It is precisely because Komatsu GmbH has extremely high requirements for product quality that its excavator production can maintain excellent mechanical quality even after long-term use. More than two-thirds of the over 1000 excavators produced since 1980 are still in use. The current record holder for the longest running time is a PC 4000 excavator, which has been running for over 150000 hours, equivalent to nearly 18 years of service life, and is still in good operation to this day.
Customer's measurement needs
The excellent mechanical and comprehensive quality of Komatsu GmbH excavator largely stems from its precise control of the dimensions of various components and positions in the assembly process during production and manufacturing. The main focus is on the following:
1.The shape of structural components and the relationship between various processing surfaces;
2. The positional relationship between each hole on the structural component and the base plane;
3. The coaxiality of the assembly holes between the main structural components of the excavator chassis and other components;
4. The coaxiality of specific holes such as each hinge point of the telescopic arm;
5. Tolerance requirements: Usually, the positional relationship is required to be between 0.1mm-0.2mm; The hole located at the hinge point needs to bear the role of hub and load-bearing, and its coaxiality requirements are more stringent, with a tolerance requirement of 0.05mm.
Large size precision measurement, optimized production process!
To meet these strict tolerance requirements, we initially used several joint arms of a certain brand. Although the accuracy was acceptable and most of the operations could be completed, its efficiency was relatively low, especially when detecting larger components, the measurement range was a significant challenge, "said Mr. Schenzer, an engineer at Komatsu GmbH, Moreover, when using articulated arms for measurement, different engineers may use different measurement techniques, and the corresponding results may also have slight differences.
Mr. Schenzer continued, "As a result, we have been searching for a flexible, easy to place, high-precision measurement device that can be used in large-scale spaces, until we used the API brand Radian Laser Tracker, which not only ensures the required measurement accuracy but also significantly improves work efficiency, allowing the entire production process to achieve obvious optimization and improvement
API Laser Tracker Solution
Based on the measurement requirements of Komatsu GmbH, using the API brand Radian laser tracker and expanding accessories with corresponding functions can achieve perfect detection.
The Radian laser tracker is an excellent solution for large-scale precision measurement, with micrometers( μ m. The measurement accuracy of 0.001mm level, with a measurement range of up to 160 meters, can provide accurate measurement guarantees that meet the accuracy and scale range for various stages of excavator manufacturing.
During measurement, the operator holds a laser tracker target ball (SMR) with a built-in prism to touch the target area. The laser tracker host will shoot a laser to lock and track the center of the SMR. When the SMR touches the target area, the 3D coordinates of the target area are accurately collected at a data acquisition rate of 1000Hz, and transmitted to the Measurement Software for recording and saving.
After collecting several such marked points on the workpiece, corresponding lines, surfaces, and bodies can be formed in the software based on the positions of each point, and corresponding geometric tolerance data can be calculated. It can also be compared with digital analog to achieve measurement and detection purposes.
Typical measurements involved in Komatsu GmbH excavator production
1. Measurement of the relationship between surfaces
Using Radian laser tracker and SMR target ball to collect several points on two surfaces, the 3D coordinates of these points are simultaneously fed back to the analysis software. After the coordinates of all points are collected, the positions of the two surfaces can be constructed based on the actual coordinates of these points in the software, and automatically calculated and analyzed to evaluate the relationship between the two surfaces.
2. Measurement of the position relationship between holes and the base plane
Firstly, use the Radian laser tracker in conjunction with the SMR target ball to measure data on the set base plane and construct the base plane in the software; Then, in conjunction with the target ball and cylindrical pin accessories (as shown in Figure 4, cylindrical pins can be used to accurately measure the target ball into the hole; deeper hole positions can be measured by using a vProbe hidden point probe), point measurements are taken on the hole to be measured, and corresponding holes (cylinders) are constructed in the software; Finally, the software can automatically construct and analyze the position relationship between the hole and the base based on the collected point data (as shown in Figure 5).
3. Coaxiality of holes and holes at special positions such as chassis component assembly points/telescopic arm hinge points
By using Radian laser trackers in conjunction with cylindrical pins or vProbe probes to collect data from the holes to be measured, and constructing cylinders in the software, the axes of each hole can be automatically calculated and the interrelationships between the axes can be analyzed to evaluate coaxiality.
Flexible data collection methods
In actual measurement operations, in addition to the cylindrical pins and vProbe intelligent probe for measuring hidden points mentioned above, API has also developed various laser tracker function expansion attachments (as shown in Figure 7) to widely adapt to various detection needs:
IScan3D scanning probe: capable of quickly scanning and collecting profile data;
-STS six dimensional sensor: used in conjunction with a tracker to achieve 6 degrees of freedom (6DoF) measurement of the target being tested;
-ActiveTarget active target: Always lock the laser tracker beam to achieve continuous automated static and dynamic measurement;
-RapidScan scanner: Cooperate with laser tracker to achieve high-precision online non-contact batch detection;
-And practical accessories such as small-sized target balls, tip probes, dotting tools, and edge holders.
conclusion
API brand Radian series laser trackers with a measurement range of 160 meters and ultra-high accuracy (micrometer level, μ m. 0.001mm), combined with extensive laser tracker functions to expand accessories, the human-machine interaction is simple and convenient, and the measurement operation is flexible and convenient, fully meeting the accuracy requirements of tolerance detection of 0.1mm-0.2mm and up to 0.05mm in various stages of Komatsu GmbH excavator manufacturing. This helps Komatsu GmbH adhere to its "quality first" principle, further optimize the measurement process, and improve overall production efficiency.
About API
The API brand was founded by Dr. Kam Lau in Rockwell, Maryland, USA in 1987. It is the inventor of laser trackers and holds multiple patents for leading global measurement technologies, making it a leader in the field of precision measurement technology; Since its establishment, API has always been committed to the research and development and production of precision measurement instruments and high-performance sensors in the field of mechanical manufacturing. Its products have been widely applied in advanced manufacturing fields around the world, and are leading in high-precision standards for coordinate measurement and machine tool performance testing.
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