Project Status Update. P09701 Corning Tropel LightGage Metrology System

Transcription

1 Project Status Update P09701 Corning Tropel LightGage Metrology System Matthew Bradley (ME) Images Courtesy of Corning Tropel

2 Project Status Update Project Name Corning Tropel LightGage Metrology System Project Number P09701 Track Equipment Development Start Term planned academic quarter for MSD1 End Term planned academic quarter for MSD2 Faculty Guide (Confirmed) Dr. Wayne Walter (ME) Primary Customer (Confirmed) Thomas J. Dunn, Ph.D Senior Optical Engineer Metrology Instruments Group t (main) dunntj@corning.com Images Courtesy of Corning Tropel

3 Project Background Corning Tropel's LightGage is a state-of-the-art metrology system that uses traditional phase interferometry as well as light source frequency modulation to deliver high resolution part measurement data. The system relies on a tunable infrared laser to measure with extreme accuracy parallelism, surface height, and surface flatness; and is designed to accommodate a 40mm maximum diameter part. To measure a part, the user simply places the part onto the glass Fizeau window of the device (which is typically offset-gapped by a fine wire lattice, or ''harp'') for measurement; the device then uses TMS software to develop the proper "recipe" required to measure the desired part. In doing so, the system provides the user with very accurate, repeatable measurements with limited set-up time.

4 Tech. Background (1) Object Fizeau Plate Objective Lens Camera Diffuser Disk BS LightGage Head Images Courtesy of Corning Tropel Tunable Laser Diode Interior Workings of the LightGage Head

5 Tech. Background (2) LightGage Measurement Example: Flatness and Parallelism of two surfaces (Fuel Pump - Automotive) Images Courtesy of Corning Tropel

6 Project: LightGage Gen. 2 To be developed in partnership with RIT Product is required to measure both sides of a part as well as accurately measure part thickness. Images Courtesy of Corning Tropel

7 Phase 0: Planning Mission Statement The contents of this section include: 0.1 Product Description / Project Overview 0.2 Key Business Goals / Project Deliverables 0.3 Primary Market / Project Opportunities 0.4 Secondary Market / Project Opportunities 0.5 Stakeholders

8 0.1 Product Description / Project Overview Description/Mission Statement The primary focus of Corning Tropel's partnership with RIT is for a MSD team to develop a system around the LightGage sensors that would allow for both sides of an object to be measured simultaneously. In order to achieve this, two LightGage heads will be aimed at one another. Again, a maximum part size of 40mm would be used for the dual-headed system. The team will need to develop a fixture capable of supporting the two heads as well as the part being measured; and be able to provide repeatable and consistent measurements.

9 0.2 Key Business Goals / Project Deliverables Develop the framework for the second generation LightGage Demonstrate the ability to measure accurately, repeatably, and quickly, both sides of a part This includes having a motorized height adjustment for the top LightGage sensor Repeatable and reproduceable part placement Environmental isolation Optimize, work into design fixes to issues on the first generation LightGage product Produce all documentation required (to Corning s standards) for manufacturing to be outsourced

10 0.3 Primary Market / Project Opportunities The primary market of the LightGage device are manufacturers of small, high precision parts with tight tolerances such as: Fuel Injectors Watches Other engine components

11 0.4 Secondary Market / Project Opportunities Because of the highly specified nature of this product, secondary markets have yet to be identified

12 0.5 Stakeholders Stakeholders The final customer The Corning Tropel Metrology Group The RIT students involved in the project The RIT MSD program and team advisors

13 Phase 1: Concept Development Identify Customer Needs - Interviews Meeting # Person Interviewed Date Notes 1 Dr. Wayne Walter 3/20/08 Introductions, verified customer contact information 2 Thomas J. Dunn, Ph.D., Senior Optical Engineer 3/27/08 Established customer needs, specs., technical background information, stakeholders 3 Corning Tropel TBD Meeting with Mr. Dunn and other engineers to finalize tech. specs and give them a status update

14 Phase 1: Concept Development Identify Customer Needs - Interpret The contents of this section include first drafts of: 1.0 Needs statements 1.1 Affinity diagram Affinity supergroups 1.2 Objective tree 1.3 Needs hierarchy 1.4 Needs summary with rankings 1.5 Process reflection

