Measurement Services with the Keyence IM_8000 Vision System

Measurement Services 

Accurate measurement is essential to precision manufacture, which is why we’re thrilled to announce the addition of the Keyence IM-8000 image dimension measurement system to Custom Converting’s suite of tools. We will be integrating the quality control possible with the Keyence IM-8000 to all of our die cutting services, and we will also offer this measurement service as a stand-alone service.

As a converter, Custom Converting works primarily with thin materials, such as plastic, films, foils, and papers. But what if your product involves thicker materials, or you’re doing manufacturing in-house? How do you get the same high-precision results on your manufacture as the parts you’re receiving from Custom Converting?

Enter the Keyence IM-8000. We are offering measurement services not only for the parts that we work with, but your manufactured parts as well. Not limited to thin or two-dimensional parts, the Keyence IM-8000 makes schematics and analyzes the accuracy of three-dimensional parts. Bring your quality questions to us and let us find the source of your problems.

Keyence Details

Capable of high-definition imaging, the IM-8000 Series Image Dimension Measurement System  has triple the detection performance of conventional systems. With a 20-megapixel CMOS sensor and a new algorithm for stable edge detection, high-accuracy measurement on up to 300 features within seconds is now possible. A newly developed, optional automated rotary fixture allows for 360′ multi-surface measurement on diverse part sizes and shapes.

This precision measurement tool will help us help innovators, allowing us to get schematics from the prototypes they’ve designed more efficiently. This improves your bottom line as a client, because you can get finished products into your hands in less time. You can bring your prototype to us for measurement services and have us produce two-dimensional schematics from your three-dimensional prototype.

Keyence IM-8000

Remember – “Quality is in our DNA!”

Statistical Methods for QA and QC:

Quality Assurance (QA) and Quality Control (QC) rely heavily on statistical methods to ensure processes and products meet predefined standards. These statistical methods help detect variation, monitor performance, and make data-driven decisions to improve quality.   Our new measurement services will help you with your QA and QC needs.

Statistical Process Control (SPC)
SPC is a method of monitoring and controlling a process through the use of control charts to ensure it operates at its full potential. The goal is to identify any variations that occur during production and distinguish between common cause variation (inherent in the process) and special cause variation (due to external factors).  SPC helps detect deviations in a process before products are outside specifications, thus enabling corrective actions before defective products are produced.

  • Control Charts:
    o X-bar and R charts: Used to monitor the mean and range of a process.
    o p-chart: For monitoring the proportion of defective items in a sample.
    o np-chart: Used to monitor the number of defective items in a sample.
    o c-chart: Used to monitor the count of defects per unit.
    o u-chart: Used to monitor the number of defects per unit when the sample size varies.

Process Capability Analysis
Process capability measures the ability of a process to produce products within specified tolerance limits consistently. This method is used to assess whether a process is capable of producing items that meet design specifications.  Process capability analysis is essential in QA/QC for ensuring that manufacturing processes are stable and capable of producing within specification limits.

  • Capability Indices:
    o Cp: Measures the potential capability of a process assuming it is centered.
    o Cpk: Accounts for how well the process is centered within the tolerance limits.
    o Pp and Ppk: Similar to Cp and Cpk but used for overall process performance over time, not just short-term.

Acceptance Sampling
Acceptance sampling is used to determine whether to accept or reject a batch of products based on a sample. It is useful in situations where 100% inspection is impractical or too costly.  Statistical sampling helps reduce the cost of quality control by minimizing the number of inspections needed while still ensuring the quality of large batches.

  • Single Sampling Plan: A random sample is taken from a lot, and the lot is accepted or rejected based on the number of defects in the sample.
  • Double Sampling Plan: If the results from the first sample are inconclusive, a second sample is taken, and the decision to accept or reject is made based on combined results.
  • Attribute Sampling: Focuses on defects present (e.g., pass/fail, yes/no).
  • Variable Sampling: Focuses on measurable quantities (e.g., dimensions, weights).

