Vision Systems – IndMacDig | Industrial Machinery Digest https://industrialmachinerydigest.com The Industry's Most Extensive Industiral Digest Wed, 11 Jun 2025 16:55:23 +0000 en-US hourly 1 https://wordpress.org/?v=6.9.1 https://industrialmachinerydigest.com/wp-content/uploads/2017/05/newIMDWeb-100x100.png Vision Systems – IndMacDig | Industrial Machinery Digest https://industrialmachinerydigest.com 32 32 Nikon Launches Enhanced Limited Angle CT technology https://industrialmachinerydigest.com/quality/vision-systems/nikon-launches-enhanced-limited-angle-ct-technology/ Wed, 11 Jun 2025 16:55:23 +0000 https://industrialmachinerydigest.com/?p=138439 Nikon Corporation (Nikon) has launched Limited Angle CT, an innovative computed tomography (CT) scanning technology for its range of VOXLS and XT H 225 industrial X-ray inspection systems. This technology advances CT scanning by delivering high-resolution imaging without the need for a full 360-degree sample rotation. By enabling samples to be positioned closer to the X-ray source, Limited Angle CT achieves higher magnification, providing detailed inspection of specific areas of interest within larger components.

Designed to meet the demands of high-end industry, this advancement is particularly well-suited for inspecting planar or geometrically complex components, such as printed circuit boards, pouch and prismatic EV battery cells, and carbon fiber parts. Its unique capabilities empower manufacturers to streamline their inspection processes while maintaining precision and efficiency.

NikonKey features include:

  • Superior resolution: Achieves smaller voxel resolution for samples with high aspect ratios or complex geometries, where traditional geometric magnification would be limited.
  • Optimized reconstruction: Nikon’s proprietary algorithm delivers datasets without quality or accuracy loss, despite reduced rotation angles, matching conventional CT performance.
  • Automated operation: Nikon’s center of rotation calculation enables fully automated scans without manual intervention or positioning aids.
  • Rapid acquisition: Completes detailed scans in minutes, significantly faster than traditional X-ray microscopy methods for comparable applications.

Nikon“Limited Angle CT represents an expansion of the inspection capabilities of our X-ray CT systems,” said Nikon’s X-ray Product Manager, Ben Morgan. “It is one of several advanced imaging techniques available within Nikon’s CT toolbox. Limited Angle CT works complementary to other methods such as X.Tend (Helical CT), Panel Shift CT, Tilted CT, and Scatter Correction CT. This versatility within a system allows operators to select the most suitable technique for each specific inspection task. With Limited Angle CT, high-magnification inspection of specific regions within larger samples is now possible.”

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The L.S. Starrett Company Announces Key Management Appointments https://industrialmachinerydigest.com/quality/the-l-s-starrett-company-announces-key-management-appointments/ Fri, 21 Feb 2025 19:29:06 +0000 https://industrialmachinerydigest.com/?p=114557 The L.S. Starrett Co., a leading global manufacturer of precision measuring tools and gages, metrology systems and more, has appointed four new executives to its global organization, further strengthening its corporate management at the highest levels. Starrett welcomes Mr. Roger N. Amrol, Jr. as President and Chief Executive Officer (CEO), Mr. Barry D. Laughlin as Chief Operating Officer (COO), Mr. Allen E. Look as Global Chief Information Officer (CIO), and Mr. Jon-Michael Raymond as Chief Revenue Officer (CRO). The new executives will be based out of Starrett corporate headquarters in Athol, MA, bringing a wealth of manufacturing industry experience, leadership and skills to Starrett as the company focuses on continuous improvement, growth and innovation.

  • Mr. Roger N. Amrol, Jr. succeeds Mr. Douglas A. Starrett whose career with Starrett spanned 48 years, as President and CEO. Mr. Amrol is poised to lead Starrett forward to a new level, joining the organization after 12 years with Robert Bosch Tool Corporation North America where he was President and CEO for approximately five years. Also, within the Bosch organization, Mr. Amrol was President for the SKIL North America brand for four years and led the North America Accessories Business Unit as President for three years. Prior to Bosch, for five years he was with Techtronics Industries as Vice President in procurement, operations, and product divisions. Mr. Amrol has a Master of Business Administration from Averett University and a Bachelor of Arts degree from the College of Charleston.
      StarrettMr. Barry Laughlin, Starrett COO
  • Mr. Barry D. Laughlin brings his extensive manufacturing operations experience to Starrett and looks forward to applying his vision and skills to meet the company’s initiatives by implementing day-to-day business strategies and plans. He was most recently COO with Group DEKKO for nine years after being promoted from Executive Vice President of Operations, a position he held for almost two years. Prior to that, Mr. Laughlin was in an operations contract role at Caterpillar Inc. for six months. Before that, he was with Navistar for 26 years in various positions increasing in responsibility, with his last position being Director of Global Manufacturing and Custom Products for Navistar, Inc. Mr. Laughlin holds a Master of Science in Manufacturing from Kettering University and a Bachelor of Business Administration from Ohio University.

