PTDF PIN: 8092761469614704 SANUSI, Olawale Monsur: PhD Proposal

RESEARCH AND DEVELOPMENT OF ADVANCED VIRTUAL COORDINATE

MEASURING MACHINE USING COMPUTER AIDED DESIGN/MANUFACTURING
1.0 INTRODUCTION
1.1 Research Background
Dimensional measurement plays a critical role in product development and quality control. With
the continuously increasing demand for tighter tolerances and more complex workpiece and shapes
in the industry, dimensional metrology often becomes the bottleneck of taking the quality and
performance of manufacturing to higher degree. As one kind of the most useful and powerful
measuring instruments, coordinate measuring machines (CMMs) are widely employed in
manufacturing industries [1-6]. Comparing to conventional inspection methods with complicated
and inefficient procedures, CMM greatly simplifies the procedure yet improves the accuracy and
precision [3].
A coordinate measuring machine (CMM) is an instrument for measuring geometrical features of
an object. A useful definition can be found in ISO10360-1: A CMM is a measuring system with
the means to move a probing system and capability to determine spatial coordinates on a workpiece
surface (International Organization for Standardization, 2000). A typical CMM usually possesses
three orthogonal axes X, Y, Z, and a probe that is attached to the third moving axis. The three axes
are stacked together, and each axis may move along its direction [4-6]. The combination of the
movements of three axes allows the probe to travel in a three dimensional space. Along with the
rotation of the probe head and tilting of the probe stylus, CMM probe has a great degree of access
to the object being inspected.
Although the CMMs are vastly useful, in today‘s rapidly developing manufacturing industry,
sometimes its speed and accuracy of inspection can still become the bottleneck of further
improving manufacturing technology. Enormous efforts have been made to help CMM keep in
pace with the modern industry. Among others, Virtual Coordinate Measuring Machine (VCMM)
is the general designation of a range of computer applications that simulate certain aspects of CMM
characteristics in one way or another, and typically facilitate the inspection planning on CMMs, or
help evaluate the measurement uncertainty associated with the CMM inspection. Since the
accuracy and efficiency of a CMM have a vital impact on the product quality, productivity and
manufacturing cost, the evaluation and improvement of CMM performance have always been
important research topics since the invention of CMM [6].
An Advanced Virtual Coordinate Measuring Machine (AVCMM) is proposed in this research
against such a background. The proposed AVCMM is a software package that provides an
integrated virtual environment, in which user can plan inspection strategy for a given task, carry
out virtual measurement, and evaluate the uncertainty associated with the measurement result, all
without the need of using a physical machine. The obtained estimate of uncertainty can serve as a
rapid feedback for user to optimize the inspection plan in the AVCMM before actual measurement,
or as an evaluation of the result of a performed measurement and subsequent production.
1.2 Problem Statement
To fulfil the industrial needs of accurate inspection in many fields, there is a wide range of CMMs
to choose from, ranging from portable models driven by hand to heavy gantry models capable of
measuring heavy equipment, providing measuring capacities from tiny part to magnificent
component, and offering accuracies ranging from better than 1 µm to around 100 µm. The choice
PTDF PIN: 8092761469614704 SANUSI, Olawale Monsur: PhD Proposal

