What needed solving
Slot, fork and toothed-end dimensions need consistent measurement from different part orientations, with minimal dependence on operator measuring technique.
How Qualitas solved it
A Gocator 2630 captures the 3D surface while precision fixturing and indexing expose the required features. Variant programs send measurements to the machine controller for pass/fail decisions.
3D measurement of Cardan shaft components across eight variants
A measurement cell combining controlled part handling, laser scanning and automatic pass/fail decisions.
A Cardan shaft component has several features that need to be measured together: the slot at one end, the faces around it, the toothed section and the distances between these features. Checking them repeatedly depends on both reliable measurement and presenting the part in the correct position.
Qualitas worked with Rcube Metrology, using LMI's 3D sensing technology, to develop and commission a measurement solution for eight shaft variants. An LMI Gocator 2630 laser profiler captures the component's 3D shape, while the machine positions and turns the part to expose the required surfaces. Measurements are passed to the machine controller and compared with the limits defined for that variant. The delivered system operates with a 7-second cycle time.
One part, several connected measurements
The inspection needed more than a single overall dimension. It had to relate the forked slot and toothed end to the rest of the component, using the appropriate measurement recipe for each variant.
| Measurement area | What the system checks |
|---|---|
| Slot and fork | Slot width and the distance across the fork faces. |
| Position and symmetry | How the slot is positioned relative to the shaft reference. |
| Toothed end | Tooth-related dimensions, including distance over pins where specified. |
| Lengths | Overall length and specified distances between component features. |
| Face geometry | Specified orientation/form checks on the fork faces, using the drawing's reference system. |
The measurement list and acceptance limits differ by variant. Each recipe applies the checks required for that component.
Controlled movement makes the 3D data usable
The operator loads a part into its fixture and selects the required model. The machine then moves the component into the scanner's field of view and indexes it through the required orientations. This exposes features that cannot all be measured from one view.
The laser profiler captures a sequence of height profiles to build the 3D surface used for measurement. Synchronising capture with controlled movement preserves the relationship between the scanned surface and the part's travel. The fixture keeps the part in a repeatable position so that the checks use the intended references.
The system sends measured values to the machine controller, which determines pass or fail against the selected variant's limits. The demonstration also shows inspection data transferred to the PC. After the measurement cycle, the operator unloads the part.
Application engineering and machine building, developed together
Qualitas supplied and commissioned the 3D measurement solution, developed the variant programs and supported prove-out and training. Rcube Metrology provided the mechanical system, fixturing and handling needed to position the component consistently. LMI provided the Gocator sensing technology.
The completed project included programs and master parts for all eight variants, correlation against reference gauges, repeatability and reproducibility work, and operator/software training. These activities connected the sensor readings to the customer's measurement process before handover.
A repeatable inspection process for multiple variants
The delivered capability brings the specified dimensional checks into a 7-second measurement cycle, with final-system accuracy below 10 µm after calibration. It reduces the operator's role in how each measurement is taken while retaining manual loading and unloading. Variant programs allow the same cell to inspect eight component variants using their own measurement limits.
Share the component drawings, critical features, tolerances and required cycle time. We can assess scan views, part handling, measurement and reference-gauge validation.
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