 

Starrett
Mr. Allen Look, Starrett Global CIO
  • Mr. Allen E. Look brings to Starrett over 25 years of information technology experience as Global CIO with skills ranging from business leadership, operational excellence, data analysis and cybersecurity proficiency. Before joining Starrett, Mr. Look held global CIO roles for 6 years at privately and publicly held companies including FBG and Hayward Holdings, Inc., and provided interim CIO and executive advisory services in the private equity sector. He has a Bachelor of Science in Computer Information Systems from Thomas College and is an alumni of Crotonville Professional Training and Coaching where he received several certifications.

 

Starrett
Mr. Jon-Michael Raymond, Starrett CRO
  • Mr. Jon-Michael Raymond brings vast experience in the industrial market space where he has held sales and finance roles for over 17 years, most recently as Global Sales and Marketing Senior Vice President at FyterTech Nonwovens. Prior to that he was Sales and Marketing General Manager at Mahr after approximately four years with Starrett as its North American Sales and Marketing Director for Industrial Products. For three years before that, he served as Vice President of Sales for PFERD Inc. and preceding that he held various sales and finance positions including with Norton | Saint-Gobain Abrasives. Mr. Raymond is a graduate of Worcester State University and Assumption College, where he received a Master of Business Administration.

About The L.S. Starrett Company

Founded in 1880 and headquartered in Athol, MA U.S.A., The L.S. Starrett Company is a leading global manufacturer of precision measuring tools and gages, optical comparators, vision systems, and force and hardness testing systems. Starrett also manufactures laser measurement systems, custom engineered granite solutions, custom gaging, band saw blades, power tool accessories, saw blades, workshop tools and jobsite tools. The Starrett brand is recognized throughout the world for exceptional quality and precision. Skilled personnel, superior products, manufacturing expertise, innovation and excellent service and support have earned Starrett its reputation as the “World’s Greatest Toolmakers”. Starrett has over 1,400 employees worldwide. The company has five manufacturing locations in the U.S.A., including facilities in Massachusetts, Georgia, Ohio, Minnesota, and California. Starrett also has three international manufacturing facilities. Plants are located in Brazil, Scotland and China, in addition to distribution centers and offices located worldwide.

For more information contact The L.S. Starrett Company, 121 Crescent Street, Athol, MA 01331 U.S.A. Telephone: (978) 249-3551, Fax: (978) 249-8495, email: general@starrett.com, internet: https://www.starrett.com/.

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Machinery Manufacturer Norwalt Moves into Larger Facility in Tampa, Expanding Footprint and Capacity https://industrialmachinerydigest.com/robotics/machinery-manufacturer-norwalt-moves-into-larger-facility-in-tampa-expanding-footprint-and-capacity/ Wed, 29 Jan 2025 16:09:26 +0000 https://industrialmachinerydigest.com/?p=103150 Norwalt Automation Group, a specialist in custom-built automation and line integration machinery for complex manufacturing applications, has moved to a new, more expansive production facility in Tampa, FL. A sign of the Randolph, New Jersey-based company’s rapid growth, the initiative comes less than two years after Norwalt’s original Tampa facility commenced operations in mid-2023.

The new facility will provide 28,000 square feet dedicated primarily to machine and systems integration for the customized, precision-engineered solutions for which the company has become known. Norwalt’s engineers design, construct, validate and install premium production equipment whose functionalities include – but are by no means limited to – packaging and product assembly, post-mold automation, modular automation cells and robotics systems. Norwalt has experienced exponential growth in recent years, prioritizing additional space to continue meeting expedited equipment delivery timeframes.

“We always love to hear when a company that expanded here from another market has found so much success that they continue to invest in our community and create more jobs,” said Ron Christaldi, chair of the Tampa Bay Economic Development Council and Shumaker Partner/President and CEO of Shumaker Advisors Florida. “Norwalt has been an excellent addition to the Tampa area’s manufacturing sector, and the Tampa Bay EDC team looks forward to continuing to support the company’s growth here.”

Norwalt serves customers in a wide array of sectors, from medical devices and food & beverage applications to personal care and household items. While the 2023 Tampa facility was largely earmarked for food, beverage, and medical device and diagnostics projects – two niches requiring pristine, tight-tolerance plastics components and products manufacturing, per Norwalt’s core engineering skillsets – this newest space will likely see parity in projects for the various sectors Norwalt services.

“With the company continuing its encouraging growth pattern and the initial Tampa facility proving to be a wise decision both economically and geographically, this new, larger Tampa-area site was an easy decision to make,” said Keith Harman, Director of Business Development for Norwalt. “In an ever-evolving manufacturing environment, demand continues to surge for automation and line integration machinery that minimizes downtime, maximizes efficiency, and tackles otherwise labor-intensive tasks.”

About Norwalt Automation Group

For more than five decades, Norwalt has specialized in custom-built automation and line integration machinery for complex manufacturing applications. The company’s engineers design, construct, validate and install premium production equipment for a wide array of sectors, including medical devices, life sciences, food & beverage, personal care, and household items. Norwalt produces machinery meeting a broad range of functionalities – from packaging and product assembly and post-mold automation to modular automation cells and robotics systems. Many customers rely on Norwalt’s vision system experience enabling them to incorporate highly technical vision systems, both stand alone and integrated, to ensure accuracy in a wide range of applications.

