In precision manufacturing processes, surface quality defects are one of the major pain points leading to workpiece rework and increased costs. Surface ripples, steps, or periodic errors caused by tool wear, chipping, or machine vibration not only affect the appearance of workpieces but may also result in functional failure. Traditional inspection methods relying on handheld probes or offline coordinate measuring machines (CMMs) are inefficient, prone to human error, and frequently cause production interruptions along with additional handling and setup costs. To address these challenges, the Renishaw OSP60 on-machine scanning probe offers an efficient integrated solution. Equipped with SPRINT™ technology, this probe delivers fast and high-precision solutions for a wide range of measurement applications. By adopting the on-machine scanning solution, the efficiency of automatic workpiece alignment, in-process verification, and adaptive machining can be significantly enhanced.

   To address these challenges, the Renishaw OSP60 on-machine scanning probe offers an efficient integrated solution. Equipped with SPRINT™ technology, this probe delivers fast and high-precision solutions for a wide range of measurement applications. By adopting the on-machine scanning solution, the efficiency of automatic workpiece alignment, in-process verification, and adaptive machining can be significantly enhanced.

   The scanning capability of CNC machine tools enables rapid acquisition of high-density 3D data, real-time detection of various surface defects including periodic errors, peaks and valleys, as well as steps, and direct calculation of waviness (Wt) parameters to provide reliable basis for process adjustments. 

• Periodic errors — manifested as repetitive patterns on the workpiece surface, typically caused by tool wear or machine vibration  

• Surface peaks and valleys — caused by tool chipping or wear 

• Surface steps — caused by unexpected variations in tool dimensions, tool deflection, workpiece shift (under cutting forces), or thermal changes in the machine tool, among other issues

Compared to using handheld devices, the automated in-machine scanning for surface quality data collection with OSP60 offers higher reproducibility because it eliminates human error.

Performing data collection on the workpiece inside the machine tool can eliminate the complex process of multiple manual handling and transfer of the workpiece, as well as the numerous setups required when moving the workpiece from the machine tool to offline measurement equipment.

In-machine monitoring can ensure the good condition of tools throughout their entire service life. Once it is determined to be necessary, backup tools can be called upon, allowing for timely process adjustments before problems become severe and irreparable; this is particularly important when processing high-value materials.

The waviness parameters calculated by the OSP60 can be stored in machine tool variables for analysis to control downstream processes, or the data can be exported to external software packages (such as OmniSurf) for further analysis.

On-machine scanning is a powerful, intelligent, and automated technology that offers multiple operational advantages:

• Significant reduction in workpiece alignment and inspection cycle time, as well as scrap rate.

• High data density inspection results. The OSP60 can capture up to 1,000 3D data points per second.

• Automatic setup and updates of machine parameters.

• Comprehensive feature information, including dimensional data, geometric data, positional offsets, angular offsets, and true feature shapes.

• Ability to perform multiple tasks using the same probe and stylus configuration, such as workpiece alignment, on-machine workpiece evaluation, surface quality inspection, and machine tool performance verification.

• Continuous exchange of positional data between the scanning system and the machine controller ensures highly reliable measurement results.

• Enhanced manufacturing capabilities and productivity, leading to optimized processes.

• Tailored software solutions provide specific inspection capabilities for various applications.

In summary, the Renishaw OSP60 on-machine scanning probe not only strengthens the in-process measurement capabilities of CNC machine tools but also supports comprehensive quality control throughout the production process. By enabling highly automated and integrated surface quality monitoring, it helps manufacturing enterprises reduce rework, enhance efficiency, and achieve end-to-end quality management.