福特白光扫描要求教材课件

APAToolingSupplierConferenceMarch21-22,2013LarryGeng耿国涛

APAToolingSupplierConferencDieSurfaceScanningOverview模具型面扫描概述Whatisdiesurfacescanning?

什么是模具型面扫描？ApplicationsofscanningdatainFord

福特如何应用模具的扫描数据？Diesurfacescanningrequestitems模具扫描作业有什么要求？Datasurfacescanningprocedure

模具扫描工作的流程是什么？

DieSurfaceScanningOverviewDieSurfaceScanningOverviewWhatisdiesurfacescanning?什么是模具的扫描？白光扫描Opticalequipment,白光扫描设备Picturepositioningtechnology拍照定位技术Gratingmeasurementtechnology光栅测量原理Capturediekeyinformationbeforeshippingdies

发运前测量获取模具的主要信息ScanningdatastoredinTCE–FordDataBase

扫描数据储存在TCE--福特的数据库DieSurfaceScanningOverviewDieSurfaceScanningOverviewApplicationofscanningdataforFordtoolingshop白光扫描技术在福特模具厂的应用

Scanningwasfirstusedtoimprovemachineperformanceonroughcastings.

扫描技术最早应用在改进铸件粗加工的加工工艺，提高加工效率Aftersuccessfulimplementationitexpandedtomanyotherapplications;成功应用后，逐渐扩展到很多其他的应用领域。DieConstruction模具装配Virtualdieassemblytoreducepresstime模具部件虚拟装配，以减少在压机上的研配时间WearPlatedimensionswerecreatedfromscandataandgiventodiemakerstogrindtosizewithouteverassemblingthedies.

通过扫描数据获得导板的位置尺寸信息，无需装配模具，即可完成导板的研配工作-Abletoalignupperandlowerdiefacestoreducespotting，凸凹模虚拟装配，减少研合时间-Eliminatedsizingwearplatesinthepresstosavepresstime，无需在压机上调配导板，提高压机利用率Tryout调试EventuallyformedtheCSIprocessforcorrectionloopsPanelscansforcorrectionloops根据钣件扫描结果制定整改方案PanelsscansforCMM钣件全尺寸扫描作为检测报告DieBuy-Off验收DieSignatures模具扫描数据作为验收确认PerishableSteels易损钢块数据备份，作为复制加工依据ScanningtechnologywasimplementedindiemanufacturingasanenablertomeetGPDStargets.

扫描技术作为得力工具保证模具制造周期满足GPDS的目标

DieSurfaceScanningOverviewDieSignatureScanningOverviewApplicationofscanningdataforFordtoolingshop白光扫描技术在福特模具厂的应用

Improvemachineperformanceonroughcastings.改进铸件粗加工的加工工艺，提高加工效率Operatorsrunprogramsat100%feedsandspeeds.数控操作者执行程序，100%的进给量和进给速度Roughingtimesarereduced76%atthemachine.铸件粗加工时间降低76%100%accuratestockmodelsresultinsaferprograms基于铸件扫描数据编制的数控程序，加工量均匀，程序更安全Thetoolingisalwaysengagedinmetalremoval.刀具始终处于切削状态，无空走刀情况DieSignatureScanningOvervieDieSurfaceScanningOverviewForProductionPlant冲压厂对模具最终状态的验收确认DieSignaturesThesearescansofthefinisheddiesurfacesofthecompleteddiesattheTryoutsource.模具制造厂负责完成模具最终状态的数据扫描ForDieMaintenance模具维护及维修AccidentsinProductionDieSurfaceisdamagedbeyondbasicfixes.生产事故造成模具型面损坏，基本修复处理无法完成。ForReworkConfirmation模具修复工作前确认DieQualityGuaranteeVerifythatthediehasnotbeenmodifiedbytheproductiondiemaintenanceteamissuchawaythatcanvoidthewarranty.模具出现异常时，确认是否被冲压厂的模具维修人员修改，如模具已不是发模前最终状态，模具制造厂将不必承担质保责任。ForDieDuplication模具复制SamepartsrunninginmultipleregionsImproveFPGqualityforduplicatetoolsGotoaNOTRYOUTlevelofdiemanufacturing相同制件在不同区域生产，需要模具复制，改善FPG钣件质量，模具无需调试即可出件ApplicationsofscanningdataforFordstampingplant福特冲压厂对扫描数据的应用