Often, Norwalt’s unique-to-customer solutions comprise intricate, low- to high-volume machinery and robotics designed from proof of concept, many of whose capabilities have never been attempted let alone realized. Always, its equipment provides maximum efficiency and minimal downtime backed by the company’s unsurpassed, engineering-centric customer service and support.

For more information visit www.norwalt.com.

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Starrett Introduces AVR400 Vision Metrology System https://industrialmachinerydigest.com/quality/starrett-introduces-avr400-vision-metrology-system/ Thu, 24 Oct 2024 14:08:49 +0000 https://industrialmachinerydigest.com/?p=81074 The L.S. Starrett Co., a leading global manufacturer of metrology systems, precision measuring tools and gages and more, has expanded its AVR Vision Metrology Line with the introduction of the AVR400 CNC Vision System, the largest benchtop platform to date from Starrett with stage travel that is twice the speed of previous Starrett AVR models. The stage travel is 15.8″x 11.8″x 7.9″ (400mm x 300mm x200mm) in the X-Y-Z axes with a speed of up to 120mm/ sec.

“We are very pleased to offer customers a new, faster vision system capable of measuring a broader range of larger part sizes, as well as providing the ability to put more parts on the stage at one time,” said Mr. Mark Arenal, General Manager, The L.S. Starrett Company – Metrology Division. “Users will reduce inspection and measurement time, while maintaining accuracy.”

The Starrett AVR400 offers full CNC capabilities including X-Y-Z positioning and comprehensive zoom and telecentric lens options. Users can also choose to use motorized manual positioning via a pendant with a joystick and track ball. Equipped with the M3 software package from MetLogix™, a traditional mouse as well as a touchscreen monitor make user interaction easy and intuitive.

Auto part recognition enables creating a part measurement program that comprises the desired features of a part for inspection, which can automatically be saved in the system or to a network. Programmable light output options can be built into the program as defined steps, including being called up as the part recognition program initiates. Once the program is created, placing that part within the camera’s field-of-view allows for the saved program to initiate and run the inspection. A Renishaw Touch Probe may also be utilized for quick acquisition of discreet points along a part’s profile as well as Z-axis measurements.

For high stability, the AVR400 features a granite base. An extensive line of accessories is available including a modular system workstation on rolling caster wheels, providing convenient repositioning on the shop floor and in QC labs. The AVR400 Vision Metrology System is Made in the U.S.A.

For more information and specifications, visit AVR 400 Vertical Benchtop Vision System | StarrettMetrology.

About The L.S. Starrett Company

Founded in 1880 and headquartered in Athol, MA U.S.A., The L.S. Starrett Company is a leading global manufacturer of precision measuring tools and gages, optical comparators and vision systems and force and hardness testing solutions. Starrett also manufactures laser measurement systems, custom engineered granite solutions, custom gaging, band saw blades, power tool accessories, saw blades, workshop tools and jobsite tools. The Starrett brand is recognized throughout the world for exceptional quality and precision. Skilled personnel, superior products, manufacturing expertise, innovation and excellent service and support have earned Starrett its reputation as the “World’s Greatest Toolmakers”. Starrett has over 1,400 employees worldwide. The company has five manufacturing locations in the U.S.A., including facilities in Massachusetts, Georgia, Ohio, Minnesota, and California. Starrett also has three international manufacturing facilities. Plants are located in Brazil, Scotland and China, in addition to distribution centers and offices located worldwide.

For more information contact The L.S. Starrett Company, 121 Crescent Street, Athol, MA 01331 U.S.A. Telephone: (978) 249-3551, Fax: (978) 249-8495, email: general@starrett.com, internet: https://www.starrett.com/.

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How Welding Robots are Emerging as a Part Deviation Solution in Industrial Operations https://industrialmachinerydigest.com/quality/how-welding-robots-are-emerging-as-a-part-deviation-solution-in-industrial-operations/ Mon, 01 Apr 2024 14:59:39 +0000 https://industrialmachinerydigest.com/?p=79227 In the quest for optimal performance in welding manufacturing, two critical factors stand at the forefront: precision and efficiency. Yet, a pervasive challenge across production lines, known as part deviation, threatens these very benchmarks. This article explores the transformative role of AI-enhanced welding robots in mitigating part deviations, thereby elevating both efficiency and precision in industrial operations.

The Challenge of Part Deviation

Understanding the nuances of part deviation in welding is crucial for maintaining the integrity and quality of welded components. Part deviations refer to the discrepancies that arise from the intended design specifications, dimensions, or properties of welding components. These deviations, influenced by a multitude of factors, can significantly impact the final product. Let’s explore some of the primary contributors to part deviations in welding.

Material Properties and Variability

The composition, thickness, and surface condition of materials play pivotal roles in the welding process. Variations in alloying elements, impurities, and surface treatments can directly influence weldability, potentially leading to inconsistencies in weld penetration and joint quality. Materials with inconsistent properties may exhibit varied thermal behaviors, causing uneven heating and cooling that contribute to part deviations.

