gage sensor monitors temperature of fixture or gage. For Temp Comp to be most effective, best to MINIMIZE contact between gage and workpiece . Albion Devices, Inc. Workpiece Gage Fixture LVDT Workpiece/ master sensor Gage sensor Note minimal contact

Applied Principles:

Applied Principles Compensate for Work, Master and Gage. Note: Gage, not ambient. Sense each temperature independently. Customizable coefficients of correction. Nominal size. Workpiece Temperature Master Temperature Gage Temperature Workpiece Coefficient Master Coefficient Gage Coefficient Compensation Algorithm Correction Offset Nominal size Albion Devices, Inc.

Linearity:

Linearity Albion Devices, Inc. Coefficients of Expansion are often non-linear over large temperature ranges. However, materials used in mass produced items are linear over the temperature range that concerns us. F F

Correction Coefficients:

Correction Coefficients Practically speaking, strict handbook COEs are not necessarily the most accurate. Several factors influence the way sizes vary with temperature (e.g. combinations of materials and geometries, thermal gradients, joints, springs). Albion refers to the net effect of these influences as the Correction Coefficient . One way to determine the Correction Coefficient is through “Characterization”. Albion Devices, Inc.

Characterization:

Characterization Empirical determination of Correction Coefficients. Patiently heat and cool parts, masters and gages independently while taking measurements. Results used to calculate linear coefficient. Albion’s new software ( DigiGage ) includes a program that facilitates this procedure. Albion Devices, Inc.

Operator Involvement:

Operator Involvement Albion Devices, Inc. Temp Comp systems are designed to run in the background. Just need to be “Zeroed” when gage is zeroed (may sometimes be automatic). System will automatically sense temperatures of work, master and gage, compute correction and apply it to measurements. The result is that the gage displays dimension as if workpiece , master and gage were at nominal temperature (usually 68  F/ 20  C)

Temperature Sensors:

Temperature Sensors Compromise between speed and durability. Custom-designed for heavy duty, shop floor use. They balance durability and speed of response. Maintenance: Keep clean and free of chips, excess oil. Graph above shows typical contact sensor asymptotic response curve. Albion Devices, Inc.

Success:

Success Data obtained by Big Three auto co. Plug gage equipped with Albion’s temperature compensation system measuring aluminum housing bore. Albion Devices, Inc.

Fireball and DigiGage:

Digital temperature sensors and gaging probes Albion Devices, Inc. Fireball and DigiGage

Fireball Temperature Sensors:

Fireball Temperature Sensors Albion Devices, Inc. Temperature sensors with direct USB connectivity. DigiGage software programmable with all variables for temperature compensation algorithm. DigiGage reads, calculates and displays.

Fireball Digital Gaging Probe:

Fireball Digital Gaging Probe Albion Devices, Inc. Low cost per measurement channel. Instant USB connectivity. 0.0001 mm/0.000005 inch accuracy and repeatability. Various measurement ranges, linear throughout. No expensive external signal conditioning and amplification circuitry. Pre-calibrated at the factory. Minimal setup time. Plug and play. Requires single master only. Multiple probes via USB ports on PC or hubs. Optional interface to SPC programs.

DigiGage Software:

DigiGage Software Albion Devices, Inc. Multiple capabilities: Temperature compensation offset output only. Temperature compensated dimension output. Gage probe display. Can be configured to output offset to other gaging software. (Needs cooperation with software vendors or software engineers to create . dll ). DigiGage includes characterization routine.

Complete Temp Comp System for PC:

Complete Temp Comp System for PC Albion Devices, Inc. Combine: Up to 8 temperature sensors DigiGage software A complete temperature compensation system based on a PC. Runs in background, interfacing to customer’s preferred host SPC or gaging software.

Thank You:

Albion Devices, Inc. www.AlbionDevices.com Thank You