Product category:
Non-contact, Optical and Laser measurement systems
News Release from: Metris | Subject: Optical CMM
Edited by the Manufacturingtalk Editorial
Team on 09 October 2006
Optical CMM for Midland F1 quality
In 2006, Midland F1 started an industrial sponsorship with Metris, a market leader in inspection systems.
Formula 1 teams are in the forefront when it comes to rapid development and rigorous testing of new cars and prototypes In order to deliver faster and more reliable cars, F1 teams rely on the latest technologies in various application areas, including dimensional measurement, where new technologies are being adopted to win the race against time
This article was originally published on Manufacturingtalk on 15 Mar 2007 at 8.00am (UK)
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In 2006, Midland F1 started an industrial sponsorship with Metris, a market leader in inspection systems.
James Key, Technical Director of Midland F1, explains: "It is a fairly simple equation.
If we want to perform successfully at the races, we need the best metrology equipment support to enable us to outperform our competitors.
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"We were particularly looking for a system that besides 3D point and laser scanning measurement, could also be used for dynamic measurements such as chassis stiffness or suspension compliance; of course everything packaged in an easy-to-mount and portable configuration.
"Dynamic testing is a very important element during the development of the car and, in particular, this application is where the Metris system provides an advantage compared to similar metrology-only solutions.
The flexible multi-tasking capabilities, together with top accuracy measurement, were the most important deciding parameters for selecting Metris as a partner." The Metris optical CMM uses a linear CCD-based camera that accurately detects infra-red moving LEDs in its six meter long measurement volume.
A combination of these LEDs is mounted on a touch probe, the SpaceProbe, to define uniquely the exact location of the probe and its measuring tip.
When the LEDs are used in combination with a handheld laser scanner - the K-Scan - it can be used to digitise parts and obtain 3D point clouds.
An important advantage of the optical CMM is so-called dynamic referencing: when the measured object is equipped with LEDs, its position can be changed during measurement, as the changes are tracked by the camera and the measured data compensated.
Another application, which differs from a classical measurement system, is to mount these LEDs on a car or component to measure its movement in space.
The Metris Optical CMM covers many applications where F1 teams can benefit.
One example is the FIA legality check, where the cars and bodywork are measured to verify compliance with the strict FIA regulations.
This legality check is performed before and after every race in the FIA box to ensure that all competing cars are tuned within the regulations.
Gauges are still used to check wing positions quickly.
The rules have become more stringent though and more intelligent methods are needed.
Especially in the field of bodywork deformation under load (flexible wings), the system has proven its value.
The system is also invaluable during wind tunnel tests to quantify and optimise the down force on the car and other aerodynamic characteristics.
Setting the car up in a wind tunnel is a very precise challenge that traditionally can take several hours.
The wheels are not attached to the car but need to be set up within a millimetre to simulate the exact wind flow.
As different car designs need to be tested, this set-up phase can lead to less efficient use of the expensive wind tunnel.
Using the Metris system, the time to set up the car model can be reduced by a factor four, so much more time can be dedicated to effective testing.
Another wind tunnel application is the recording of changes applied to the car during wind tunnel optimisation.
Often, small manual adjustments are made to the car model and using the SpaceProbe, the user can measure and store the different set-ups for evaluation of the best circumstances.
Another application is 3D digitising of bodywork for inspection or reverse engineering.
Scanning is performed using a handheld 3D scanner (K-Scan) and results in a point cloud, i.e a digital copy of the part.
This 3D point cloud can be used for comparison of the physical part against the CAD model, reverse engineering or rapid prototyping purposes.
As such, design optimisations or actual changes to the bodywork can be fed back to the original CAD model.
To produce ever stiffer and lighter composite structures, the Metris optical CMM also proves its benefits.
The cars are mounted on a multi-poster shaker rig where suspension and chassis are subject to the various racetrack profiles to test dynamic behaviour, such as stiffness and compliance of chassis and suspension.
Various LEDs (up to 256 3D positions are measured) are now attached to wheels or structure and tracked by the optical CMM.
All motions are captured in 3D, enabling detailed stiffness and modal analysis.
The same dynamic testing technique is also applied in static stiffness and compliance tests to nearly all individual components, such as rods, rockers, connectors and suspension parts.
These tests are made to optimise their performance against weight.
A typical test where the Metris system is used is kinematics and compliance (KandC) testing of the suspension.
It is fully compressed to analyse the behaviour of the chassis by tracking the LEDs mounted on the suspension and chassis.
The Metris system can also facilitate other applications such as geometry definition for modal analysis, crash test analysis or CMM assistance as the cars are built.
This is not only beneficial for the system cost, but also minimises investment in training.
It is a major benefit that so many measurement applications can be handled by a single system.
Furthermore, the fact that the Metris system is adopted by various other F1 teams, as well by the FIA, indicates endorsement at the highest levels of the sport. Request a free brochure from Metris ...
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