BlueTC

The BlueTC with radio data transmission.

 

The BlueTC is used as a remote device for wireless connection of our ZEROTRONIC and ZEROMATIC sensors with our remote display BlueMETER SIGMA.

 

The BlueMETER SIGMA acts as a host to send measured data via our interface wylerCONNECT to a PC/laptop. There you can use the data in combination with our software wylerSPEC, wylerDYNAM or wylerINSERT.


MACHINE TOOLS / CHECKING OF ROTATION ERRORS

Subject:

Machine tools must be checked periodically for geometrical deviations, since changes of the geometry have a direct influence on the quality of the parts manufactured on that machine. 

It is very important that during the displacement in one axis the tool will follow a straight path compared to the table. On machines of light-weight construction the table can show a deformation due to its own weight. 

If the complete machine construction is tilting during the displacement of the table this is a sign for insufficient stability of the foundation or for a flexibility of the stand (damping elements).

 

Measuring task:

The geometry of a machine tool must be verified. The check must show rotational errors of the table during displacement. The measurement should be made reliably and efficiently. 

 

PRINTING INDUSTRY / ADJUSTMENT OF STANDS AND PRINTING CYLINDERS

Subject:

A modern multi-color printing system consists of several separate units, one unit per primary color. To achieve high-quality print products, these units must be precisely aligned and adjusted when assembled.

 

Measuring task:

Each single color unit provides horizontal and/or vertical reference faces, which must be used during the manufacturing process in the production plant as well as for the adjustment of the printing line. The positions of the reference faces must be adjusted in accordance to each other, measured, and a record must be printed. The positions of the printing cylinders must be precisely aligned to each other (horizontally).

POWER SUPPLY SECTOR / ALIGNMENT OF LARGE PUMP SHAFTS

Subject:

During maintenance works on the pumps of the cooling circuit of a cooling tower in nuclear power plants, quick and precise methods for the required alignment works are indispensable. Large electro motors with vertical axis drive evenly large centrifugal pumps situated one floor below.

Measuring task:

  • The horizontal positions of the connecting lines between the bearing faces on the bearing ring for the stator must be checked. The flatness and the horizontal position of the bearing ring must be assured.
  • The pump housing, one floor below, must be adjusted horizontally as well.
  • The center points of the pump shaft and the drive shaft of the motor must be aligned to each other in order to assure that the transmission shaft can work free of any bending moment.

MACHINE TOOLS / SPINDLE ALIGNMENT

Subject:

The main spindle of a milling machine can be set for vertical as well as for horizontal milling. To change between the two settings, the milling head rotates on a bearing set at 45°. 

 

Measuring task:

The deviation from the right angle between the two working positions “horizontal” and “vertical” must not exceed 2 arcsec. 

The measurement (and correction) is first made during assembly, and again during final inspection of the finished machine. 

MEASUREMENT OF THE FLATNESS IN AN OVEN WITH LIMITED HEIGHT

Subject:

A bio-technical company must measure the flatness of plates in an oven (at room temperature), to ensure that all objects stored in that oven are horizontally aligned. Distance between plates are only 100 mm. Size of each plate is 800 mm x 800 mm.

Normally a BlueSYSTEM Sigma together with wylerSPEC is used for flatness measurement. For this application here the height of the instruments exceeds the space available.

 

Measuring task:

Flatness measurement of the plates in the oven with precision inclination measurement instruments, despite the limited space available.

ALIGNMENT OF AN INJECTION MOLDING MACHINE WITH WIRELESS INCLINATION SENSORS

Subject:

Each injection molding machine must be properly aligned during commissioning. This process uses 5 precision spirit levels and requires 2 technicians. One of them is reading the spirit levels and the other one is adjusting the 6 supports. This is an iterative and tedious work, since all 5 spirit levels must be re-checked after every adjustment. The available height on each of the 5 measuring points is limited to 120 mm.

 

Measuring task: 

The customer is searching for a more efficient solution for this process during in-house commissioning as well as for the commissioning

at the customers premises. If possible, the adjustment should be done by one single technician. To assure that no instrument is accidentally pulled down, a wireless solution is favored.

POSITIONING OF A HEAVY PART WITH AN OVERHEAD CRANE

Subject:

In a large production hall, a heavy part shall be positioned in the correct height with an overhead crane in order to allow a stress-free mounting. First tests show that the building is not stable enough: Depending on the weight of the part, vertical offsets are measured which are larger than the required positioning 

accuracy.

 

Measuring task: 

In order to achieve the required accuracy, the bending of thebuilding respectively of the overhead crane should be measured.From these values, the vertical correction of the crane should be calculated.