Welding Parameters

The parameters set during the welding process, such as heat input, welding speed, and electrode orientation, are critical determinants of weld quality. Deviations in these parameters can introduce welding defects including porosity, incomplete fusion, excessive spatter, and irregular bead formation, all contributing to part deviations. Tailoring welding parameters to suit specific material and joint configurations is essential for minimizing such deviations.

Thermal Distortion and Residual Stress

The localized heating and cooling inherent in welding lead to material expansion and contraction, potentially causing significant distortion and warping. These thermal effects can divert the welded components from their intended design dimensions. Moreover, the cooling phase can introduce residual stresses, which may result in material deformation or component misalignment, further exacerbating part deviations.

Joint Design and Fit-Up

Achieving a high-quality weld heavily relies on the joint design and the precision of part alignment before welding. Inadequate joint design or improper fit-up can create challenges in achieving uniform weld penetration and formation, leading to gaps, overlaps, or misalignments. Such issues not only weaken the welds but also result in deviations from the desired part dimensions and tolerances.

Operator Skill and Technique

In scenarios where welding is performed manually, the skill level and consistency of the operator become crucial. Variability in welding techniques, including fluctuations in welding speed, arc length, and travel angle, can lead to inconsistent weld quality. Additionally, factors like operator fatigue, inexperience, or insufficient training can further contribute to part deviations. Ensuring comprehensive training and adherence to consistent welding practices is vital for mitigating these deviations.

The Implications of Part Deviation

When welding, part deviation poses several difficult problems that can affect the final product’s quality, the effectiveness of production, and the cost of manufacturing. These difficulties result from the fundamental nature of manufacturing procedures, the complexity of welding, and the possibility of mistakes or discrepancies at different production stages. Here, we go into the specifics of part deviation’s challenges and how they affect the manufacturing sector.

Structural Integrity and Safety Concerns

Compromise in structural integrity is one of the biggest problems caused by part deviation. The total strength and load-bearing capability of the finished product can be decreased by weak spots in the structure caused by welds that are not in line with the original design. Any reduction in structural integrity caused by part deviation can have major repercussions in sectors like construction, aerospace, and automotive where safety and dependability are top priorities.

Assembly and Fit Issues

Part deviation might make it challenging to precisely assemble components. When assembled, welded parts may not fit together perfectly if their dimensions differ from those specified in the design. This may result in manufacturing line bottlenecks, longer assembly delays, or even the requirement for manual alterations or revisions to guarantee a good fit.

Aesthetic Concerns

Even tiny part deviations can cause products to appear inconsistent or unattractive in markets where aesthetics matter a lot, such as consumer electronics and luxury goods. As a result, brand value, consumer satisfaction, and market competitiveness may all suffer.

Rework and Wastage

Rework is frequently necessary to address part deviation, which not only eats up important time but also raises manufacturing costs. Material wastage can happen in traditional manufacturing settings where manual changes are performed to remedy deviations due to trial and error methods. This waste results in increased material costs and a less environmentally friendly manufacturing process.

Quality Control and Inspection Complexity

Part deviation increases the complexity of quality control and inspection procedures. To make sure that each welded component complies with design requirements, manufacturers might have to spend more money on examining and validating each one. The likelihood of problems evading inspection can rise because of production being slowed down.

The Role of AI-Integrated Welding Robots

The integration of advanced AI into industrial robots marks a transformative era for the manufacturing sector, significantly enhancing the capabilities of traditional robots. This advancement enables robots to undertake more intricate tasks and adapt to evolving environments, ultimately boosting both efficiency and productivity. Central to these enhancements is the robots’ ability to deliver precise and consistent welding, effectively mitigating the adverse impacts of part deviation. Below, we delve into the specific roles these AI-equipped welding robots play:

Joint Configuration Recognition

Equipped with sophisticated vision systems, AI-integrated welding robots excel in identifying various joint configurations. They adeptly adjust their welding strategies to suit different geometries and orientations, significantly minimizing the likelihood of weld defects and part deviations.

Material Variability Adaptation

AI-driven systems are adept at tailoring welding parameters to accommodate material variations, such as thickness, composition, or surface conditions. Through meticulous analysis of data from each welding operation, AI algorithms fine-tune the welding process for each unique scenario, guaranteeing superior weld quality even in the face of material inconsistencies.

Continuous Improvement through Machine Learning

AI-integrated welding robots leverage machine learning algorithms to glean insights from every welding task they perform. This continuous learning process allows them to refine their welding parameters, enhancing both the quality and efficiency of their work over time.

Real-time Adjustments

The power of AI enables these welding robots to execute real-time modifications during the welding process. By interpreting data from sensors, such as those in vision or laser-based systems, the robots can identify and rectify any deviations from the predetermined weld path or penetration depth, ensuring precision in each weld.

Consistent Replication

AI-integrated robots stand out for their ability to consistently replicate precise welding parameters—such as speed, angle, and distance—across numerous parts. This capability starkly contrasts with manual welding, which is prone to variations due to human error or fatigue, thereby significantly diminishing the chances of part deviations.

