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It’s hard to believe that in the late 1980s, metrology companies were early adopters of touch technology for surface and form systems. When computers started adapting to everyday life, metrology companies saw their advantage. The move from dedicated controllers with single-use buttons and integrated keyboards began to be replaced by computers and software that were more flexible, faster, and powerful. As features or specifications changed, they could easily be added to the software without expensive hardware changes.

To make the interface simpler for those who were just getting accustomed to having a computer in front of them, let alone having to use one, a way of making this technology easy to navigate had to be implemented if it was to be employed by the operator.

Thus, touchscreen monitors started to be integrated with metrology software for surface and form systems to provide an easy interface for users. This began the process of eliminating dedicated controllers, with rows of keys being replaced by screens dedicated to the function needed at the time and large colored coded touchscreen “buttons” that made the system much easier to use. The revolution to touch metrology had begun.

Today, touch technology and controllers are everywhere on the manufacturing floor. Manufacturing has embraced touch technology, from machine tools to CMMs to high-end measuring systems. However, the wide use of personal touch technology came from a different direction.

Of course, metrology companies were not the only ones exploring touch technology. As early as 1994, IBM introduced the first touchscreen phone. But it wasn’t until 2007 that the first iPhone really brought personal touch technology to the everyday user. Since then, we (along with our one-year-old children) have lived by our phones and tablets and the touch capabilities they provide.

This technology has many advantages for the user and the manufacturer. Gone are the specially built, dedicated controllers, which were expensive to manufacture because of their low volume. Previously, multitudes of switches were subject to failure, causing serious downtime and repair. Simple things like the switch labeling would wear off from constant use or chemicals found in the manufacturing area – making use by someone new challenging.

On the other hand, having a dedicated screen for a specific function reduced complexity and allowed the user to focus on the task at hand. Today’s machinists were schooled in manufacturing technology. However, they are often asked to be quality control or even metrologists at the point of manufacture for the part.

Metrology companies are now, more than ever, employing touch technology to make hand tools easier to use at the point of manufacture.

More Surface Finish Parameters at Hand

When measuring surface finish, tighter dimensional tolerances often necessitate additional information about the surface to guarantee it functions per the design engineer’s requirements. Measuring the surface finish at the point of manufacture is becoming more important, often performed by the machinist who is also manufacturing the part. While the machinist is typically an expert on running a particular machine, they may not be an expert on making surface finish measurements (as well as tasks such as collecting and documenting data).

Thus, manufacturers need tools for operators that meet test requirements and are simple to use. For example, Ra (Roughness Average) is the preferred method for analyzing surface finish for numerous applications. With their small size, robustness, and simple one-button operation, pocket-sized portable surface gages are ideal for performing these basic measurements. Manufacturers have successfully used them for roughness measurements on the shop floor for more than 25 years.

However, while Ra may be the go-to method for a quick analysis of the surface, it may not be enough to ensure that the surface will ultimately meet its design requirements. With more than 30 different roughness parameters, deeply investigating how a surface might perform (no pun intended) will require moving from a portable skidded system to a more capable skidless system. Skidless systems allow for the measurement of roughness and the waviness and profile of the surface.

Whether it is a skidded roughness system or a skidless roughness system with a reference surface built into the drive, the technology common in the lab is making its way to the shop floor.

As a result, usability becomes a substantial issue. The latest portable surface gages interface with the user just like a smartphone’s touchscreen. It allows the user to adjust the orientation of the display for the correct viewing angle—horizontally, vertically, or upside down—to provide the best option for the operator, just like the rotation feature on a smartphone.

Because the interface is so similar to a smartphone, a typical user will require very little training and can use the handheld portable surface gage in minutes. Almost like using an app on a phone, the units are intelligent enough to automate filter setting and cut-off selection, providing optimal results for the user. Also, users can customize the screen and measurements to only see the desired results without sifting through a lot of unnecessary information. The display can be customized to show “favorite” functions, such as sending data or accessing specific trace details for fast access to commonly used features.

Since today’s machinists have also become surface finish inspectors, they may as well have the tools to become documentation, data collection, and analysis experts, too. New portable surface finish products make the collection and transfer of measurement results transparent to the user. With each measurement cycle, settings allow for data results to be saved on the device automatically, both in data and PDF formats. At the same time, the results can be sent through an output connector (or wireless data transmitter) to a computer for Excel or third-party data collection and SPC analysis. Or the profile information can be wirelessly sent to a printer for an immediate hard copy to move along with the part. All of this can now be completed with only the single start button and no added steps.

