Automated Inspection of Cold Automated Inspection of Cold Formed BoltsFormed Bolts

Troy D. Wells / CMfgT

INDEN 5303

Fall 1999

Hilti Plant 5Hilti Plant 5• Plant Operations

– Opened in Tulsa, OK in 1979– Employment 165

• Products Produced– Carbide Tipped Masonry Drill Bits (for hammer drills)

– DX Pins (nails for powder actuated tools)

– Anchors• Kwik Bolts (expansion bolts)

• HDI (drop in anchors)

• HAS (chemical anchors)

Automated Inspection NeedsAutomated Inspection Needs

• NUPIC – Annual Audits– Final Inspections

• Definition: The Number of Parts Produced Without any Failures Divided by the Total Number of Parts Produced.

• Goal is 98%

• Current is 94%• Failures-lost parts, rejects, scrap

Production Methods for Kwik BoltsProduction Methods for Kwik Bolts• Cold Forming

– FX45 production standard=10,000/hr• Ø1/4” x L 1 3/4” - 3 1/4”• Ø3/8” x L 2 1/4” - 3 3/4”

– 750 production standard=5,400/hr• Ø1/4” x L 4 1/2”• Ø3/8” x L 5”• Ø1/2” x L 2 3/4” - 5 1/2”

– 1012 production standard=3,000/hr• Ø3/8” x L 7”• Ø1/2” x L 7”• Ø5/8” x L 3 3/4” - 10”

• Ø3/4” x L 4 3/4” - 12”

• Screw Machining• Ø1” x L 6” - 12”

Production MIPProduction MIPM a n u f a c t u r i n g

a n dI n s p e c t i o n P l a n

A 1 0 0 0 2

R e v . P

2 o f 2

P l a n t 5 M I P N u m b e r S h e e t

C o l d F o r m / T h r e a d S e e B e l o w *W o r k C e n t e r D e s c r i p t i o n W o r k C e n t e r N u m b e r

1 2 - K B I I C o l d F o r m / T h r e a dI t e m N a m e O p e r a t i o n D e s c r i p t i o n

A

L ±0.5

K +3.0/-0

All DimensionsBefore Plating

All Dimensions Metric Except P.D.

0.2RMin.

Letter - I.D.

1.5 Min.

12.70

Min.

Ref.

2.7 ±0.5

9.45 ±

0.25

-1

12.8

±0.10

9.75 ±

0.10

11.3 ±0

.25 +.25/-0R

12.65

±0.20

29.3 ±0.35

3.5 ±0.5

View A

11.05

Min.

Burr Max. 0.5

8° ±3

0' 19.8 / 20.6

30° ±5°

1/2

- 13 U

NC(P

.D. -.

437 /

.442

)(M

.D. -1

2.36 /

12.66

)

11.30

+0.10

/-0.15

M a n u f a c t u r i n ga n d

I n s p e c t i o n P l a n

A 1 0 0 0 2

R e v . P

1 o f 2

P l a n t 5 M I P N u m b e r S h e e t

C o l d F o r m / T h r e a d S e e B e l o w *W o r k C e n t e r D e s c r i p t i o n W o r k C e n t e r N u m b e r

1 2 - K B I I C o l d F o r m / T h r e a dI t e m N a m e O p e r a t i o n D e s c r i p t i o n

N o . F e a t u r e / A c t i v i t y F i x t u r e / T o o l i n g / G a u g e F . C l a s sC l a s s

F r e q . R e s p .0 1 1 2 . 8 0 + 0 . 1 0 / - 0 . 1 0 G a u g e 0 2 6 5 1 1 5 4 H O p e r