of CMM configurations and size for specific tasks depends on several factors such as accuracy
requirement, operation modes, size of the workpiece, and loading requirement.
Common applications of CMM system include dimensional measurement, angularity or
orientation measurement, profile measurement, depth mapping, shaft measurement, digitizing,
reverse engineering and rapid prototyping. However, virtual combination of these functionalities
in an environment in enhancing efficient parts manufacturing as well as inspection processes has
generated research gaps in engineering metrology.
1.3 Significant of the Research
Virtual Coordinate Measuring Machine (VCMM) would simulate significant aspects of CMM
characteristics and typically facilitate the inspection planning on CMMs. It will help in evaluating
the measurement uncertainty associated with the CMM inspection. Consequently, the design and
development of universal interchangeable machine components and toolings used in the petroleum
and other related industries would be made to precisions and easily accessible for training purpose.
2.0 Aims and Objectives
While the overall aim of this research is to design, develop and evaluate Advanced Virtual
Coordinate Measuring Machine (AVCMM) system that can generally improve the performance of
CMM measurements, the distinct objectives include:
 To critically review the current state of CMM related researches with respect to inspection
planning and uncertainty evaluation, focusing on the development of VCMMs.
 To establish methodology and to propose a sound architecture for the VCMM-CAD/CAM
metrology system.
 To design the AVCMM system and its important component.
 To implement a prototype of the proposed AVCMM system, using data obtained from
experiments, CAD and finite element analysis (FEA).
 To validate the implemented AVCMM prototype with experiments.
2.1 Literature Review
Modern CMMs are of CNC type and can be driven automatically from the CMM program.
Following features became common in modern CMMs: crash protection, offline programming,
CAD model import capability, temperature and error compensations, etc. [2-6]. Most designs of
CMM are based on a Cartesian coordinate system, i.e. three mutually orthogonal axes, due to the
simplicity and universality of such an arrangement.
Danuta et al. [1] presented an approach to automate the process of fixturing planning for CMM
inspection in the context of automatic manufacturing system environment. A modular,
configurable fixture system was established which is suitable for not only measuring process but
also automated fixturing planning.
Klodian [5] developed a generic algorithm for CAD-directed CMM inspection planning, based on
the modified ray tracing technique which uses B-Rep (boundary representation) data from any
geometric modelling systems. The concept is to establish an imaginary ray between start point and
target point, and if intersection with workpiece is encountered then an optimal detour path must
be created to avoid collision between probe and workpiece.
PTDF PIN: 8092761469614704 SANUSI, Olawale Monsur: PhD Proposal

Wang et al. [9] presented an automatic inspection planning method utilizing computer vision. They
established a vision guided CMM by attaching a camera to CMM probe. When the camera moves
along with the probe, it captures images of the workpiece from different positions, hence constructs
a stereo vision system. These images are then processed by using symmetric multi-baseline
matching to acquire 3D edge characters, based on which the inspection planning is then conducted.
Salah [6] conducted a research to compare uncertainties from different evaluation methods of form
errors, namely the least square method and the genetic algorithm-based method. The computation
uncertainties to flatness and roundness were taken as examples in the research, and the results led
to two conclusions: the differences between uncertainties from the two evaluation methods were
very small but the least square method was considered better because the genetic algorithm-based
method was a little unstable; and the uncertainties to the form errors were mostly affected by CMM
sampling hence the measurement strategies are very important.
3.0 Research Methodology
Materials- Probes, linear/rotary encoders, transducers, interferometers, probe holder, corundum,
sensors, actuators, composite, CAD and CAM, NX, etc.
Conceptual Design- Since the surfaces are always more or less rotationally symmetric, or an off-
axis part of such a surface, a cylindrical coordinate measuring machine setup is desired which
scans a non-contact probe over the surface to be measured. The probe is therefore to be mounted
on a rotation axis, which would be mounted on translation stages R and Z. This motion system
will position the probe with respect to the workpiece surface.
When measuring a free-form product, the surface will depart from rotational symmetry. To avoid
dynamically following the surface with the large R and Z stages, the optical probe should have an
axial range of 5 mm. This way a free-form surface can be scanned swiftly with minimal dynamics
in the system because the R and Z stages and the ψ-axis can be stationary. The machine will further
incorporate an intermediate body on which a product is to be mounted. This intermediate body
reproducibly interfaces to the spindle of the measurement machine as well as to other
manufacturing machine spindles, to provide quick measurement of a product without the need for
re-alignment on the machines. The proposed work flow chart of the AVCMM is attached as Figure
1. The position of each axis is to be measured by the corresponding laser interferometer. The
reflection mirrors and of X- and Y-interferometers are fixed on two of the lateral sides of Y-stage.
The main mechanical assembly of the targeted CMM is to be located in a thermostatic chamber
isolated on an anti-vibration base.

Architecture- Direct linking of 3D CAD definition and its tolerances to the CMM. The
infrastructure and volume of data storage and configuration control is reduced by this interface.
When the factory is able to use the 3D data directly in a realtime graphics enabled metrology
platform, the opportunity for reduced drawing interpretation errors [6].
AVCMM is to be programmed in the CAD/CAE environment using Unigraphics software (NX);
other CAM softwares would be integrated as well. This would be based on the experimental
observations of CMM-CAD system and the data generated therefrom.
PTDF PIN: 8092761469614704 SANUSI, Olawale Monsur: PhD Proposal

