Efficient and accurate operations are vital to the success of today''s manufacturer. Newcomb Spring, one of North America''s largest manufacturers of custom springs, wire forms and stampings, is continually working to improve their production processes. The Company has also seen an increasing number of requests for reports that detail the compliance of completed orders. Newcomb''s in-house Research and Development Department is tasked with developing and building new technologies and equipment to solve unique challenges as well as improve overall operations and efficiency. Recently, Newcomb Spring introduced its own Camera Gauge System, developed by its R&D team, which was designed to provide high-speed manufacturing with automatic adjustments, extremely high levels of compliance and reportable accuracy, unmatched in the industry.

A NEW KIND OF GAUGE SYSTEM

While other camera gauge systems are available in the market today, they lack features that Newcomb felt were important to their operations. "Our goal was to design and build a new gauge system that would bring ''real-time inspection'' to a more current mode," said John Jacobson, Vice President of Newcomb Spring Corp. "We are constantly improving our production processes by adding state-of-the-art computer-controlled forming equipment and retro-fitting or re-building older forming machines. While most traditional coiling machines run with some type of length gauging, these gauges utilize non-contact capacitance systems that measure the distance from the end of the spring to a fixed probe tip located in front of the spring. We wanted a system that would offer a better view of what was taking place, and at the same time provide excellent gauging accuracy."

The development of their own system not only allowed for improvements compared to publicly-available systems, but would also allow the company to adapt operations to meet specific customer needs, now and in the future. Newcomb Spring''s R&D department looked at specific manufacturing processes and what management viewed as the technology''s future requirements, and created an innovative system of computer-controlled forming equipment, software and camera monitoring.

SYSTEM OPERATION

The Camera Gauge System''s operations center on a camera-based pixel resolution that is referenced as a measurement basis. A high-resolution camera fitted with a zoom lens monitors part dimensions, and as each part is formed, the camera rapidly captures multiple images of the part. Each image is transmitted to the system''s software, which measures the part horizontally and vertically in real-time, analyzing and recording dimensions with software that the Company also developed. Unlike traditional gauges this new Camera Gauge System can be positioned at different views and capture different measurements, monitoring not only the length of the part, but also a second dimension, such as width.

A 20-inch color touch screen interface allows technicians 
to monitor and interact with the Newcomb Camera System, 
and to download order reports that confirm compliance 
for the full production run.

Extremely high-resolution cameras provide detailed pixel analysis, and are linked to Newcomb''s proprietary software. During set-up, the software and equipment is programmed by the operator who inputs part dimensions, allowable variances, order identification information and production quantities. Different modes of correction are also entered, depending on part requirements. During set-up the system''s resolution is also verified for accuracy, confirming it is correct for the controlled tolerance levels.

As each part is formed, multiple dimensions are captured by the camera, and measured and recorded by the software. If part measurements approach maximum tolerance levels the program will automatically trigger an adjustment in the connected wire coiling machinery, which causes the equipment to recalibrate and comply more closely to nominal specifications.

Any parts that exceed allowable tolerances are automatically rejected and sorted into a separate holding bin. Real-time operation allows the system to detect non-compliant parts as they are completed, segregating them from the order, and virtually eliminating the risk of components that do not meet order specifications. When the order is complete a manual count of rejected parts is performed and checked against system data.

The Newcomb Camera Gauge System is programmed to automatically shut down when order quantities are fulfilled, or if too many parts exceed allowable tolerances. There is also a safety shutdown if there is ever a problem.

DESIGNED FOR THE SHOP FLOOR

"It was important for us to ensure our Camera Gauge System was as user-friendly as possible," said Jacobson. "While we can have the most state-of-the-art equipment available, there is always the possibility of human error. We designed the system to make it easy for the operator to use while maximizing the technology. There are still multiple, manual quality control checks, but with the integration of special features we worked to reduce the potential for errors."

The system captures and records multiple dimension 
of each part as it is formed, in real-time.

The system utilizes a 20-inch color touch screen for the operator interface and display, which makes viewing parts significantly easier than other gauge systems. Backlights of varying sizes are utilized to provide a consistent backdrop to view the part against, and at high zoom levels, even the surface of the part''s material can be seen clearly.

"The large display offers a magnified view of the spring, which makes the set-up very straight forward," noted Craig Stevens, R&D Specialist at Newcomb Spring of Tennessee, who installs the Camera Gauge System and trains operators on its use. "It allows for a quick visual check of the parts while in production. Unlike some of the other gauge systems I have used, you don''t need to be inches from the part to see it in detail."

The screen is mounted on top of the forming machinery in such a way that it can be seen from a distance by anyone in the department. The positioning ensures maximum visibility, so issues that may have gone unnoticed with previous gauge systems are much more likely to be observed. Since the system is operating automatically, without operator oversight, fast response to any issues can dramatically reduce costly problems.

-The 19th China (Guangzhou) Int’l Spring Industry Exhibition