DieSurfaceScanningOverviewDieSurfaceScanningOverviewApplicationofscanningdatainFord福特对扫描数据的应用–案例1

Signature,Duplicationandstudy状态确认，复制，研究

CapturingqualityimprovementsdoneinTryout,forreverseengineering&ensuringaquickturnaroundincaseofacrash.Scanisnowthemaster.测量获得模具调试后状态的数据，作为逆向复制及快速修复模具时的加工基准。Analyzingdatatobetterunderstandeffectsofspringbackandtomeasurethesuccessofcompensationstrategies.分析扫描数据以深入理解回弹对模具的影响，以及测量对比冲压变型补偿策略的实际效果。Mappingthequalityofthedrawnstampingatthetimeofthebuyoff模具验收时，测量并分析所有成型模具的质量情况DieSurfaceScanningOverviewDieSurfaceScanningOverview

Diemaintenance

DSPrequestedlowerfrontdoorhingesurfacestobemovedforward1.5mm.GrindingLess减少打磨SpottingLess减少研配Problem;NoCadDataexistsfortheP-221doorsthatweremanufacturedoutsideoftheUnitedStates.

模具不是在北美制造，丢失CAD数据DSPdoesnothavethepresstimeforextensivetryoutofchangesinproductiontooling.DSP没有大量的压机工时来完成模具的调试工作ResolutionScanthediegeometryandcreatenewsurfacesinTebisusingRSC(RapidSurfaceCreation)

扫描模具型面，并用Tebis生成可加工用型面数据。Newsurfacesweremachinedintheupperdiehalfbyusingamaterialthicknessoffset,thisensureddimensionalaccuracybetweentheupperandlowerdies.用于加工凹模侧的型面数据偏置一倍料厚，以保证上下模之间间隙的尺寸精度Cutterpathwasbeingpreparedwhiledieswereinproduction.

模具冲压生产的同时，制作机加编程数据DSPjobwasabletobeaddedtothemachineschedulewithnointerruptiontoinhouseworkloadDSP的工作编入加工计划，与厂内模具任务无冲突ResultsDiesweremachinedwitha2dayturnaround.

模具在两天内轮班加工完成DSPpolishedchangeareasandwasabletoscheduleawindowforTryoutinthepress.

DSP抛光模具修改区域，安排计划上压机调试Diewasbroughttohomepositionwithnointerferenceandnogrindingrequired.模具无需打磨即可冲压到底，且无干涉Thefirstblankresultedinasplitfreepanel.

第一张坯料即可打出不裂的钣件Thedieswerereadyfortheirnextscheduledproductionrun.

模具以具备生产状态，可准备下次生产计划F-150frontdoorassemblyissuesduetolackofadjustmentoflowerdoorhinge.前门总成问题，与门下铰链调整量不足ApplicationofscanningdatainFord福特对扫描数据的应用

案例2

Diemaintenance

Thefirstblankresultedinasplitfreepanel.整改模具，第一张坯料即可打出不裂的钣件。DieSurfaceScanningOverviewDieSurfaceScanningOverviewStampingPlantSupport

Diemaintenance

ApplicationofscanningdatainFord福特对扫描数据的应用

案例3

Maintenance维修scrapratereductionfrom2.4%to.6%废品率从2.4%降到0.6%DSPrequestedanalysisondoubleattachedF-150SuperCabreardoorouterstoreduceproductionscraprate.DSP要求分析后门外板双槽模具状态，发现并解决模具存在问题，以降低生产中废品率Problem;RHdoorsplitsLHdoesn’t.右门钣件裂BothDoorsshouldbeidentical左右门应该一致Howcandifferencesbetweenthe2doorsbeidentified?左右门为什么会有差异？Analysis分析ThediewasscannedandtheLHdatawasmirroredinTebis.(CAD/CAMSoftware)ThisproducedavirtualRHdiesurface.扫描左侧模具型面，在Tebis中镜像为右侧型面Thevirtualsurfacewascomparedtotheactualsurface.比较虚拟右侧型面与实际型面的差异AreasofconcernwereidentifiedandDSPTryoutpersonnelweregivenadimensionalroadmapformakingimprovementswithzeroriskfortheassemblyplant.问题区域，左右件的差异值报告以云图形式提供给调试者，作为模具整改的依据，确保不会给装配车间带来任何风险。Results结果Theresultswereareductioninscrapratefrom2.4%inJanuaryto.6%inApril.