0 2 9 . 7 5 + 0 . 1 0 / - 0 . 1 0 G a u g e 0 2 6 5 1 1 5 4 H O p e r

0 3 1 2 . 6 5 ± 0 . 2 0 G a u g e 0 2 6 5 1 1 5 4 H O p e r

0 4 1 1 . 3 0 + 0 . 1 0 / - 0 . 1 5 C a l i p e r N O p e r

0 5 2 9 . 3 ± 0 . 3 5 G a u g e 0 2 6 5 1 1 5 3 H O p e r

0 6 2 . 7 ± 0 . 5 0 G a u g e 0 2 6 5 1 1 5 3 N O p e r

0 7 L ± 0 . 5 0 G a u g e 0 2 6 5 1 1 4 7 H O p e r

0 8 K + 3 . 0 / - 0 . 0 G a u g e 0 2 6 5 1 1 5 6 H O p e r

0 9 9 . 4 5 ± 0 . 2 5 C a l i p e r N O p e r

1 0 3 . 5 0 ± 0 . 5 0 C a l i p e r N O p e r

1 1 L e t t e r S t a m p - S e e * V i s u a l N O p e r

1 2 1 9 . 8 0 / 2 0 . 6 0 @ 1 1 . 3 0 ± 0 G a u g e 0 2 6 5 1 1 5 2 H O p e r

1 3 8 d e g ± 3 0 m i n G a u g e 0 2 6 5 0 8 9 3 H O p e r

1 4 1 2 . 7 0 M i n R e f . , 1 . 5 M i n G a u g e 0 2 6 5 0 8 9 3 N O p e r

1 5 0 . 2 5 + 0 . 2 5 , - 0 R . G a u g e 0 2 6 5 0 8 9 3 N O p e r

1 6 1 1 . 0 5 M i n . G a u g e 0 2 6 5 0 8 9 3 N O p e r

1 7 B u r r M a x 0 . 5 0 p e r m i t t e d C o m p a r a t o r ( N o t i n c l u d e d i n O . A . L . ) N O p e r

1 8 1 / 2 - 1 3 U N C ( P . D . 0 . 4 3 7 ” , 0 . 4 4 2 ” ) G a u g e 0 2 6 5 1 1 5 5 H O p e r

1 9 1 / 2 - 1 3 U N C ( M . D . 1 2 . 3 6 / 1 2 . 6 6 ) G a u g e 0 2 6 5 1 1 5 4 H O p e r

2 0 R e m o v e a n d r e c o r d a l l c o i l w e l d s V i s u a l O p e r

2 1 O t h e r f e a t u r e s V i s u a l / C o m p a r a t o r O p e r

2 2 O p e r a t o r i n s p e c t i o n f r e q u e n c y 3 p c s . / 0 . 5 H o u r O p e r

* I t e m N u m b e r S i z e L ± 0 . 5 + 3 . 0 - 0 . 0 I . D .

D r a w i n gN u m b e r

W . C .N u m b e r

0 0 2 9 0 7 7 2 1 / 2 x 2 3 / 4 6 9 . 9 3 2 C 0 0 2 9 0 7 7 1 1 9 4 0 0

0 0 2 9 0 7 7 3 1 / 2 x 3 3 / 4 9 5 . 3 3 2 E 0 0 2 9 0 7 7 1 1 9 4 0 0

0 0 2 8 8 5 3 4 1 / 2 x 3 3 / 4 9 5 . 3 5 7 E 0 0 2 9 0 7 7 1 1 9 4 0 0

0 0 2 9 0 7 7 7 1 / 2 x 4 1 / 2 1 1 4 . 3 3 2 G 0 0 2 9 0 7 7 1 1 9 4 0 0

0 0 2 8 8 5 4 1 1 / 2 x 4 1 / 2 1 1 4 . 3 7 6 G 0 0 2 9 0 7 7 1 1 9 4 0 0

0 0 2 9 0 7 7 8 1 / 2 x 5 1 / 2 1 3 9 . 7 3 2 I 0 0 2 9 0 7 7 1 1 9 4 0 0

0 0 2 8 8 5 4 2 1 / 2 x 5 1 / 2 1 3 9 . 7 7 6 I 0 0 2 9 0 7 7 1 1 9 4 0 0

0 0 2 9 0 7 7 9 1 / 2 x 7 1 7 7 . 8 1 0 2 L 0 0 2 9 0 7 7 1 1 9 6 0 0

O . B y e R e v . L e v e l K L M N O P

I s s u e r M C R N o . 3 2 1 3 3 5 1 3 3 6 2 3 3 6 8 9 3 8 3 0 3 8 6 1

1 2 - J u l y - 9 1 I n i t ’ l P 5 E o b P 5 E o b P 5 E o b P 5 A o b P 5 A o b

K

Common RejectsCommon Rejects

Failure Mode Reject Scrap

Head Form out of round 0.90% 0.40%

Thread Length 2.80% 0.01%

Burr Ring 2.12% 0.00%

Bite Marks 1.70% 0.07%

Selection CriteriaSelection Criteria

• J. Teegarden, Modern Machine Shop 1998– Number & Type of features to be inspected– Throughput requirements– Level of accuracy required– 100% inspection or audit methods– Operator skills– Portability (gauge vs. workpiece)– Inspection environment– Workpiece condition– Workpiece material– Data output format– Budget

Inspection MethodsInspection Methods

• Current– Manual & Semiautomatic

• Non-Contact - Contact– Vision Systems– Mechanical

• In-process - Post-process

Planning BudgetPlanning Budget

• Non-Contact– Basic System $15,000– Automated System $100,000

• Contact– Basic System $15,000– Automated System $50,000

Gauge DesignGauge Design

• Robot

• Transfer Station Style

• Features to be Inspected

• Cycle Time

• Operator Feedback