In today’s competitive manufacturing environment, quality control is more critical than ever. Manufacturers are constantly seeking to enhance accuracy and reliability, while also lowering costs and increasing efficiency. That’s where automation becomes helpful. By automating quality control processes, manufacturers can achieve consistent, repeatable results that fulfill or exceed customer expectations.
One example of an automated quality control system is the Q-Span Gauging System from New Scale Robotics. This system automates gauging processes by combining existing manual gauges with a collaborative robot, grippers for part handling, easy-to-use metrology and robot control software, and automated data collection. In this article, we will explore the latest enhancement to the Q-Span system – thread verification – and how this feature can benefit manufacturers in a variety of industries.
The Q-Span Gauging System automates a variety of gauging processes, including dimensional measurements, surface finish analysis, and now, thread verification. Before diving into thread verification, let us take a closer look at this system. The system uses a collaborative robot to load parts into a fixture and activate the appropriate gauge. Then, it collects data from the gauge and stores it for later analysis.
One of the key benefits of the Q-Span system is its flexibility. The system can be configured for “GO” gauging, “NO GO” gauging, combination gauging, or even thread chasing. This means that manufacturers can use the system to verify a wide range of parts, from small components to large assemblies.
Thread Verification with Q-Span is the latest enhancement to the system. This feature allows manufacturers to verify or chase threaded holes or external threads using a dedicated thread gauge. The robot arm loads the part into the fixture and activates the thread gauge which then measures the thread size, pitch, and depth. The system collects and stores this data for later analysis.
Thread verification is particularly useful for manufacturers who produce parts with threaded features. These features are critical to the function of many products, and even a small error in the thread size or pitch can result in a product that does not meet customer specifications. By automating thread verification with the Q-Span system, manufacturers can ensure that threaded parts are accurate and consistent every time.
Gauging Configurations Available
As mentioned earlier, the Q-Span system can be configured for a variety of gauging processes. In addition to thread verification, the system can be used for dimensional measurements, surface finish analysis, and more. This flexibility makes the Q-Span system a versatile tool for manufacturers who need to verify the quality of their parts.
The system can also be configured to work with different types of gauges, depending on the manufacturer’s needs. For example, the system can be used with pneumatic or mechanical gauges, dial indicators, or laser sensors. This means that manufacturers can use the gauges they already have, rather than investing in new equipment.
Statistical Process Control (SPC)
One of the key benefits of the Q-Span system is its ability to collect and analyze data from multiple gauges. The system combines data from all gauges into one convenient output for statistical process control (SPC). SPC is a method of quality control that uses statistical analysis to monitor and improve manufacturing processes.
By using SPC with the Q-Span system, manufacturers can identify trends and patterns in their quality data and make adjustments to their processes as needed. This can help to reduce defects, minimize waste, and improve overall product quality.
In addition to SPC, the Q-Span system also allows manufacturers to use data from any or all gauges in real-time for in-process decision making and process monitoring. This means that manufacturers can identify and address quality issues as they occur, rather than waiting for the end of the production run.
Real-time process monitoring and decision-making are particularly useful for manufacturers who produce high-mix, small-batch products. These types of products often require frequent changeovers and adjustments, and real-time data can help manufacturers make these adjustments quickly and accurately.
Incorporating Universal Robots (UR)
The Q-Span system incorporates a Universal Robots (UR) collaborative robot for flexibility, ease of use, and a rapid return on investment. UR robots are designed to work safely alongside human operators without the need for safety barriers or fencing. This makes them ideal for use in manufacturing environments where space is limited.
UR robots are also easy to program and operate. The Q-Span system includes intuitive software that allows operators to quickly set up and run gauging processes without the need for robotics experience or special training.
Customization for Individual Needs
Another benefit of the Q-Span system is its ability to be customized for individual needs. New Scale Robotics incorporates gauges and grippers to meet each customer’s unique requirements, and users can effortlessly configure the control software themselves for additional parts and processes.
This flexibility means that manufacturers can start with a basic system and add on additional features as needed. It also means that manufacturers can tailor the system to their specific production requirements, rather than using a one-size-fits-all approach.
Q-Span is a do-it-yourself (DIY) robotic automation system designed for quality teams in high-mix, small-batch manufacturing. The system is easy to set up and operate without the need for outside consultants or integrators.
This DIY approach means that manufacturers can achieve a rapid return on investment while maintaining control over their processes. It also means that manufacturers can experiment with different gauging processes and configurations without incurring high costs or long lead times.
In conclusion, the Q-Span Gauging System from New Scale Robotics is a versatile, flexible, and easy-to-use system for automating gauging processes in manufacturing. The latest enhancement, thread verification, is a valuable feature for manufacturers who produce parts with threaded features. The system has the ability to collect and analyze data from multiple gauges, along with its real-time process monitoring and decision-making capabilities, making it an ideal tool for manufacturers in a variety of industries. Finally, the system’s DIY approach means it is accessible to manufacturers of all sizes and budgets.