4.0 Expected Result

This research recognizes the limitations of the existing CMMs, especially the absence of a
comprehensive, integrated system that covers functions related to multiple aspects of the CMM
and allows different functions to seamlessly share data and interact with each other. Against such
a background, this research has proposed an Advanced Virtual Coordinate Measuring Machine
(AVCMM) system, which is expected to combine inspection simulation with uncertainty
evaluation features, while improving the usability and efficiency of the system.
The system is expected to carry out inspection planning in AVCMM by operating a visualized
CMM model, and then have the results of planned tasks including the associated uncertainties
quickly calculated and evaluated. The AVCMM will support the simulation and combination of
errors from different sources.
Without involving a physical CMM in the inspection planning or evaluation of uncertainty, the
AVCMM can greatly reduce the time and cost needed for such processes. Furthermore, as the
package is expected to offer vivid 3D visual representation of the virtual environment and supports
operations similar to a physical CMM, it does not only allow the user to easily plan and optimize
the inspection strategy, but also will provide a cost-effective, risk-free solution for training CMM
operators in Petroleum and other industries. This will finally result in a complete and tested
machine prototype aiding the metrology technology in an oil and gas industry.
Reference
[1] Danuta, O., Ksenia, O. and Wiktor, H. (2015). Estimation Of Measurement Uncertainty With The Use Of
Uncertainty Database Calculated For Optical Coordinate Measurements Of Basic Geometry Elements.
Advances in Science and Technology Research Journal, Volume 9, No. 27; 112–117. DOI:
10.12913/22998624/59092.
[2] Dongeek, Sh., Kirmani, A., Goyal, K. V., Shapiro, H. J. (2015). Photon-Efficient Computational 3D and
Reflectivity Imaging with Single-Photon Detectors, IEEE Transactions on Computational Imaging, 1: 112-
125.
[3] Gallivanoni, A., Rech, I., Resnati, D., Ghioni, M., Cova, S. (2006). Monolithic Active Quenching and
Picosecond Timing Circuit Suitable for Large-Area Single-Photon Avalanche Diodes, Optics Express, 14:
5021-5030.
[4] Hammad Mian, S and Al-Ahmari, A. (2014). New developments in coordinate measuring machines for
manufacturing industries. International Journal Metrol. Qual. Eng. 5, 101; 1-10. DOI:
10.1051/ijmqe/2014001.
[5] Klodian, D. (2016). Measurement Methods with 3D Coordinate Measuring Machine and Improved
Characterization Setup for Detector Performance. PhD Thesis, Tallinn University of Technology, Estonia.
[6] Salah H. R. A. (2010). Probing System Characteristics in Coordinate Metrology. Measurement Science
Review, Volume 10, No. 4; 120-129.
[7] TESA MICRO-HITE 3D Coordinate Measuring Machine Brochure [WWW]
http://swissinstruments.com/downloads/metrology_coordinate.pdf (21.03.2015).
[8] Vornicu, I., Carmona-Galán, R., Rodríguez-Vázquez, A. A (2013). CMOS 8x8 SPAD Array for Time-of-
Flight Measurement and Light-Spot Statistics, In:Proceedings IEEE International Symposium on Circuits
and Systems: 2626-2629.
[9] Wang, Y., Chen, Y., Nan, Z. & Hu, Y. (2016). Accessibility analysis for CMM inspection planning using
haptic device. In IEEE International Conference on Robotics and Biomimetics - ROBIO2006. Kunming,
China, 2016. IEEE.
[10] Xiaobin, X. (2007). Design and fabrication of 4H-SiC Detectors towards Single Photon Counting:
Doctoral Thesis, New Jersey, Rutgers University.
PTDF PIN: 8092761469614704 SANUSI, Olawale Monsur: PhD Proposal

