Brief Description of the assessment
Given some measurement tasks in an industrial context, you will need to complete two tasks: 1) to identify and evaluate the suitable measurement solutions and 2) to design/develop the Matlab or Excel program for the measurement data analysis. Both tasks are related to the key topics of the module.
Assessment method by which a student can demonstrate the learning outcomes
Identification and evaluation of the practical measuring systems for the given measurement tasks. Design and implementation of algorithms and Matlab programs for practical data analysis.
Format of the assessment/coursework
Format is a formal written report including diagrams/code; calculations (with data; formula; workings and assumptions) and discussion/ comments. Report to be written using Word in a 12-point font. Typical length of report is 2500 words, comprising Title Page; Introduction; Task 1, Task 2, Discussions, Conclusions and References. Word count does not include code done in Matlab or excel, which should be included in an appendix.
Over recent years your company has been making substantial investments in automated machine tools, but the inspection techniques have remained virtually unchanged. Most operators use go/no-go gauges and comparators etc. The emphasis has been on the detection of non-conforming components which are either scrapped or reworked.
The largest overall linear dimension on any components manufactured by the company is 400 mm. The main products are turned and milled components with a substantial number of features with tolerances in the region of 30 µm, but some precision spindles have tolerances of only 5 microns. The surface roughness ranges from 12.5-0.025 µm.
The Managing Director has given you the task of preparing a report on the types of equipment which could be employed to improve the measurement and product quality within the company. You should aim to demonstrate comprehensive knowledge of relevant measuring techniques with sound / innovative solution (paying attention to new and emerging technologies) and also skills for broader considerations, e.g. implications due to batch sizes, component types and materials, commercial and industrial constraints. Your report should cover the use of suitable sensors and transducers (e.g. LVDTs and/or optical encoders), coordinate measuring machines (CMMs) and surface measuring machines, including their operating principles, characteristics, performance. Since CMMs are complicated measuring machine, you should discuss their common error sources and how you are going to calibrate them. You should also describe the important surface parameters the company will likely use.
Your company has a manual 2D microscope which can measure the coordinates of 2D profiles. You have been asked to develop a least square algorithm in either Matlab or Excel to calculate the centre and radius of circular features.
Describe briefly how measurement uncertainty is evaluated. Given the standard uncertainty of x and y coordinates is 20 µm, calculate the uncertainties associated with the radius and centre coordinates. Describe how to reduce the measurement uncertainties.
To test your algorithm, you can use the following measurement results, the XY coordinates recorded for a ring gauge:
Measurement Results (unit: mm)
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