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

2. 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 ”
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

3. 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

4. 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

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

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

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

8. Cad Drawing 1 – Table Overview

9. Cad Drawing 2 – Tabletop

10. Cad Drawing 3 – Railing and Movement

11. Cad Drawing 4 – Sensor Brackets

12. Cad Drawing 5 – Arm Brackets

13. Finished Product

14. Calibration and Testing
Setup a two point calibration at ” 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

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

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

17. 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

18. 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

19. Questions?