废品率从一月份的2.4%降低到四月份的0.6%Improvementsinperformancetoschedule

模具的整改工作按计划完成DieSurfaceScanningOverviewDieSurfaceScanningOverviewDiesurfacescanningrequestitems模具型面扫描的基本要求FromC489Program从C489项目开始Finishattryoutsource由模具厂完成数据扫描Draw,redrawandformdies拉延，二次拉延等成型类模具Corebodypanel,criticalunderbodypanel,seebelownotefromSOW

主要车身件及某些底盘件，具体以SOW所述为准，见下图注释Dieitemsneedscan模具需要扫描的项目FollowForddiescanningprocedure遵照福特的扫描流程标准报价要求报价中应该包含如下信息要求扫描数据的模具为：主要车身钣件的成型类模具，比如机盖内外板，翼子板，顶盖，行李箱内外板，门子内外板，背门内外板，侧围内外板及地板，对于底盘类零件以报价单要求为准DieSurfaceScanningOverviewDieSurfaceScanningOverviewAllDieworkingsurface模具所有的工作型面

Anysurfaceorareathatwasmachinedonthe5-axis.

所有在五轴机床上加工出的加工面或区域Allgagingordeviceusedtolocatetheblankwithinthedie.

模具上所有用来钣件定位的定位距或其他装置Allguidingcomponents--wearplates,guidepostandbushing

所有的导向部件，导板，导柱，导套

Allstopblocks,bottomblocks,balanceblocks,coneblocks

所有的礅死块，平衡块，锥形定位快Alltoolingholes,datumsurface,keyways.所有的基准孔,基准面，键槽Allitemsthatwasusedtofindlocationduringsetupandmachiningofthedies

所有模具加工时需要用来定位的项目Itemsthatneedscanning模具需要扫描的项目

DieSurfaceScanningOverviewDieSurfaceScanningOverviewDiescanningprocedure模具基本扫描流程

Setupandmakepreparation

扫描前准备工作Scanningdiesurfacewithequipment

用设备扫描模具型面Postprocedure

扫描数据的后处理DieSurfaceScanningOverviewDieSurfaceScanningOverviewDiescanningprocedure–setupandpreparation模具扫描流程—设置及准备

Goodsetupswillprotecttheintegrityofthedata

正确的设置及准备工作能确保扫描数据的完整性Cleandietoensureallworkingandmountingsurfacesarefreeofoilanddirt.

清洁模具，确保所有的工作面及安装面无油无尘Placedieonaflatsurfaceorleveltableandmakesuretheflatness

模具防置在平面或平板上，并保证平板的平面度Alllowerandupperringsmustbeassembledwiththepunchinhomepositionbeforescanning.扫描开始前，保证上下压边圈和凸模装配在一起，并处于工作位置Leveltable测量用平板，平板平面度可调DieSurfaceScanningOverviewDieSurfaceScanningOverviewDiescanningprocedure—scanning模具扫描流程—扫描过程

Makesuretheenvironmentlightisstrongenough

保证环境有足够的光强，否则无法测量深腔部位Makesuretheaccuracyofscanningprocess-parameterssetupinsoftwareandhardwarecalibration

保证扫描过程中精度的控制，软件中精度参数设置，硬件标定Makesurealltheitemsarecaptured保证获得所有要求测量项目数据Ifthereflectionoflightisserious,shouldspraydevelopertodecreasereflection

对反光强烈区域，需要喷一层现象剂来降低反射

DieSurfaceScanningOverviewDieSurfaceScanningOverviewDiescanningprocedure—postprocedure模具扫描流程—数据后处理