The New Generation of Touch Electronic Digital Indicators

Digital indicators have been a successful improvement of dial indicators, combining multiple features and configurations into a product that can replace many dedicated and increasingly difficult-to-manufacture and maintain dial indicator products. Also, digital indicators and digital comparators provide higher resolution, better accuracy, and versatility. However, like mechanical dial indicators or any other tool used at the point of manufacture, they are subject to the environment they are used in – which can be pretty harsh with coolants and oil mist in the air. It’s not unusual that mechanisms become contaminated over time, dedicated buttons are subject to wear, markings are apt to fade, and typically, user buttons provide openings to water, oil, and dirt egress. This is an ideal place where touch technology can improve existing technology.

With shop-hardened glass touch control panels, a new generation of digital indicators offers maximum measuring reliability even in harsh workshop environments. One would naturally assume glass is probably not the best medium for something that is dropped, pushed, tapped, or generally handled day after day. But glass isn’t what it used to be; new versions are being used in smartphones every day – and standing up to tough use. This same glass technology is being built into digital indicators used in very harsh shop environments. Rather than dedicated buttons, a light touch on the screen is enough to securely operate the digital indicator with one’s finger, even when wearing most commercially available shop gloves.

For high-performance bench stand applications, the light touch required eliminates the possibility of accidental deformation of a measuring system. A slight time delay can also be employed to ensure any physical deformation is stabilized before zeroing. The full-surface glass display also offers protection against liquids and dirt, which cannot penetrate the sealed housing. And, since the keys’ labels are behind the glass, there is no chance that the labeling will degrade or be erased over time. Of course, because the glass is clear, it is easy to employ colored LED lighting for red/green/yellow classification based on tolerances, making it easier for quick part qualification by the user.

Employing Touchscreen Tablets on Height Gages

Touchscreen interfaces are also growing in size, and it is not uncommon to have a larger tablet to supplement a touch phone or to have a larger touch phone in general. These use the same user interface—sliding lists, touch keys, scalable sizes, and all the common features everyone now takes for granted.

It is natural then to take this touch tablet and begin employing it in various gaging devices in an effort to make it easier for the user to become comfortable with the gage. An electronic height gage is an ideal place to begin using this technology.

Until now, users were faced with large keypads with dozens of dedicated keys. A typical keypad for entering names/dates and other part-related information was needed. The keyboard was complemented with dedicated keys for the height gage’s various measuring functions and capabilities. It’s no wonder that operators wanted extensive training on using the height gage; they were overwhelmed with all the keys and options available, which often lacked rhyme or reason.

Using a swivel touch display on a height gage ensures that it can be operated as comfortably as a tablet. Large buttons, self-explanatory icons, and clearly structured menus enable fast, fluid processes, accelerating the measuring procedure. Measurements can be started conveniently, and with simple scrolling and sliding, the touchscreen operates similarly to large smartphones and tablets. The keys are arranged on the display, so frequently used functions are easily accessible. They are limited to the functions used at the time; for example, the keyboard for data entry disappears when not in use, and help screens are available by simply touching a question mark and the function where further details are needed. The touch display is at eye level with the user, whether standing or sitting, and can be rotated or tilted as required.

A touch interface is not only limited to tablet-like displays. When using a “quick-mode” function to measure from the top or the bottom dimension, all the operator has to do is bring the height gage to the part (or part to the gage) and press the carriage in the direction of the measurement. The operator does not even have to touch the tablet – sensing the measurement movement initiated by the user, the height gage takes over and completes the measurement.

Motorized height gages ensure consistent and controlled gaging force, ensuring the most consistent and repeatable measuring results. Side function keys and a thumbwheel enable the measuring carriage to be conveniently positioned and measurements to be started directly. Handles on both sides coupled with integrated air bearings guarantee the device can be moved effortlessly and precisely on the measuring plate.

Simplified Part Programming and Data Collection

Whether the height gage is a 350 mm, 600 mm, or 1,000 mm version, the touch interface also makes other operator features simpler and faster to work with, such as part programming for batch running of parts or data logging/transfer options for easy measurement data processing.

The tablet provides a variety of interfaces for saving part measurement routines and data transfer/storage. Once a part is measured using the touch measuring routines, the sequence of operation is viewable and can be selected and saved as a customized part program. There is no complex part programming; just save the cycle performed with a simple touch.

Data transfer is possible both wirelessly and by cable and allows the transmission of the height gage ID number to ensure traceability of measurement results. For reports, users can choose between complete representations in PDF format, sending individual measured values to a PC or Bluetooth printer, or saving as a TXT file, all with a selection of easy-to-understand icons.

Parting Words

Making high-precision surface roughness, waviness, and profile measurements doesn’t always require that large system in the back corner of the manufacturing area. In today’s high-productivity manufacturing environment, providing hand tools that are almost second nature makes operators comfortable with their use and more apt to accept them.

With touch technology and smartphone-like operation, these portable systems provide the same precision capabilities but are made for the machinist to use at the point of manufacture. More and more hand tool manufacturers will certainly employ this technology in the next generation of products.