Conclusion

AI-integrated welding robots, pioneering innovation in manufacturing, tackle part deviation with precision and adaptability. By merging robotic welding consistency with AI’s dynamic learning, these systems enhance efficiency and product quality. As AI evolves, so does the promise of groundbreaking advancements in robotic welding, leaving part deviation challenges behind.

By Daryl Lim

About The Author

Daryl Lim, Co-founder and CEO of Augmentus, drives innovation in autonomous manufacturing by pioneering intelligent computer vision and AI robot motion planning systems to enable truly autonomous manufacturing even in high-mix and complex applications.

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The Essential Role of Fixture Design in Laser-Based Welding Applications https://industrialmachinerydigest.com/quality/the-essential-role-of-fixture-design-in-laser-based-welding-applications/ Thu, 01 Feb 2024 14:19:05 +0000 https://industrialmachinerydigest.com/?p=78595 Laser-based welding has revolutionized the manufacturing landscape, enabling the precise and efficient joining of intricate assemblies across diverse sectors, including medical devices, automotive, aerospace, and the growing battery and electric vehicle (EV) industries. While lasers are undeniably crucial for achieving top-tier welds, the significance of fixture design cannot be over-emphasized. A well-crafted fixture is the backbone of the welding process, ensuring stability, repeatability, and, ultimately, the operation’s success.

Five essential functions must be meticulously addressed in fixture design to unlock the full potential of laser-based welding in these industries: ease of loading/unloading, ensuring intimate contact between parts being welded, maintaining consistent component tolerances and fixture registration, and providing a clear line of sight for laser welding and alignment verification through cameras. Neglecting these functions can lead to subpar weld quality, early failures, and significant production setbacks. Figure 1 shows how gaps can impede proper and satisfactory welds.

Figure 2 shows a palletized fixture being placed into the laser welding tool.

Streamlined Loading/Unloading

Efficiency is paramount in the fast-paced world of manufacturing. A well-designed fixture must facilitate the smooth loading and unloading of components to be welded. This is especially crucial in industries like medical devices, automotive, aerospace, and EVs, where precision and speed are imperative. A fixture that hampers the easy placement and removal of parts can impede production throughput. This is further highlighted in cases where fixtures act as pallets, preloading components within the fixture before transferring them to the laser system, as shown in Figure 2.

Consider a medical device manufacturing scenario where tiny, intricate components must be laser-welded. An inadequately designed fixture can make it difficult for operators to position these delicate parts accurately. In many cases, fixture selection might involve robotic handling to bring the components together one assembly at a time. In another case, this prolongs the assembly process and increases the risk of damaging the components. In contrast, a fixture that enables quick and precise loading/unloading (manually or automatically) ensures that the welding process remains efficient, minimizes operator errors, and maximizes productivity.

Figure 3 shows a typical lever clamp to fix the pallet fixture in place, where the pallet fixture was pre-loaded with components and assembled externally.

Ensuring Optimal Part Contact

Achieving high-quality welds demands optimal contact between the parts to be joined. Gaps or misalignment between components can result in subpar weld quality, compromising the structural integrity and reliability of the final product. This requirement is particularly vital in aerospace and EVs, where safety and performance are paramount.

Imagine an aerospace component with a slight gap between two critical parts due to inadequate fixture design; Figure 1 shows such a case. These gaps can lead to stress concentrations when exposed to rigorous flight conditions, causing premature component failure. In the EV sector, where battery packs are assembled using laser welding, any gaps or misalignment in the components can affect the overall performance and longevity of the battery, potentially leading to costly recalls. These gaps also lead to a failure mode where the weld acts as a hinge flexure, subjecting it to stress and ultimately causing weld failure over time. Furthermore, such gaps can serve as collectors of oxides and contaminants, leading to further oxidation of the weld from its backside.

Consistent Registration and Tolerances

Maintaining consistent registration and tight tolerances between components is another crucial function of a well-designed fixture. In precision-critical industries such as medical devices and automotive, even minor variations in alignment can result in unacceptable product deviations and increased reject rates. Fixtures must ensure that parts are securely held in their intended positions throughout welding. Tolerance plays a vital role in both the fixture and the components.

Unacceptable component tolerance stack-ups can lead to mispositioned components, part gaps, over- or under-clamping of the element within the fixture, and overall yield issues in the laser welding process. It should be noted that various clamps may be needed, and the setup of these clamps becomes critical; you don’t want heavy clamping, just a slight preload to keep the parts in a fixed position and the overall fixture in place. Figure 3 shows the typical clamping of a palletized fixture.

Figure 4 shows an image of a window and the resulting ejected materials. This view is from the laser side.

Unobstructed Line of Sight and Camera Alignment Verification

In laser-based welding applications, maintaining an unobstructed path for the laser beam is evident and crucial for achieving precision. With a variety of off-the-shelf welding optical heads, manufacturing engineers need to be aware of the characteristics of the laser beam output of the lens within that focusing head. The collimated beam diameter received at the focus lens, the cone angle output, the working distance of the focusing lens, and the spot size on the target all play a vital role in the laser material interaction during welding.

Once the welding parameters are established, initial testing parameters can be brought to the laser machine tool. The design of the fixture must take into consideration several factors for proper laser welding, including nozzle gas pressure, nozzle end size, the reflectivity of the material being processed, the angle at which the laser focus head is angled to eliminate back reflections, and the observed visual alignment verification to ensure the accuracy of the welding process.