Orientationofdataforcomparison扫描数据定位Alltheitemsshouldbeinthesamecoordinates，carposition

所有的测量项目都应该在同一个坐标系，车身坐标系下2.Scanningdatamustusesamecoordinatesystemandmakesuregapfromscanningdataisasthedieonpress

单套模具扫描数据必须用.一致基准建立坐标系，保证凸凹模的间隙与模具在压机工作状态一致Filesizemanagement文件大小控制Usethecorrectqualitytype,fordiesignatureusehighqualitytype

选用正确的点云质量类型，比如模具的验收确认选用高级质量类型WhenalldiesarescannedexportthescandataintheSTLformat.

当所有项目扫描完成，将数据格式输出为STL格式Namingconventions数据命名规则

TherearestandardsforstoringscandatainTeamCenterthatneedtobefollowedforcreatingthefilename

存入TCE的扫描数据及创建文件夹必须遵照命名规则StorethedatainTeamCenterinthestampingtopfolderunderthecarprogramandpartnumberintheDieScanfolder.

扫描数据存储在项目-零件菜单下的扫描数据文件夹内DieSurfaceScanningOverviewQuestionsandAnswersThanksQuestionsandAnswersAPAToolingSupplierConferenceMarch21-22,2013LarryGeng耿国涛

APAToolingSupplierConferencDieSurfaceScanningOverview模具型面扫描概述Whatisdiesurfacescanning?

什么是模具型面扫描？ApplicationsofscanningdatainFord

福特如何应用模具的扫描数据？Diesurfacescanningrequestitems模具扫描作业有什么要求？Datasurfacescanningprocedure

模具扫描工作的流程是什么？

DieSurfaceScanningOverviewDieSurfaceScanningOverviewWhatisdiesurfacescanning?什么是模具的扫描？白光扫描Opticalequipment,白光扫描设备Picturepositioningtechnology拍照定位技术Gratingmeasurementtechnology光栅测量原理Capturediekeyinformationbeforeshippingdies

发运前测量获取模具的主要信息ScanningdatastoredinTCE–FordDataBase

扫描数据储存在TCE--福特的数据库DieSurfaceScanningOverviewDieSurfaceScanningOverviewApplicationofscanningdataforFordtoolingshop白光扫描技术在福特模具厂的应用

Scanningwasfirstusedtoimprovemachineperformanceonroughcastings.

扫描技术最早应用在改进铸件粗加工的加工工艺，提高加工效率Aftersuccessfulimplementationitexpandedtomanyotherapplications;成功应用后，逐渐扩展到很多其他的应用领域。DieConstruction模具装配Virtualdieassemblytoreducepresstime模具部件虚拟装配，以减少在压机上的研配时间WearPlatedimensionswerecreatedfromscandataandgiventodiemakerstogrindtosizewithouteverassemblingthedies.

通过扫描数据获得导板的位置尺寸信息，无需装配模具，即可完成导板的研配工作-Abletoalignupperandlowerdiefacestoreducespotting，凸凹模虚拟装配，减少研合时间-Eliminatedsizingwearplatesinthepresstosavepresstime，无需在压机上调配导板，提高压机利用率Tryout调试EventuallyformedtheCSIprocessforcorrectionloopsPanelscansforcorrectionloops根据钣件扫描结果制定整改方案PanelsscansforCMM钣件全尺寸扫描作为检测报告DieBuy-Off验收DieSignatures模具扫描数据作为验收确认PerishableSteels易损钢块数据备份，作为复制加工依据ScanningtechnologywasimplementedindiemanufacturingasanenablertomeetGPDStargets.

