Laser Measurement System Team Leader: William Benedict Members: Branden Austin, Ben Lewandowski, Yousef Zakri

Project Background Materion produces beryllium and beryllium alloys One product they produce are coils of sheet metal Z-mill produces light gauge sheet ranging from 0.015” to 0.003” Must ensure quality material is produce on the mill Needs accurate and precise measurements of thickness Poorly measured material can result in loss of product and increased down and retooling costs

Issues with Measurement Currently for measuring thickness, hand-mics are used Material can only be measured few inches from the edge Operator tooling differences Alternative measurement system is needed

Requirements Measurement system must be non-touch to remove human error Must be accurate and precise to 5 decimal places Display for measurements is easily readable Measure multiple locations across the metal Easy to use

Solution Overview Lasers to measure thickness Design new inspection table Ensure repeatability and accurate results Easy to use

Design Overview Lasers Table Keyence LK-H157wide type measuring head Tabletop Railing and movement Brackets

Laser Overview Keyence LK-H157 Wide Type, Laser Class 2 Repeatability at 0.25 μm Measuring range of 5.91” +/- 1.57”

Cad Drawing 1 – Table Overview

Cad Drawing 2 – Tabletop

Cad Drawing 3 – Railing and Movement

Cad Drawing 4 – Sensor Brackets

Cad Drawing 5 – Arm Brackets

Finished Product

Calibration and Testing Setup a two point calibration at 0.03125” to 0.125” Formed a linear curve within the senor controller Test Plan Measured a calibrated block at each slot at three different positions. Repeat test three times Preform three tests with different thicknesses

Performance Analysis Did not receive favorable test results Results were within 0.001, but did not meet design requirements

Issues Slight movement in arm Tabletop surface not flat Laser alinement Angle change Tabletop surface not flat

Future Improvements Design a more ridged structure to support the sensors Possibly arm spanning across the table attached to each side Stone tabletop for an even surface Either marble or granite with a machined surface

Conclusion Able to prove proof of concept Easy to use Reduce time spent measuring Found ways to improve the design More ridged structure Machined table surface Currently waiting on customer feedback for next steps

Questions?