Fixtures must provide clear access for the laser beam to reach the welding zone and enable operators to verify component alignment through cameras or other machine vision optical systems. These openings must also ensure that the welding spatter can eject and that those openings can be cleaned easily. Figure 4 shows an image of a typical window and how it might get contaminated over time, requiring maintenance and cleaning.

In the automotive industry, for example, welding intricate components within the confined spaces of a vehicle chassis requires fixtures that allow the laser beam to reach every weld joint without obstruction. Additionally, using cameras or vision systems is essential to verify the alignment of components and ensure that the welding process is on track. Narrow weld zones or obstructions caused by weld angles and positioning could result in partial laser beam blockage, leading to poor welding performance and potentially no weld due to such shadowing.

Consequences of Neglected Laser Welding Fixture Design

Neglecting any of these crucial functions in fixture design can have significant consequences. Mismatched part tolerances, gaps between parts due to poor clamping, loose component registration, inadequate vision illumination, or laser beam obstruction can all lead to subpar welding quality and product failures. These failures not only necessitate costly rework and potential recalls, but they also have safety and financial implications for the manufacturer.

Conclusion

Fixture design is integral in laser-based welding applications across industries such as medical devices, automotive, aerospace, and EVs. To achieve the stability and repeatability required for precision welding, fixtures must excel in essential functions: ease of loading/unloading, ensuring optimal part contact, maintaining consistent fixture registration and component tolerances, and providing an unobstructed path for laser welding and alignment verification. Neglecting these functions can lead to subpar weld quality and costly production setbacks.

As these industries continue to push the boundaries of innovation, the role of fixture design in laser-based welding will remain indispensable. Manufacturers must recognize the importance of well-designed fixtures and invest in their development to ensure the success, quality, and reliability of their products in an increasingly competitive marketplace.

By Todd E. Lizotte, Orest Ohar, and Joseph Dagher of Bold Laser Automation, Inc. Bedford, NH

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Machinery Manufacturer Norwalt Continues to Invest in Career Path Program for Aspiring College Students https://industrialmachinerydigest.com/robotics/machinery-manufacturer-norwalt-continues-to-invest-in-career-path-program-for-aspiring-college-students/ Tue, 09 Jan 2024 15:50:18 +0000 https://industrialmachinerydigest.com/?p=78224 Norwalt, a specialist in custom-built automation and line integration machinery for complex manufacturing applications, continues to expand on its immersive education program for college students interested in careers in machine design, manufacturing, and other automation-adjacent niches. The company’s Collegiate Automation Program (CAP) forges partnerships with the University of Delaware and other colleges to give aspiring students real-life experiences that bolster their learning in the classroom.

For example, at the University of Delaware, Norwalt is assisting with facets of the school’s engineering curriculum, and providing funding for hands-on junior- and senior-level projects that complement classroom instruction. Norwalt also offers internship programs, and conducts recruitment seminars offering opportunities to join its machine design team. Financial donations and close collaboration with the school’s education administrators round out Norwalt’s CAP program.

NorwaltIn recent years, Norwalt has also reached out to the County College of Morris, and several other community colleges with machinery component donations, helping these educational facilities maintain equipment vital for comprehensive student instruction.

With facilities in Randolph, New Jersey and Tampa, Florida, Norwalt is a supplier of concept-to-completion manufacturing equipment solutions. The company’s engineers design, construct, validate and install premium production equipment whose functionalities include – but are by no means limited to – packaging and product assembly, post-mold automation, modular automation cells and robotics systems. Norwalt serves customers in a wide array of sectors, from medical devices and food & beverage applications to personal care and household items.

“It is highly rewarding to have the opportunity to nurture and mentor the machine designers and engineers of tomorrow,” said Mike Seitel President at Norwalt. “Our partnership with the University of Delaware is already showing tremendous promise, as we strive to provide real-life machining experience that positively influences the overall education process. Supplementing classroom instruction with hands-on scenarios is vital is a field such as ours, and we’re grateful to do our part.”

About Norwalt

For more than five decades, Norwalt has specialized in custom-built automation and line integration machinery for complex manufacturing applications. The company’s engineers design, construct, validate and install premium production equipment for a wide array of sectors, including medical devices, life sciences, food & beverage, personal care, and household items. Norwalt produces machinery meeting a broad range of functionalities – from packaging and product assembly and post-mold automation to modular automation cells and robotics systems. Many customers rely on Norwalt’s vision system experience enabling them to incorporate highly technical vision systems, both stand alone and integrated, to ensure accuracy in a wide range of applications.

Often, Norwalt’s unique-to-customer solutions comprise intricate, low- to high-volume machinery and robotics designed from proof of concept, many of whose capabilities have never been attempted let alone realized. Always, its equipment provides maximum efficiency and minimal downtime backed by the company’s unsurpassed, engineering-centric customer service and support.

For more information visit www.norwalt.com.