扫描技术作为得力工具保证模具制造周期满足GPDS的目标

DieSurfaceScanningOverviewDieSignatureScanningOverviewApplicationofscanningdataforFordtoolingshop白光扫描技术在福特模具厂的应用

Improvemachineperformanceonroughcastings.改进铸件粗加工的加工工艺，提高加工效率Operatorsrunprogramsat100%feedsandspeeds.数控操作者执行程序，100%的进给量和进给速度Roughingtimesarereduced76%atthemachine.铸件粗加工时间降低76%100%accuratestockmodelsresultinsaferprograms基于铸件扫描数据编制的数控程序，加工量均匀，程序更安全Thetoolingisalwaysengagedinmetalremoval.刀具始终处于切削状态，无空走刀情况DieSignatureScanningOvervieDieSurfaceScanningOverviewForProductionPlant冲压厂对模具最终状态的验收确认DieSignaturesThesearescansofthefinisheddiesurfacesofthecompleteddiesattheTryoutsource.模具制造厂负责完成模具最终状态的数据扫描ForDieMaintenance模具维护及维修AccidentsinProductionDieSurfaceisdamagedbeyondbasicfixes.生产事故造成模具型面损坏，基本修复处理无法完成。ForReworkConfirmation模具修复工作前确认DieQualityGuaranteeVerifythatthediehasnotbeenmodifiedbytheproductiondiemaintenanceteamissuchawaythatcanvoidthewarranty.模具出现异常时，确认是否被冲压厂的模具维修人员修改，如模具已不是发模前最终状态，模具制造厂将不必承担质保责任。ForDieDuplication模具复制SamepartsrunninginmultipleregionsImproveFPGqualityforduplicatetoolsGotoaNOTRYOUTlevelofdiemanufacturing相同制件在不同区域生产，需要模具复制，改善FPG钣件质量，模具无需调试即可出件ApplicationsofscanningdataforFordstampingplant福特冲压厂对扫描数据的应用

DieSurfaceScanningOverviewDieSurfaceScanningOverviewApplicationofscanningdatainFord福特对扫描数据的应用–案例1

Signature,Duplicationandstudy状态确认，复制，研究

CapturingqualityimprovementsdoneinTryout,forreverseengineering&ensuringaquickturnaroundincaseofacrash.Scanisnowthemaster.测量获得模具调试后状态的数据，作为逆向复制及快速修复模具时的加工基准。Analyzingdatatobetterunderstandeffectsofspringbackandtomeasurethesuccessofcompensationstrategies.分析扫描数据以深入理解回弹对模具的影响，以及测量对比冲压变型补偿策略的实际效果。Mappingthequalityofthedrawnstampingatthetimeofthebuyoff模具验收时，测量并分析所有成型模具的质量情况DieSurfaceScanningOverviewDieSurfaceScanningOverview

Diemaintenance

DSPrequestedlowerfrontdoorhingesurfacestobemovedforward1.5mm.GrindingLess减少打磨SpottingLess减少研配Problem;NoCadDataexistsfortheP-221doorsthatweremanufacturedoutsideoftheUnitedStates.

模具不是在北美制造，丢失CAD数据DSPdoesnothavethepresstimeforextensivetryoutofchangesinproductiontooling.DSP没有大量的压机工时来完成模具的调试工作ResolutionScanthediegeometryandcreatenewsurfacesinTebisusingRSC(RapidSurfaceCreation)

扫描模具型面，并用Tebis生成可加工用型面数据。Newsurfacesweremachinedintheupperdiehalfbyusingamaterialthicknessoffset,thisensureddimensionalaccuracybetweentheupperandlowerdies.用于加工凹模侧的型面数据偏置一倍料厚，以保证上下模之间间隙的尺寸精度Cutterpathwasbeingpreparedwhiledieswereinproduction.

模具冲压生产的同时，制作机加编程数据DSPjobwasabletobeaddedtothemachineschedulewithnointerruptiontoinhouseworkloadDSP的工作编入加工计划，与厂内模具任务无冲突ResultsDiesweremachinedwitha2dayturnaround.

模具在两天内轮班加工完成DSPpolishedchangeareasandwasabletoscheduleawindowforTryoutinthepress.

DSP抛光模具修改区域，安排计划上压机调试Diewasbroughttohomepositionwithnointerferenceandnogrindingrequired.模具无需打磨即可冲压到底，且无干涉Thefirstblankresultedinasplitfreepanel.

第一张坯料即可打出不裂的钣件Thedieswerereadyfortheirnextscheduledproductionrun.