RESEARCH AND DEVELOPMENT OF ADVANCED VIRTUAL COORDINATE

MEASURING MACHINE USING COMPUTER AIDED DESIGN/MANUFACTURING
1.0 INTRODUCTION
1.1 Research Background
Dimensional measurement plays a critical role in product development and quality control. With
the continuously increasing demand for tighter tolerances and more complex workpiece and shapes
in the industry, dimensional metrology often becomes the bottleneck of taking the quality and
performance of manufacturing to higher degree. As one kind of the most useful and powerful
measuring instruments, coordinate measuring machines (CMMs) are widely employed in
manufacturing industries [1-6]. Comparing to conventional inspection methods with complicated
and inefficient procedures, CMM greatly simplifies the procedure yet improves the accuracy and
precision [3].
A coordinate measuring machine (CMM) is an instrument for measuring geometrical features of
an object. A useful definition can be found in ISO10360-1: A CMM is a measuring system with
the means to move a probing system and capability to determine spatial coordinates on a workpiece
surface (International Organization for Standardization, 2000). A typical CMM usually possesses
three orthogonal axes X, Y, Z, and a probe that is attached to the third moving axis. The three axes
are stacked together, and each axis may move along its direction [4-6]. The combination of the
movements of three axes allows the probe to travel in a three dimensional space. Along with the
rotation of the probe head and tilting of the probe stylus, CMM probe has a great degree of access
to the object being inspected.
Although the CMMs are vastly useful, in today‘s rapidly developing manufacturing industry,
sometimes its speed and accuracy of inspection can still become the bottleneck of further
improving manufacturing technology. Enormous efforts have been made to help CMM keep in
pace with the modern industry. Among others, Virtual Coordinate Measuring Machine (VCMM)
is the general designation of a range of computer applications that simulate certain aspects of CMM
characteristics in one way or another, and typically facilitate the inspection planning on CMMs, or
help evaluate the measurement uncertainty associated with the CMM inspection. Since the
accuracy and efficiency of a CMM have a vital impact on the product quality, productivity and
manufacturing cost, the evaluation and improvement of CMM performance have always been
important research topics since the invention of CMM [6].
An Advanced Virtual Coordinate Measuring Machine (AVCMM) is proposed in this research
against such a background. The proposed AVCMM is a software package that provides an
integrated virtual environment, in which user can plan inspection strategy for a given task, carry
out virtual measurement, and evaluate the uncertainty associated with the measurement result, all
without the need of using a physical machine. The obtained estimate of uncertainty can serve as a
rapid feedback for user to optimize the inspection plan in the AVCMM before actual measurement,
or as an evaluation of the result of a performed measurement and subsequent production.
1.2 Problem Statement
To fulfil the industrial needs of accurate inspection in many fields, there is a wide range of CMMs
to choose from, ranging from portable models driven by hand to heavy gantry models capable of
measuring heavy equipment, providing measuring capacities from tiny part to magnificent
component, and offering accuracies ranging from better than 1 µm to around 100 µm. The choice
PTDF PIN: 8092761469614704 SANUSI, Olawale Monsur: PhD Proposal

of CMM configurations and size for specific tasks depends on several factors such as accuracy
requirement, operation modes, size of the workpiece, and loading requirement.
Common applications of CMM system include dimensional measurement, angularity or
orientation measurement, profile measurement, depth mapping, shaft measurement, digitizing,
reverse engineering and rapid prototyping. However, virtual combination of these functionalities
in an environment in enhancing efficient parts manufacturing as well as inspection processes has
generated research gaps in engineering metrology.
1.3 Significant of the Research
Virtual Coordinate Measuring Machine (VCMM) would simulate significant aspects of CMM
characteristics and typically facilitate the inspection planning on CMMs. It will help in evaluating
the measurement uncertainty associated with the CMM inspection. Consequently, the design and
development of universal interchangeable machine components and toolings used in the petroleum
and other related industries would be made to precisions and easily accessible for training purpose.
2.0 Aims and Objectives
While the overall aim of this research is to design, develop and evaluate Advanced Virtual
Coordinate Measuring Machine (AVCMM) system that can generally improve the performance of
CMM measurements, the distinct objectives include:
 To critically review the current state of CMM related researches with respect to inspection
planning and uncertainty evaluation, focusing on the development of VCMMs.
 To establish methodology and to propose a sound architecture for the VCMM-CAD/CAM
metrology system.
 To design the AVCMM system and its important component.
 To implement a prototype of the proposed AVCMM system, using data obtained from
experiments, CAD and finite element analysis (FEA).
 To validate the implemented AVCMM prototype with experiments.
2.1 Literature Review
Modern CMMs are of CNC type and can be driven automatically from the CMM program.
Following features became common in modern CMMs: crash protection, offline programming,
CAD model import capability, temperature and error compensations, etc. [2-6]. Most designs of
CMM are based on a Cartesian coordinate system, i.e. three mutually orthogonal axes, due to the
simplicity and universality of such an arrangement.
Danuta et al. [1] presented an approach to automate the process of fixturing planning for CMM
inspection in the context of automatic manufacturing system environment. A modular,
configurable fixture system was established which is suitable for not only measuring process but
also automated fixturing planning.
Klodian [5] developed a generic algorithm for CAD-directed CMM inspection planning, based on
the modified ray tracing technique which uses B-Rep (boundary representation) data from any
geometric modelling systems. The concept is to establish an imaginary ray between start point and
target point, and if intersection with workpiece is encountered then an optimal detour path must
be created to avoid collision between probe and workpiece.
PTDF PIN: 8092761469614704 SANUSI, Olawale Monsur: PhD Proposal