15 1.0 Needs Statements 1. Accommodate Part Thickness Variations 2. Minimized Air-Gap 3. Tightest Mechanical Loop Possible 4. Vibration Isolation 5. Light Polarity 6. Repeatability 7. Ease of Use 8. Robustness 9. Setup Speed 10. Design For Manufacturing

16 1.1 Affinity Diagram (Groups) LABEL: Manufacturability & Cost LABEL: Ease of Use LABEL: Measurement Accuracy Portable Any one can Use it LABEL: Part Manipulation/Control Tight Mechanical Loop (2) Ease of Manufacturing Small package Easy/Repeatable Calibration C.O.T.S. Parts Low Complexity Low cost of build Easy to Maintain (2) Intuitive interface Short Setup time Easy to use Automation LABEL: Speed of Measurement High throughput Fast measurement repeatable Efficient operation Way to hold parts Control Position Motorized positioning Part thickness From 1mm-100mm Automatic positioning Measure both Sides of part Can hold/measure Any part LG Gen. 1 could Part detection Low mechanical drift Lowest air gap possible Vibration isolation Light canceling /polarity Isolated from Outside env. Repeatable Part placement Low sensitivity To temp. differences High accuracy

17 1.1.1 Affinity Diagram (Supergroups) SUPERGROUP: Part Measurement LABEL: Part Manipulation/Control LABEL: Measurement Accuracy LABEL: Manufacturability & Cost SUPERGROUP: Efficiency/Throughput LABEL: Speed of Measurement LABEL: Ease of Use

18 1.2 First Draft Objective Tree (1) LightGage Gen. 2 Manufacturable & Cost Effective Part Measurement Efficiency/ Throughput (Slide 19) (Slide 20) (Slide 19)

19 1.2 First Draft Objective Tree (2) Continued from slide 18 Efficiency/Throughput Manufacturable & Cost Effective Ease of Manufacturing C.O.T.S. Parts Low Complexity Easy to Maintain Low Cost to Build Portable Small Package Ease of Use Intuitive Interface Easy to Use Anyone can Use it Portable Small Package Easy/Repeatable Calibration Speed of Measurement High Throughput Fast Measurement Efficient Operation Repeatable

20 1.2 First Draft Objective Tree (3) Continued from slide 18 Part Measurement Way to Hold Parts Low Mechanical Drift Part Manipulation/Control Measure Both Sides of Part Can hold any part Gen. 1 could Part Thickness From 1-100mm Control Head Position Motorized Automatic? Part detection? Measurement Accuracy High Accuracy Low Sensitivity to Temp. Differences Tight Mechanical Loop Lowest Air Gap Possible Vibration Isolation Isolated from Outside Env. Light Canceling/ Polarity Repeatable Part Placement

21 1.3 First Draft Needs Hierarchy (1) Continued on next slide

22 1.3 First Draft Needs Hierarchy (2) Continued from previous slide

23 1.4 Needs Summary Chart

24 1.5 Process Reflection The customer has provided a lot of information, with very explicit needs, and desired specifications I still need to verify my observations with the customer and have them approve the work thus far Need to better establish relative importance of needs Need more technical background understanding

25 Work Breakdown Structure LightGage Gen. 2 Complete Design Complete Documentation Complete Prototype/P.O.C. Built Design Verified/Approved Design Approved Mech. Design Complete Risk Analysis Complete Detailed specs. Approved Drawing package complete Design Reviewed Materials Selected Suppliers Identified Needs Understood Drawing package complete To Corning Standards Materials Selected Suppliers Identified Design Complete/Approved MSDI Complete Test Plan Complete Components Built/Back from manufacturer System integration complete Mechanical sys. Built Electrical sys. Built Parts received from Corning Tropel Prototype/P.O.C. built Debugged Mechanical Electrical Computer Optics Corning Tropel Repeatability Tests Passed Accuracy demonstrated Repeatability demonstrated Product Approved by Customer Meets customer specs/expectations Note: In keeping with the spirit of the exercise, the needs are listed in no particular order or sequencing

26 Preliminary Schedule

27 Future Plan Where do you go from here? Another meeting with Corning Tropel engineers to further revise technical specifications to move ahead with project (tentatively scheduled for next week) Continue updating EDGE website Building a technical background section Finish adding all diagrams from this presentation Revise/refine work breakdown structure, schedule