模具以具备生产状态，可准备下次生产计划F-150frontdoorassemblyissuesduetolackofadjustmentoflowerdoorhinge.前门总成问题，与门下铰链调整量不足ApplicationofscanningdatainFord福特对扫描数据的应用

案例2

Diemaintenance

Thefirstblankresultedinasplitfreepanel.整改模具，第一张坯料即可打出不裂的钣件。DieSurfaceScanningOverviewDieSurfaceScanningOverviewStampingPlantSupport

Diemaintenance

ApplicationofscanningdatainFord福特对扫描数据的应用

案例3

Maintenance维修scrapratereductionfrom2.4%to.6%废品率从2.4%降到0.6%DSPrequestedanalysisondoubleattachedF-150SuperCabreardoorouterstoreduceproductionscraprate.DSP要求分析后门外板双槽模具状态，发现并解决模具存在问题，以降低生产中废品率Problem;RHdoorsplitsLHdoesn’t.右门钣件裂BothDoorsshouldbeidentical左右门应该一致Howcandifferencesbetweenthe2doorsbeidentified?左右门为什么会有差异？Analysis分析ThediewasscannedandtheLHdatawasmirroredinTebis.(CAD/CAMSoftware)ThisproducedavirtualRHdiesurface.扫描左侧模具型面，在Tebis中镜像为右侧型面Thevirtualsurfacewascomparedtotheactualsurface.比较虚拟右侧型面与实际型面的差异AreasofconcernwereidentifiedandDSPTryoutpersonnelweregivenadimensionalroadmapformakingimprovementswithzeroriskfortheassemblyplant.问题区域，左右件的差异值报告以云图形式提供给调试者，作为模具整改的依据，确保不会给装配车间带来任何风险。Results结果Theresultswereareductioninscrapratefrom2.4%inJanuaryto.6%inApril.

废品率从一月份的2.4%降低到四月份的0.6%Improvementsinperformancetoschedule

模具的整改工作按计划完成DieSurfaceScanningOverviewDieSurfaceScanningOverviewDiesurfacescanningrequestitems模具型面扫描的基本要求FromC489Program从C489项目开始Finishattryoutsource由模具厂完成数据扫描Draw,redrawandformdies拉延，二次拉延等成型类模具Corebodypanel,criticalunderbodypanel,seebelownotefromSOW

主要车身件及某些底盘件，具体以SOW所述为准，见下图注释Dieitemsneedscan模具需要扫描的项目FollowForddiescanningprocedure遵照福特的扫描流程标准报价要求报价中应该包含如下信息要求扫描数据的模具为：主要车身钣件的成型类模具，比如机盖内外板，翼子板，顶盖，行李箱内外板，门子内外板，背门内外板，侧围内外板及地板，对于底盘类零件以报价单要求为准DieSurfaceScanningOverviewDieSurfaceScanningOverviewAllDieworkingsurface模具所有的工作型面

Anysurfaceorareathatwasmachinedonthe5-axis.

所有在五轴机床上加工出的加工面或区域Allgagingordeviceusedtolocatetheblankwithinthedie.

模具上所有用来钣件定位的定位距或其他装置Allguidingcomponents--wearplates,guidepostandbushing

所有的导向部件，导板，导柱，导套

Allstopblocks,bottomblocks,balanceblocks,coneblocks

所有的礅死块，平衡块，锥形定位快Alltoolingholes,datumsurface,keyways.所有的基准孔,基准面，键槽Allitemsthatwasusedtofindlocationduringsetupandmachiningofthedies

所有模具加工时需要用来定位的项目Itemsthatneedscanning模具需要扫描的项目

DieSurfaceScanningOverviewDieSurfaceScanningOverviewDiescanningprocedure模具基本扫描流程

Setupandmakepreparation

扫描前准备工作Scanningdiesurfacewithequipment

用设备扫描模具型面Postprocedure

扫描数据的后处理DieSurfaceScanningOverviewDieSurfaceScanningOverviewDiescanningprocedure–setupandpreparation模具扫描流程—设置及准备

Goodsetupswillprotecttheintegrityofthedata

正确的设置及准备工作能确保扫描数