Wang et al. [9] presented an automatic inspection planning method utilizing computer vision. They
established a vision guided CMM by attaching a camera to CMM probe. When the camera moves
along with the probe, it captures images of the workpiece from different positions, hence constructs
a stereo vision system. These images are then processed by using symmetric multi-baseline
matching to acquire 3D edge characters, based on which the inspection planning is then conducted.
Salah [6] conducted a research to compare uncertainties from different evaluation methods of form
errors, namely the least square method and the genetic algorithm-based method. The computation
uncertainties to flatness and roundness were taken as examples in the research, and the results led
to two conclusions: the differences between uncertainties from the two evaluation methods were
very small but the least square method was considered better because the genetic algorithm-based
method was a little unstable; and the uncertainties to the form errors were mostly affected by CMM
sampling hence the measurement strategies are very important.
3.0 Research Methodology
Materials- Probes, linear/rotary encoders, transducers, interferometers, probe holder, corundum,
sensors, actuators, composite, CAD and CAM, NX, etc.
Conceptual Design- Since the surfaces are always more or less rotationally symmetric, or an off-
axis part of such a surface, a cylindrical coordinate measuring machine setup is desired which
scans a non-contact probe over the surface to be measured. The probe is therefore to be mounted
on a rotation axis, which would be mounted on translation stages R and Z. This motion system
will position the probe with respect to the workpiece surface.
When measuring a free-form product, the surface will depart from rotational symmetry. To avoid
dynamically following the surface with the large R and Z stages, the optical probe should have an
axial range of 5 mm. This way a free-form surface can be scanned swiftly with minimal dynamics
in the system because the R and Z stages and the ψ-axis can be stationary. The machine will further
incorporate an intermediate body on which a product is to be mounted. This intermediate body
reproducibly interfaces to the spindle of the measurement machine as well as to other
manufacturing machine spindles, to provide quick measurement of a product without the need for
re-alignment on the machines. The proposed work flow chart of the AVCMM is attached as Figure
1. The position of each axis is to be measured by the corresponding laser interferometer. The
reflection mirrors and of X- and Y-interferometers are fixed on two of the lateral sides of Y-stage.
The main mechanical assembly of the targeted CMM is to be located in a thermostatic chamber
isolated on an anti-vibration base.

Architecture- Direct linking of 3D CAD definition and its tolerances to the CMM. The
infrastructure and volume of data storage and configuration control is reduced by this interface.
When the factory is able to use the 3D data directly in a realtime graphics enabled metrology
platform, the opportunity for reduced drawing interpretation errors [6].
AVCMM is to be programmed in the CAD/CAE environment using Unigraphics software (NX);
other CAM softwares would be integrated as well. This would be based on the experimental
observations of CMM-CAD system and the data generated therefrom.
PTDF PIN: 8092761469614704 SANUSI, Olawale Monsur: PhD Proposal