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Mitutoyo America Corporation Continues to Lead Vision Systems Market with New Technology Advancements https://industrialmachinerydigest.com/quality/mitutoyo-america-corporation-continues-to-lead-vision-systems-market-with-new-technology-advancements/ Wed, 18 Oct 2023 19:21:59 +0000 https://industrialmachinerydigest.com/?p=77333 Mitutoyo America Corporation, a leading manufacturer of precision metrology instruments and solutions, announces new enhancements to its Vision Pro vision measurement system line. The most recent market research shows the vision machine measuring (VMM) market is set to explode with an expected value of $41Billion by 2030.1 The company’s recent product enhancements help further establish Mitutoyo as an industry leader with the most technologically advanced equipment available.

Mitutoyo’s recent introduction of the QV Vision Pro Series has set the stage for the future of vision measurement with several new features. The StrobeSnap vision measuring function speeds up quality run time compared to other competitor’s machines by approximately 35 to 45 percent regardless of measurement position or continuity while achieving higher throughput and high-precision measurements. Additionally, autofocus on the QV Pro Series is about 39 percent faster than previous models, which were already the fastest in their class, without loss of accuracy for measurement.

“It’s an exciting time in the marketplace for machine vision measurement and Mitutoyo is at the forefront of the industry bringing our customers best-in-class machines and real-time solutions to meet the biggest and most complicated quality measuring challenges they will be facing in the years ahead,” states Matt Dye, President Mitutoyo America Corporation.

The vision market’s expansion is attributed to many new developments over the last several years, including Congress’ passage of the Chips and Science Act in 2022 which provides more than $52 billion to strengthen, boost, and incentivize semiconductor production and supply chains in the United States.2 Currently, roughly 75 percent of semiconductors are produced in Asia and now vision measurement systems will play a vital role in this massive manufacturing expansion.

Additionally, as the automotive industry transitions from combustion engines to electric, vision measurement is taking on a larger role in the construction of electric vehicles (EV). EV motors are now manufactured in a way which makes vision measurement a more accurate, effective, and cost-effective solution than its CMM counterparts for parts quality inspection, with motors typically composed of several layers of rotors that are stamped and stacked on top of each other and laminated together. Most CMM probes would have a difficult time measuring these parts with any accuracy.

As vision measurement continues to move forward, Mitutoyo is offering an opportunity to its customers to purchase the newest vision measuring machines to update their own shop floors. The Mitutoyo Vision Trade-In Trade-Up Program is an opportunity to upgrade to new technologically advanced Mitutoyo precision measuring equipment for less money and less hassle. Mitutoyo will give a significant trade-in allowance for your current vision measuring machine (Mitutoyo or other brands) to put toward a new Mitutoyo precision measurement system. Mitutoyo will remove, ship, and recycle your existing machine at no charge if it is located at the same site where your new machine will be installed.

The Mitutoyo measuring equipment eligible for purchase with this trade-in trade-up program includes:

  • Vision: Quick Vision Pro series (Apex and Hyper models)

For more information regarding Mitutoyo’s Quick Vision Pro Vision Series or the Trade-In-Trade-Up Program, contact the Mitutoyo Inside Sales Team at info@mitutoyo.com or visit https://www.mitutoyo.com/.

Mitutoyo Corporation is the world’s largest global provider of measurement and inspection solutions offering the most complete selection of machines, sensors, systems, and services with a line encompassing CMM (coordinate measuring machines), vision, form and finish measuring machines, as well as precision tools and instruments, and metrology data management software. Mitutoyo’s nationwide network of Metrology Centers and support operations provides application, calibration, service, repair, and educational programs to ensure that our 5,500+ metrology products will deliver measurement solutions for our global customers throughout their lifetime.

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Starrett Names New Strategic Accounts Manager for Industrial Products in North America https://industrialmachinerydigest.com/quality/starrett-names-new-strategic-accounts-manager-for-industrial-products-in-north-america/ Tue, 22 Aug 2023 16:11:03 +0000 https://industrialmachinerydigest.com/?p=76690
The L.S. Starrett Company,  a leading global manufacturer of precision measuring tools and gages, metrology systems, saw blades, power tool accessories and more, has recently appointed Mr. Seth Downing as its new Strategic Accounts Manager North America, Industrial Products. The role was previously held by Mr. Michael Connor who was recently promoted to Sales and Marketing Director North America, Starrett Industrial Products.

“We are very pleased to welcome Seth to Starrett,” said Connor. “He brings successful industry sales and marketing experience to his new role, along with proven results when managing and growing large industrial national accounts such as MSC, Grainger and Fastenal.”

Mr. Downing has over 10 years of experience in tool manufacturing focusing on the industrial, retail, and automotive channels. His background spans roles such as industrial national account manager and channel marketing manager, and also includes experience in business development and sales management.

Mr. Downing holds a bachelor’s degree in business administration from the University of Nebraska-Lincoln. He resides in Tennessee and will be based out of the company’s headquarters in Athol, Massachusetts.