Design of Experiments (DOE)
DOE is a structured method for systematically planning, conducting, analyzing, and interpreting controlled tests. This method is used to understand the relationship between different factors (inputs) affecting a process and the resulting output.  DOE is particularly valuable for improving manufacturing processes by identifying which factors have the most significant impact on quality and which can be optimized.

  • Full Factorial Designs: Examines all possible combinations of factors at different levels.
  • Fractional Factorial Designs: Tests a subset of the possible combinations to reduce the number of experiments.
  • Response Surface Methodology (RSM): Used for optimizing processes by exploring the relationships between the input variables and response variable.

Failure Mode and Effects Analysis (FMEA)  FMEA is a proactive tool used to identify potential failure modes in a manufacturing process and assess their impact on product quality.  FMEA helps manufacturers systematically evaluate and mitigate risks, improving the overall quality and reliability of the product.

  • Risk Priority Number (RPN): Combines the severity, occurrence, and detection of potential failures to prioritize the most critical risks.
  • Process FMEA (PFMEA): Focuses on identifying risks in manufacturing processes.
  • Design FMEA (DFMEA): Focuses on identifying risks in the design phase of a product.

Fundamental Measurement Services

These are some of the most fundamental measurements that vision systems handle, ensuring the dimensions meet the required tolerances.

  • Length/Width:  Part length and width are commonly measured to ensure the overall size of a part falls within specified tolerances. For instance, in a rectangular part, the vision system will capture the outer boundary and measure the distance between opposite edges to confirm that dimensions align with engineering specs.
  • Hole Diameter:  The diameter of circular features like holes, bosses, or pegs is crucial in many parts, especially for assembly. A vision system can measure diameters with micrometer precision, ensuring that the feature is neither undersized nor oversized.
  • Height (Step Height Measurement):  Though height is a 3D dimension, it can often be calculated through the system’s edge detection, such as measuring the step height of different features on a flat part by comparing distances from one surface to another.
  • Slot Width/Groove Depth:  For parts with slots or grooves, the vision system can measure the width and depth to ensure they meet the engineering drawing specifications. This is critical in machined parts or those requiring precise fitting of other components.

Geometric Tolerances:  Geometric tolerances are essential for ensuring proper functionality and fitment, often more critical than simple linear dimensions. Vision systems excel in measuring the following tolerances:

  • Position (True Position): Ensures the center point of a feature (such as a hole or boss) is located accurately relative to a reference point or another feature. Misalignment can cause significant issues in part assembly.
  • Concentricity:  Measures the center alignment of two or more circular features on the same part. Vision systems help ensure the centers are coincident, which is critical for rotating components or bearings that need to be concentric to function correctly.
  • Flatness:  Even in a 2D measurement, vision systems can capture surface flatness by examining the evenness of a part’s surface along multiple points, ensuring no warping or deformation, which is critical in parts that must interface with other flat surfaces.
  • Parallelism/Perpendicularity:  Measures how parallel or perpendicular two surfaces or features are to each other. For example, vision systems can assess if two sides of a part are perfectly parallel, or if a hole’s axis is perpendicular to a reference plane, ensuring proper alignment for assembly.
  • Symmetry:  In parts requiring symmetry about an axis (e.g., mirror-image halves), the vision system can measure the relative distance of features from the centerline to ensure that the part is evenly balanced.

Angles:  Many parts include angular features like chamfers, tapers, or inclined surfaces. Vision systems can precisely measure angles between lines or surfaces, which is vital for fitting and functionality.

  • Chamfer/Taper Angles:  Ensuring that angled cuts on part edges meet exact specifications. For example, a 45° chamfer should be measured to confirm it is precise, especially for parts that need to mate with other angled surfaces.
  • Hole Inclination: Measuring the angular deviation of a hole’s axis relative to the part surface is important for proper insertion of fasteners or shafts.