4.0 Expected Result

This research recognizes the limitations of the existing CMMs, especially the absence of a
comprehensive, integrated system that covers functions related to multiple aspects of the CMM
and allows different functions to seamlessly share data and interact with each other. Against such
a background, this research has proposed an Advanced Virtual Coordinate Measuring Machine
(AVCMM) system, which is expected to combine inspection simulation with uncertainty
evaluation features, while improving the usability and efficiency of the system.
The system is expected to carry out inspection planning in AVCMM by operating a visualized
CMM model, and then have the results of planned tasks including the associated uncertainties
quickly calculated and evaluated. The AVCMM will support the simulation and combination of
errors from different sources.
Without involving a physical CMM in the inspection planning or evaluation of uncertainty, the
AVCMM can greatly reduce the time and cost needed for such processes. Furthermore, as the
package is expected to offer vivid 3D visual representation of the virtual environment and supports
operations similar to a physical CMM, it does not only allow the user to easily plan and optimize
the inspection strategy, but also will provide a cost-effective, risk-free solution for training CMM
operators in Petroleum and other industries. This will finally result in a complete and tested
machine prototype aiding the metrology technology in an oil and gas industry.
Reference
[1] Danuta, O., Ksenia, O. and Wiktor, H. (2015). Estimation Of Measurement Uncertainty With The Use Of
Uncertainty Database Calculated For Optical Coordinate Measurements Of Basic Geometry Elements.
Advances in Science and Technology Research Journal, Volume 9, No. 27; 112–117. DOI:
10.12913/22998624/59092.
[2] Dongeek, Sh., Kirmani, A., Goyal, K. V., Shapiro, H. J. (2015). Photon-Efficient Computational 3D and
Reflectivity Imaging with Single-Photon Detectors, IEEE Transactions on Computational Imaging, 1: 112-
125.
[3] Gallivanoni, A., Rech, I., Resnati, D., Ghioni, M., Cova, S. (2006). Monolithic Active Quenching and
Picosecond Timing Circuit Suitable for Large-Area Single-Photon Avalanche Diodes, Optics Express, 14:
5021-5030.
[4] Hammad Mian, S and Al-Ahmari, A. (2014). New developments in coordinate measuring machines for
manufacturing industries. International Journal Metrol. Qual. Eng. 5, 101; 1-10. DOI:
10.1051/ijmqe/2014001.
[5] Klodian, D. (2016). Measurement Methods with 3D Coordinate Measuring Machine and Improved
Characterization Setup for Detector Performance. PhD Thesis, Tallinn University of Technology, Estonia.
[6] Salah H. R. A. (2010). Probing System Characteristics in Coordinate Metrology. Measurement Science
Review, Volume 10, No. 4; 120-129.
[7] TESA MICRO-HITE 3D Coordinate Measuring Machine Brochure [WWW]
http://swissinstruments.com/downloads/metrology_coordinate.pdf (21.03.2015).
[8] Vornicu, I., Carmona-Galán, R., Rodríguez-Vázquez, A. A (2013). CMOS 8x8 SPAD Array for Time-of-
Flight Measurement and Light-Spot Statistics, In:Proceedings IEEE International Symposium on Circuits
and Systems: 2626-2629.
[9] Wang, Y., Chen, Y., Nan, Z. & Hu, Y. (2016). Accessibility analysis for CMM inspection planning using
haptic device. In IEEE International Conference on Robotics and Biomimetics - ROBIO2006. Kunming,
China, 2016. IEEE.
[10] Xiaobin, X. (2007). Design and fabrication of 4H-SiC Detectors towards Single Photon Counting:
Doctoral Thesis, New Jersey, Rutgers University.
PTDF PIN: 8092761469614704 SANUSI, Olawale Monsur: PhD Proposal

