(Renishaw: West Dundee, IL) -- Renishaw, a global leader in metrology systems, showcased its innovative 5-axis measurement technology for CMMs at IMTS 2024 in McCormick Place, Chicago.

The REVO 5-axis multisensor system was displayed with an extensive range of probes. The 5-axis CMM measurement system offers automatic switching between tactile scanning, touch-trigger, ultrasonic, vision, and surface finish measurement.

By integrating multiple sensors on the same CMM, the REVO system enables manufacturers to increase productivity significantly and can eliminate the need for other dedicated inspection equipment. This single-machine solution also overcomes the delays and risks of damage associated with transferring parts across multiple inspection locations. Reducing the number of machines required can lead to lower energy consumption and maintenance costs.
 
Renishaw’s 5-axis technology minimizes dynamic errors at ultrahigh measuring speeds by synchronizing the motion of the three CMM axes and the measuring head’s two axes. This technology provides access to part features that are out of reach for conventional 3-axis systems, significantly reducing inspection cycle times, enhancing throughput, and guaranteeing part quality. The resulting improvement in throughput times can reduce the overall CMM count when, for example, two 5-axis-equipped machines achieve the same throughput as three 3-axis-equipped machines.

The CMM demonstration highlighted the crucial role of Renishaw’s 5-axis multisensor CMM measurement capability in manufacturing electric vehicle (EV) parts. The REVO 5-axis system’s flexibility allows for inspection of the features of stator laminate stack subassemblies, preventing faulty components from rendering valuable finished parts as scrap.

The REVO system’s RSP2 tactile scanning probe leverages the 5-axis motion to inspect complex geometries rapidly and accurately. It’s particularly effective in scanning planes, cylinders, and valve seats and guides on an engine head. While traditional methods often involve slower, point-by-point data collection, with RSP2, dense data sets are gathered quickly, leading to more efficient inspection processes. Additionally, the RSP2 probe’s ability to sweep-scan the hairpin heights on the top of an EV stator and report the highest point of these pins provides valuable data for quality control and process optimization.

The ability to automatically change between sensor types on a single CMM is particularly significant for automotive manufacturing. The SFP2 surface finish probe offers a wide range of specialized modules and extends the surface finish measurement capability of the REVO system. The SFP2 probe allows access to surfaces that are challenging to reach with conventional equipment.

For example, the G1 surface finish module is used for groove measurement in engine cylinder bores before a plasma coating process (also known as LDS). Another example is the H1 module, characterized by its elongated skid with a large radius (125 mm), enabling it to be used with components such as cutoff values larger than 0.8 mm. This makes the SFP2 capable of measuring parts that might not be perfectly clean while still complying with international standards.

Another valuable tool available to the REVO system is the RVP vision probe, which enables inspection of features that are difficult to reach. One of its critical applications is measuring the heights of paper insulators used to isolate the hairpins from the housing in an EV stator. The noncontact probe measures these heights without disturbing the paper insulators, ensuring they remain in the correct position throughout the process. This capability is crucial in maintaining the integrity of the insulation system and the overall performance of the EV stator.

Software is an integral element of the REVO 5-axis measurement solution. Renishaw’s MODUS metrology software delivers high-performance industrial inspection, optimizing the performance of the REVO multisensor measurement system.  
 
MODUS 1.13 software offers multiple enhancements in flexibility and usability for REVO sensors. Users can benefit from powerful new features within its specialist programming (MODUS Planning Suite ) and reporting (MODUS CHART) tools.
 
Additionally, MODUS software enhances process monitoring capability by linking directly to the Renishaw central manufacturing connectivity and data platform, making it easy for a variety of systems and processes to access Renishaw device data.
 
For further information on Renishaw’s latest industrial metrology solutions for improved productivity, visit www.renishaw.com/revo.