Radius and Curvature:  Many parts have curved surfaces or rounded edges that need to meet specific design criteria. Vision systems are well-suited to measure:

  • Fillet Radii:  Ensures the radius of curved edges (fillets) are correct, which is critical for reducing stress concentrations in parts subject to loads.
  • Curved Surfaces:  For complex parts with non-linear edges, the vision system can map and measure these curves to ensure that the profile follows the design drawing precisely. This is especially important in parts with aerodynamic or fluid flow applications.

Edge Detection and Chamfer Measurement:  Vision systems excel in edge detection, which can be used to measure features like:

  • Sharp Edges and Burrs:  Identifying sharp edges and burrs is important in quality control, especially for components that need to be safe to handle or fit tightly in assemblies.
  • Bevel and Chamfer Size:  The system can measure the size and angle of chamfers or bevels cut into the part. This is crucial in ensuring that parts fit together correctly, especially in mechanical or structural assemblies where sharp corners are intentionally removed for better interfacing or load distribution

Circularity, Cylindricity, and Roundness:  For cylindrical parts or features like shafts, pins, and holes, the system can measure:

  • Roundness:  Ensures that circular features are perfectly round. Imperfections in roundness could cause issues in rotating parts or tight-fitting assemblies.
  • Circularity:  Similar to roundness, this measures how closely a shape approaches a perfect circle, which is essential in ensuring parts that rotate (like gears or wheels) function smoothly.
  • Cylindricity:  For 3D cylindrical features, the system can measure the consistency of the shape from one end to the other, ensuring the part is uniformly shaped.

 Pattern and Feature Recognition Modern vision systems, like the IM-8000, can perform pattern matching and feature recognition, allowing for:

  • Verification of Complex Profiles: For parts with intricate or irregular profiles (e.g., custom molds or castings), the system can compare the actual part shape against the CAD data, ensuring the entire profile is correct.
  • Hole or Slot Patterns:  If a part has a specific arrangement of holes, slots, or other features, the vision system can verify the spacing and pattern accuracy to ensure the correct layout for assembly.

Profile Measurement and Contour Analysis:  Vision systems can analyze the entire contour or profile of a part to ensure it matches the desired design.

  • Profile Tolerance:  This measures the overall shape of a part or feature, ensuring it falls within the allowable deviations from the specified profile, which is especially important in parts with complex or non-standard shapes.
  • Cross-Sectional Measurement:  Vision systems can capture cross-sectional measurements of complex parts to verify the part geometry and thickness at various points.

 

Accuracy and Outputs:

With an accuracy of up to 2 μm +/- 0.00008 in, the Keyence IM-8000 not only serves to measure your prototype for manufacture, it can keep your manufactured parts on-spec throughout the manufacturing process.  

These tools help in understanding the distribution of product dimensions, defect rates, or process outcomes, aiding in decision-making and process improvements.

  • Trending graphs for production
  • OOS dimensions
  • Diagnosing sequential measurements
  • SQL and sigma reports
  • Potential risk analysis evaluation
  • Pass/fail evaluations

    A Full-Service Manufacturer:

    At Custom Converting, we have built our business on serving the needs of our customers.   The Keyence IM-8000 tool is a great addition to Custom Converting’s suite of tools, and we are excited to not only integrate it into our own processes, but give you the ability to bring precision manufacture to your own components.

    Quality is in our DNA – we’re ready to make it your hallmark, too.  With our new measurement services, you’ll be ready to manufacture as precisely as we do.  When you sell the products that we manufacture to your customers, they’ll notice the difference.  

    Custom Converting pairs the best of innovation with the reliability of a familiar manufacturing partner. We provide jobs in our local communities, exclusively utilizing on-shore manufacturing.

    Complete the form on our website or the detailed request for quotation available here and email it to sales@customconverting.com. You can also call us at (760) 724-0664.