TQM Itaca Technology - SISTEMI DI MISURA

The software Itageo 6

Itageo 6^© is the most innovative software for the management of the automatic control stations for brake discs. It’s able to manage the following functions:

management of the dynamic, geometric and dimensional measurements of brake discs and brake drums.
control of the production process.
data saving in SQL database, with fully network functionality.
possibility to make a remote real time monitoring.
management of remote tele-assistance.
dialogue with external devices (load robot, marking machines, processing machines, etc...).
management of the marking of the pieces and traceability.

Main characteristics:

Immediate and visual configuration of the station
Creation of control plans with rapid and intuitive graphic support
Definition of complex characteristics using the selection of the probes from the picture
User interface totally configurable: simple and immediate, with the global result of the test (green for good, red for reject and yellow for uncertain) and the punctual values for each characteristic of the control plan
Possibility to display up to 6 graphics for the critical sections
Display of complex geometrical characteristics in 3D mode
Control of the interrupted surfaces (for example in correspondance with fixing holes). By inserting the parameter "number of interruptions", Itageo 6^©identifies the interruption areas and excludes them from the analysis
Itageo 6^©uses an algorithm for the compensation of the errors of the mandrel perpendicularity. In this mode, the values of the run-out and of the ondulation of the braking surfaces are real, and they are not influenced by the rotation system
Harmonic Analysis (Fourier Analysis) with possibility to verify each harmonic, each with its tolerance
Settable cut-off filter of the harmonics of high frequency (normally 0-50 Hz)
Settable dirty filter
Possibility to configure the harmonics and dirty filters for each section of the control plan
Generation of an univocal Id code for the piece, in case of control with posistive result, and transmission of the code to the markig machine for the printing on the disc
Saving in database of measurements + profiles + Id piece. It guarantees the traceability one by one
Automatic management of the cycle of Master Verification and Master Zero Setting
Possibility of monitoring in real time all the measuring stations connected to the network, from any network PC on which is installed the software Italarm
Management of remote tele-assistance

Itageo 6^© is optimized for the dynamical controls and allows to control diameters with a single probe for each section. The result is the simplicity of the mechanical configuration and type change.
To guarantee the highest precision and reliability of the measurement, Itageo 6^© works on the same measurement principles as laboratory roundness measuring instruments: a piece is put on rotation on a precision mandrel, angular control via encoder, a contact probe on each section to be measured, acquisition of at least 7.200 points/rotation for each analysed section, reconstruction and analysis of the obtained profile.

The analysis of the profiles allows:
•   Visualization in real time of real profiles, big help in order to individuate possible causes of technical problems due to the production of the same pieces.
•   Fourier Analysis, with decomposition of the form errors in single components, with the possibility of manage different tolerances for each error.
•   Possibility to implement filters.
•   Possibility to implement dirty filter.
•   Possibility to analyse for sections of circumference: ex. Roundness each 30°.
•   Possibility to compensate the rotation errors generated by the mandrel.

Itageo 6 configurations

100% dimensional and geometric control of brake discs

Itageo6^© station in line for the 100% control of brake discs. Automatic management of the cycle of Master Verification and Master Zero Setting. Management of the dialogue with production machines. Connection with marking systems in order to guarantee the traceability.

Approximate cycle time: 10 seconds.

The station is available in different configurations, according to customer’s requirements.

100% dimensional, geometric and FRF control of brake discs

Itageo6^© station in line for the 100% geometric and FRF control of brake discs. Automatic management of the cycle of Master Verification and Master Zero Setting. Management of the dialogue with production machines. Connection with marking systems in order to guarantee the traceability.

FRF control integrated: there is an elevator on which the disc is put by the robot. The elevator puts the disc on the mandrel, dimensional measuring cycle, the disc is released by the mandrel, frequencies cycle, the disc is extracted by the robot.

Approximate cycle time: 10 seconds

The station is available in different configurations, according to customer’s requirements.

Automatic Retooling measuring stations for
100% Dimensional and geometrical control of Brake Discs

Itageo 6^© station to be included in lines or island for dimensional and geometrical (and FRF, on request) of 100% Brake Disc production.
Probes are using an automatic retooling system that place them in position depending on the Control Program in use. This allow a retooling in few seconds.
Automatic zerooing and verification Master cycle.
Dialogue with working island/line for feedback.
Marking station connection for a complete traceability feature.

Integrated FRF control (on request): there is an elevator on which the disc is put by the robot. The elevator puts the disc on the mandrel, dimensional measuring cycle, the disc is released by the mandrel, frequencies cycle, the disc is extracted by the robot.

Estimated cycle time: 10 seconds.

The station can be customized depending on customer needs

Complete Station Description

Special / Custom Measuring stations for
100% Dimensional and geometrical control of Brake Discs

Itageo 6^© station for dimensional and geometrical (and FRF, on request) of 100% Brake Disc production.
Zerooing and verification Master cycle.
Connection to Roughness meters (external, USB) to save data from operator measurement.

Estimated cycle time: 10-15 seconds.

The station can be customized depending on customer needs

Itageo6^© station for the control of brake discs in production line equipped by powered roller conveyor and linear system for the handling of pieces.

This solution is studied for the integration in a production line equipped with a roller conveyor. All the dimensions and the positioning of single components can be defined according to customer’s requirements. It’s a extremely flexible modular solution.

Thank to this configuration it’s possible to add different stations, like a marking station, the roughness control, cleaning station in entry, the FRF control, cracks detection, True Position control of the holes made by a video camera, marking of the serial number in order to guarantee the traceability at 100%. The addition of supplementary modules doesn’t influence the cycle time because the control time are kept aligned among the different modules.

In case of use of an anthropomorphic robot for the movement of the pieces in the isle, it would be easy to integrate the measuring station in the work area. In this case, the system for the control of the discs is composed of an automatic gauge, a marking station and an electrical cabinet containing the PC, PLC and all the others electronic components. The lay-out of the measuring station is defined considering the spaces available in the production line. Normally, the gauge is mounted on a special truck equipped by wheels and a specific fastener device. The electrical cabinet is often put out of the work area.

Tecnology

Tecnology

Tecnology

Tecnology

The software Itageo 6

Measuring principles

Itageo 6 configurations

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