RESEARCH AND DEVELOPMENT OF ADVANCED VIRTUAL COORDINATE

MEASURING MACHINE USING COMPUTER AIDED DESIGN/MANUFACTURING
1.0 INTRODUCTION
1.1 Research Background
Dimensional measurement plays a critical role in product development and quality control. With
the continuously increasing demand for tighter tolerances and more complex workpiece and shapes
in the industry, dimensional metrology often becomes the bottleneck of taking the quality and
performance of manufacturing to higher degree. As one kind of the most useful and powerful
measuring instruments, coordinate measuring machines (CMMs) are widely employed in
manufacturing industries [1-6]. Comparing to conventional inspection methods with complicated
and inefficient procedures, CMM greatly simplifies the procedure yet improves the accuracy and
precision [3].
A coordinate measuring machine (CMM) is an instrument for measuring geometrical features of
an object. A useful definition can be found in ISO10360-1: A CMM is a measuring system with
the means to move a probing system and capability to determine spatial coordinates on a workpiece
surface (International Organization for Standardization, 2000). A typical CMM usually possesses
three orthogonal axes X, Y, Z, and a probe that is attached to the third moving axis. The three axes
are stacked together, and each axis may move along its direction [4-6]. The combination of the
movements of three axes allows the probe to travel in a three dimensional space. Along with the
rotation of the probe head and tilting of the probe stylus, CMM probe has a great degree of access
to the object being inspected.
Although the CMMs are vastly useful, in today‘s rapidly developing manufacturing industry,
sometimes its speed and accuracy of inspection can still become the bottleneck of further
improving manufacturing technology. Enormous efforts have been made to help CMM keep in
pace with the modern industry. Among others, Virtual Coordinate Measuring Machine (VCMM)
is the general designation of a range of computer applications that simulate certain aspects of CMM
characteristics in one way or another, and typically facilitate the inspection planning on CMMs, or
help evaluate the measurement uncertainty associated with the CMM inspection. Since the
accuracy and efficiency of a CMM have a vital impact on the product quality, productivity and
manufacturing cost, the evaluation and improvement of CMM performance have always been
important research topics since the invention of CMM [6].
An Advanced Virtual Coordinate Measuring Machine (AVCMM) is proposed in this research
against such a background. The proposed AVCMM is a software package that provides an
integrated virtual environment, in which user can plan inspection strategy for a given task, carry
out virtual measurement, and evaluate the uncertainty associated with the measurement result, all
without the need of using a physical machine. The obtained estimate of uncertainty can serve as a
rapid feedback for user to optimize the inspection plan in the AVCMM before actual measurement,
or as an evaluation of the result of a performed measurement and subsequent production.
1.2 Problem Statement
To fulfil the industrial needs of accurate inspection in many fields, there is a wide range of CMMs
to choose from, ranging from portable models driven by hand to heavy gantry models capable of
measuring heavy equipment, providing measuring capacities from tiny part to magnificent
component, and offering accuracies ranging from better than 1 µm to around 100 µm. The choice
PTDF PIN: 8092761469614704 SANUSI, Olawale Monsur: PhD Proposal

of CMM configurations and size for specific tasks depends on several factors such as accuracy
requirement, operation modes, size of the workpiece, and loading requirement.
Common applications of CMM system include dimensional measurement, angularity or
orientation measurement, profile measurement, depth mapping, shaft measurement, digitizing,
reverse engineering and rapid prototyping. However, virtual combination of these functionalities
in an environment in enhancing efficient parts manufacturing as well as inspection processes has
generated research gaps in engineering metrology.
1.3 Significant of the Research
Virtual Coordinate Measuring Machine (VCMM) would simulate significant aspects of CMM
characteristics and typically facilitate the inspection planning on CMMs. It will help in evaluating
the measurement uncertainty associated with the CMM inspection. Consequently, the design and
development of universal interchangeable machine components and toolings used in the petroleum
and other related industries would be made to precisions and easily accessible for training purpose.
2.0 Aims and Objectives
While the overall aim of this research is to design, develop and evaluate Advanced Virtual
Coordinate Measuring Machine (AVCMM) system that can generally improve the performance of
CMM measurements, the distinct objectives include:
 To critically review the current state of CMM related researches with respect to inspection
planning and uncertainty evaluation, focusing on the development of VCMMs.
 To establish methodology and to propose a sound architecture for the VCMM-CAD/CAM
metrology system.
 To design the AVCMM system and its important component.
 To implement a prototype of the proposed AVCMM system, using data obtained from
experiments, CAD and finite element analysis (FEA).
 To validate the implemented AVCMM prototype with experiments.
2.1 Literature Review
Modern CMMs are of CNC type and can be driven automatically from the CMM program.
Following features became common in modern CMMs: crash protection, offline programming,
CAD model import capability, temperature and error compensations, etc. [2-6]. Most designs of
CMM are based on a Cartesian coordinate system, i.e. three mutually orthogonal axes, due to the
simplicity and universality of such an arrangement.
Danuta et al. [1] presented an approach to automate the process of fixturing planning for CMM
inspection in the context of automatic manufacturing system environment. A modular,
configurable fixture system was established which is suitable for not only measuring process but
also automated fixturing planning.
Klodian [5] developed a generic algorithm for CAD-directed CMM inspection planning, based on
the modified ray tracing technique which uses B-Rep (boundary representation) data from any
geometric modelling systems. The concept is to establish an imaginary ray between start point and
target point, and if intersection with workpiece is encountered then an optimal detour path must
be created to avoid collision between probe and workpiece.
PTDF PIN: 8092761469614704 SANUSI, Olawale Monsur: PhD Proposal