About The L.S. Starrett Company

Founded in 1880 and headquartered in Athol, MA U.S.A., The company is a leading global manufacturer of precision measuring tools and gages, optical comparators and vision systems and force and hardness testing solutions. Starrett also manufactures laser measurement systems, custom engineered granite solutions, custom gaging, band saw blades, power tool accessory saw blades, workshop tools and jobsite tools. The company brand is recognized throughout the world for exceptional quality and precision. Skilled personnel, superior products, manufacturing expertise, innovation and excellent service and support have earned Starrett its reputation as the “World’s Greatest Toolmakers”. Starrett has over 1,400 employees worldwide and annual sales exceeding $250 million. The company has five manufacturing locations in the U.S.A., including facilities in Massachusetts, Georgia, Ohio, Minnesota, and California. The company also has three international manufacturing facilities. Plants are located in Brazil, Scotland and China, in addition to distribution centers and offices located worldwide. The L.S. Starrett Company is publicly traded on the NYSE, symbol SCX.

For more information contact The L.S. Starrett Company, 121 Crescent Street, Athol, MA 01331 U.S.A. Telephone: (978) 249-3551, Fax: (978) 249-8495, email: general@starrett.com, internet: https://www.starrett.com/.

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Starrett Introduces High Productivity TENNAX™-PROBi-Metal Band Saw Blades for Structural Cutting https://industrialmachinerydigest.com/quality/starrett-introduces-high-productivity-tennax-probi-metal-band-saw-blades-for-structural-cutting/ Wed, 05 Jul 2023 19:56:38 +0000 https://industrialmachinerydigest.com/?p=76024 The L.S. Starrett Co., a leading global manufacturer of saw blades, precision measuring tools and gages, metrology systems and more, has announced the introduction of TENNAX™-PRO Bi-Metal Band Saw Blades designed to cut challenging tubes, pipes, profiles and structural shapes in both single pieces and bundles. Providing lower noise and vibration as well as improved cutting performance, TENNAX™-PRO blades outlast and outperform competitive blades, making up to 25% more cuts per blade.

Starrett TENNAX™-PRO Band Saw Blades feature high-speed M-42 steel teeth with a new special tooth geometry/ profile that optimizes the tip profile for tube, pipe and other structural cuts, dissipating stress during cutting for greater resistance to wear and tooth breakage. In addition, TENNAX™-PRO band saw blades are designed with an exclusive tooth-setting process which minimizes pinching when cutting structural and bundled materials.

“We are excited to introduce TENNAX™-PRO, the next generation of Starrett Bi-Metal Band Saw Blades,” said Charlie Starrett, Product Manager, Saws and Hand Tools, The L.S. Starrett Co. “Specifically designed to cut structural materials, TENNAX™-PRO blades offer a higher level of productivity and extended blade life in difficult cutting processes, increasing your saw operation’s efficiency.”

TENNAX™-PRO blades are ideal for cutting a wide range of materials including carbon steel, carbon steel alloys, stainless steel, and non-ferrous materials. In addition to pipes, tubes, structural and bundled materials, TENNAX™-PRO applications include small solids. The blades are available in widths of 3/4″, 1″, 1 1/4″, 1 1/2″, 2″, and 2 5/8″, and can be used with manually operated, gravitational, and hydraulic machinery, making them a versatile and adaptable choice for a variety of applications.

TENNAX™-PRO Band Saw Blades replace the Versatix™ MP line.

For more information visit www.starrett.com/tennax-pro.

As the “World’s Largest Saw Blade Manufacturer”, Starrett offers a wide range of saw products including Bi-Metal band saw blades for cutting a variety of ferrous and non-ferrous materials, and Carbide Tipped, which are ideal for cutting extremely hard, abrasive materials. Band saw blades coated with Carbide Grit and Diamond Grit cut abrasive materials with precision, producing an excellent finish. A complete line of Carbon Band Saw Blades is also available for horizontal and vertical machines with manual or gravity feed. Other saw products include Hole Saws, Jig and Reciprocating Blades, Hacksaw Blades and Portable Band Saw Blades. The Starrett team of saw experts can help select the right saw blade, set up band saw machines, and help customers maximize their sawing operation.

About The L.S. Starrett Company

Founded in 1880 and headquartered in Athol, MA U.S.A., the company is a leading global manufacturer of precision measuring tools and gages, optical comparators and vision systems and force and hardness testing solutions. Starrett also manufactures laser measurement systems, custom engineered granite solutions, custom gaging, band saw blades, power tool accessory saw blades, workshop tools and jobsite tools. The Starrett brand is recognized throughout the world for exceptional quality and precision. Skilled personnel, superior products, manufacturing expertise, innovation and excellent service and support have earned Starrett its reputation as the “World’s Greatest Toolmakers”. Starrett has over 1,400 employees worldwide and annual sales exceeding $250 million. The company has five manufacturing locations in the U.S.A., including facilities in Massachusetts, Georgia, Ohio, Minnesota, and California. Starrett also has three international manufacturing facilities. Plants are located in Brazil, Scotland and China, in addition to distribution centers and offices located worldwide. The L.S. Starrett Company is publicly traded on the NYSE, symbol SCX.

For more information contact The L.S. Starrett Company, 121 Crescent Street, Athol, MA 01331 U.S.A. Telephone: (978) 249-3551, Fax: (978) 249-8495, email: general@starrett.com, internet: https://www.starrett.com/.

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