130 THE DISTRIBUTOR’S LINK GENERAL INSPECTION PUSHING THE LIMITS OF FLAWLESS FASTENER MANUFACTURING from page 66 “Measuring 360 degrees around each part is critical,” explains Chris Alexander, a Product Manager at General Inspection, a developer of high-speed measuring and sorting fastener inspection systems. “Defects can be located anywhere so inspection needs to take place over 360 degrees. “You have to measure all the way around or you are missing defects. The device measures 360 degrees around each part to detect any small thread damage that may only be on a small portion of the shaft.” The device Brugola selected for its critical fasteners, called the GI-360, measures a number of crucial fastener features such as head and shaft diameter, lengths, straightness, concentricity, thread angle and diameter (including major, minor and pitch diameter). It also detects any damaged threads, along with cracks on the bolt head and flange. To meet the rigorous demands required for flawless dimensional precision, Brugola turned to a leading gauging equipment manufacturer, General Inspection, to develop a number of novel inspection features. “When you have a hexagonal bolt, you have crucial dimensions from a flat to the opposite flat on each of the six sides,” explains Alexander. “It is also crucial to measure across corner dimensions as well.” “Brugola Italy and Brugola USA worked with General Inspection to advance the capabilities of the laser gauging inspection equipment,” adds Occhionero. “The equipment is looking at lot of things at one time. We look at all the dimensions you can think of on the screw, all the dimensions required by the customer for a critical fastener.” When the fastener inspection system manufacturer worked to improve the accuracy of dimensional measurements, the result was a redesigned version of the device, the GI-360T, which includes a tilt and lift feature for the laser head. This ensures the lasers are perpendicular to the part and corrects for the cosine error of headed parts, providing improved measurement readings for diameter (.005mm) and length (.01mm), total error. With Brugola’s dedication to zero defect manufacturing of its critical engine fasteners, the company sought to further enhance the fastener inspection system. As an option on its high-speed fastener inspection system, Brugola selected an axial viewer lens system for 360-degree head crack detection. In support of the Brugola’s goals, General Inspection improved crack detection in order to detect cracks, scratches, or missing features on the side flange of bolts. This specialty lens ‘sees’ around the head of the part. “A standard lens cannot see a crack on the side of a bolt flange, so we developed a special lens that visually flattens out the flange to detect any cracks,” explains Alexander. “With a standard lens and camera, you can only see one side of a game die when viewed from above. With the specialized lens, you can see five sides of the die.” Along with the wider viewing angle lens, the fastener inspection system manufacturer developed sophisticated image analysis software that minimizes surface and lighting variations. A strobe LED ring light also improves illumination of each part head for a better image. “A standard light only generates so many lumens, so we used a strobe controller to overdrive the light for more light output,” says Alexander. “As each part triggers the sensor, the flash goes off at the moment the image is taken for better feature illumination.” “We can sleep well at night because we know the 3D laser gauging, axial vision, and eddy current inspection equipment is helping to ensure flawless fastener manufacturing,” says Occhionero. Occhionero adds the Brugola brand is becoming more recognizable internationally due in part to its exhaustive pursuit of quality and its eye for detail. GENERAL INSPECTION
MFDA 21st ANNUAL GOLF OUTING & COCKTAIL RECEPTION WILD TURKEY GOLF COURSE, NJ - SEPTEMBER 17-18, 2016 more photos on page 157
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