Wang et al. [9] presented an automatic inspection planning method utilizing computer vision. They
established a vision guided CMM by attaching a camera to CMM probe. When the camera moves
along with the probe, it captures images of the workpiece from different positions, hence constructs
a stereo vision system. These images are then processed by using symmetric multi-baseline
matching to acquire 3D edge characters, based on which the inspection planning is then conducted.
Salah [6] conducted a research to compare uncertainties from different evaluation methods of form
errors, namely the least square method and the genetic algorithm-based method. The computation
uncertainties to flatness and roundness were taken as examples in the research, and the results led
to two conclusions: the differences between uncertainties from the two evaluation methods were
very small but the least square method was considered better because the genetic algorithm-based
method was a little unstable; and the uncertainties to the form errors were mostly affected by CMM
sampling hence the measurement strategies are very important.
3.0 Research Methodology
Materials- Probes, linear/rotary encoders, transducers, interferometers, probe holder, corundum,
sensors, actuators, composite, CAD and CAM, NX, etc.
Conceptual Design- Since the surfaces are always more or less rotationally symmetric, or an off-
axis part of such a surface, a cylindrical coordinate measuring machine setup is desired which
scans a non-contact probe over the surface to be measured. The probe is therefore to be mounted
on a rotation axis, which would be mounted on translation stages R and Z. This motion system
will position the probe with respect to the workpiece surface.
When measuring a free-form product, the surface will depart from rotational symmetry. To avoid
dynamically following the surface with the large R and Z stages, the optical probe should have an
axial range of 5 mm. This way a free-form surface can be scanned swiftly with minimal dynamics
in the system because the R and Z stages and the ψ-axis can be stationary. The machine will further
incorporate an intermediate body on which a product is to be mounted. This intermediate body
reproducibly interfaces to the spindle of the measurement machine as well as to other
manufacturing machine spindles, to provide quick measurement of a product without the need for
re-alignment on the machines. The proposed work flow chart of the AVCMM is attached as Figure
1. The position of each axis is to be measured by the corresponding laser interferometer. The
reflection mirrors and of X- and Y-interferometers are fixed on two of the lateral sides of Y-stage.
The main mechanical assembly of the targeted CMM is to be located in a thermostatic chamber
isolated on an anti-vibration base.

Architecture- Direct linking of 3D CAD definition and its tolerances to the CMM. The
infrastructure and volume of data storage and configuration control is reduced by this interface.
When the factory is able to use the 3D data directly in a realtime graphics enabled metrology
platform, the opportunity for reduced drawing interpretation errors [6].
AVCMM is to be programmed in the CAD/CAE environment using Unigraphics software (NX);
other CAM softwares would be integrated as well. This would be based on the experimental
observations of CMM-CAD system and the data generated therefrom.
PTDF PIN: 8092761469614704 SANUSI, Olawale Monsur: PhD Proposal

4.0 Expected Result

This research recognizes the limitations of the existing CMMs, especially the absence of a
comprehensive, integrated system that covers functions related to multiple aspects of the CMM
and allows different functions to seamlessly share data and interact with each other. Against such
a background, this research has proposed an Advanced Virtual Coordinate Measuring Machine
(AVCMM) system, which is expected to combine inspection simulation with uncertainty
evaluation features, while improving the usability and efficiency of the system.
The system is expected to carry out inspection planning in AVCMM by operating a visualized
CMM model, and then have the results of planned tasks including the associated uncertainties
quickly calculated and evaluated. The AVCMM will support the simulation and combination of
errors from different sources.
Without involving a physical CMM in the inspection planning or evaluation of uncertainty, the
AVCMM can greatly reduce the time and cost needed for such processes. Furthermore, as the
package is expected to offer vivid 3D visual representation of the virtual environment and supports
operations similar to a physical CMM, it does not only allow the user to easily plan and optimize
the inspection strategy, but also will provide a cost-effective, risk-free solution for training CMM
operators in Petroleum and other industries. This will finally result in a complete and tested
machine prototype aiding the metrology technology in an oil and gas industry.
Reference
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Uncertainty Database Calculated For Optical Coordinate Measurements Of Basic Geometry Elements.
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10.12913/22998624/59092.
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http://swissinstruments.com/downloads/metrology_coordinate.pdf (21.03.2015).
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Flight Measurement and Light-Spot Statistics, In:Proceedings IEEE International Symposium on Circuits
and Systems: 2626-2629.
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Doctoral Thesis, New Jersey, Rutgers University.