ADJUSTMENT OF A CEMENT OVEN DRIVE

Subject:

Cement is manufactured in a so-called turn-tube oven. The oven itself is a about 50 to 70 m long, slightly tilted steel tube with a diameter of 4 to 5 m which turns around its longitudinal axis (max. 20 rpm).

 

Measuring task:

The inclination of the cement-oven drive- gear wheel (diameter approx. 1.5 m) should be the same as the inclination of the turn-tube oven gear wheel (diameter approx. 6 m). The required accuracy is 0.01° = 0.2 mm/m.

MEASUREMENT OF A CIRCLE ON A ROUND TABLE OF A GRINDING MACHINE

Subject:

A manufacturer of large metal plates has several large surface grinding machines in his workshop. The geometry of these machines must be checked and documented periodically, and, where required, to be corrected.

 

Measuring task:

The flatness of a rotating table of a grinding machine with a diameter of 3200 mm must be measured. Thereby only the flatness of a circle must be measured and not the whole table.

MEASUREMENT OF PITCH AND ROLL ON A GRINDING MACHINE

Subject:

A manufacturer of large metal plates has several large surface grinding machines in his workshop. The geometry of these machines must be checked and documented periodically, and, where required, to be corrected.

 

Measuring task:

On a large surface grinding machine with guide ways with a length of 18m pitch and roll must be checked. The maximum tolerance is 0.1 mm/m.

MEASUREMENT OF THE RECTANGULARITY OF THE HEAD OF A ROUND TABLE GRINDING MACHINE

Subject:

A manufacturer of large metal plates has several large surface grinding machines in his workshop. The geometry of these machines must be checked and documented periodically, and, where required, to be corrected.

 

Measuring task:

The rectangularity of the axis of a grinding head of large grinding machine in relation to the bearing of a round table with a diameter of 3200 mm must be measured. Based on the results, if necessary, the inclination of the head must be adjusted.

ALIGNMENT OF THE HOLES OF FLANGES

Subject:

A pipe must be welded in between two vertical flanges with holes. These pipes have a length between 2m and 10m and a diameter between 400mm and 1000mm. 

The material of the flanges and the tubes is either aluminum or stainless steel.

 

Measuring task:

Before the welding process, the holes of the 2 flanges must be aligned in such a way that the holes on the left have less than ±15arcsec deviation from the holes on the right side after the welding process.

PITCH AND ROLL MEASUREMENT WITH 2D-ZEROTRONIC MEASURING UNIT AND MT-SOFT-SOFTWARE

Subject:

Alignment of a turning lathe with an oblique bed and establishing a pitch and roll measuring protocol for the longitudinal and transversal axis.

 

Measuring task:

The machine should first be very accurately levelled in both X- and Y-direction.

Afterwards a pitch and roll measuring report with numerical and graphical information is required.

MEASUREMENT AND CERTIFICATION OF THE TORQUE-RESISTANCE ON AN ENGINE-SHAFT

Subject:

The torque-resistance of an engine shaft is decisive for the reliability and durability of the engine. However, to measure this resistance for long shafts is a challenging task.

 

Measuring task:

The torsion of an engine-axis mounted on a testing-rig with a base of 12m x 12m must be measured precisely by recording the change of the twist-inclination and by putting it in relation to the applied torque.

MONITORING OF AN OFFSHORE WIND TURBINE TRIPOD DURING PLACEMENT AND ANCHORING IN THE SEA

Subject:

An offshore wind turbine requires a stable and exactly horizontal base. To achieve this, the tripod, on which afterwards the wind turbine will be mounted, must be monitored during the anchoring process.

 

Measuring task:

The position of the Tripod must be monitored during the anchoring rocess with inclination sensors mounted at the upper end of the Tripod. The sensors must withstand the high accelerations occurring during the ramming process. The measured data must be transmitted wireless to the boat controlling the whole process.

RAILWAY CONSTRUCTION

Subject:

The requirements in railway construction are increasing continuously. Specifically, high speed tracks put very high demand on track geometry and therewith on track construction. A tamping machine requires exact information about the condition and position of the track ahead to make the required corrections and to work precisely and efficiently

 

Measuring task:

The positioning errors of the track shall be measured with a mobile measuring unit. The measuring data shall then be used by the tamping machine.

ALIGNMENT OF SOLAR PANELS

Subject:

Solar panels must be perfectly adjusted to the sun to ensure best possible performance.

 

Measuring task:

The inclination of each single solar panel must be verified periodically. A measuring range of up to ±60° is required.

CALIBRATION OF ROBOTS

Subject:

The precision of an industry robot is directly depending on the precise alignment of each single axis.

 

Measuring task / Goal:

The offset of each axis has to be measured not only in 

production, after mounting the robot, but also after the 

installation at customer site. These offsets are then to be known and compensated by the process control system.