| The formation of a partnership between Carl Zeiss and Xtrac has provided the opportunity to improve the manufacturing process of dog retention angles on transmission parts and geometry of engine gear components, supplied to the motor sport industry.
The ability to qualify each product produced is critical to Xtrac, which is the leading supplier of high-performance transmissions for a variety of motor sport companies. With a reputation for impeccable quality and a passion for customer service, Xtrac sought greater reliability in the inspection methods used to control and improve its manufacturing processes.
Of particular interest was the measurement of compound dog retention angles on the gears used in the transmission products, which Xtrac manufactures at its site in Thatcham, Berkshire in the UK. As part of the manufacturing process, products are now routinely inspected using a Zeiss Prismo, to validate dimensions and permit any corrective settings to be made to production machines.
The product is angled on two different planes, and due to its complex geometry, the recording of accurate measurements using other measuring methods did not offer the level of accuracy that the latest technology requires.
A variety of other measuring techniques were thoroughly investigated before the Zeiss Prismo was selected. Measurement trials conducted prior to selection of the Prismo proved the superiority of the Zeiss machine against the other techniques trialed. As part of these trials Xtrac also proved that the measurement uncertainty associated with standard class CMMs was too great for the intended application.
The Zeiss Prismo HTG is the benchmark for production-based measurement. Pioneered by Carl Zeiss, the High Temperature Gradient technology, which guarantees measuring uncertainties for temperatures ranging from 15°C to 30°C, leads to more accurate measurement and cost-effective temperature control. It is thermally stable, shop hardened and extremely efficient. At Xtrac the Prismo is housed in a temperature-controlled measurement room, thus it was not necessary to consider Zeiss’ ultimate shop floor based machine, the GageMax.
Typical measuring systems, which compensate mathematically for deformations caused by temperature fluctuations, require a large number of sensors to provide the information. Sensors introduce a further source of uncertainty and furthermore if a sensor fails, measurement errors that have a substantial influence on the entire production process are often discovered too late, Xtrac cannot afford such a risk.
Xtrac is also deploying the renewed capability that the Zeiss Prismo offers to its engine gear product ranges. The technology is ideally suited to managing the production of tight limit geometries. Unlike other scanning technologies, the Zeiss Prismo uses its patented Active VAST scanning head, which secures the necessary levels of accuracy and repeatability, allowing form elements, such as roundness and cylindricity to be measured, with high speed and repeatability.
The Zeiss Prismo HTG as used by specialist transmission manufacturer Xtrac |
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With a commitment to continuous improvement and to support the researching of new processes, Xtrac’s product designs are continuously enhanced in keeping with the advances made in manufacturing techniques. Due to its Object Oriented approach, any such design changes, affecting elements of the part, can be simply altered by the Zeiss Calypso measuring programme. This results in significant cost savings over the life cycle of the CMM and secures future product flexibility.
Ian Shirlaw, quality manager at Xtrac commented: "The Zeiss Prismo has become the 'Gold Standard' measuring process for Xtrac. We have been astounded by its accuracy and repeatability, and its ability to help us to both control and improve our manufacturing processes."
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