### TABLE OF CONTENTS

INTRODUCTION .......................................................................................................................... 1

OBJECTIVE

.............................................................................................................................. ..... 1

DELIVERABLES ........................................................................................................................... 2

APPROACH

.............................................................................................................................. ..... 2

SETUP

.............................................................................................................................. .............. 2 Equipment List ............................................................................................................................ 2 Configuration of the Tractor for Scanning .................................................................................. 4 Configuration of the Trailer for Scanning .................................................................................. 6 Configuration of the iG PS System for Scanning ........................................................................ 8

SCANNING AND MOD ELING ASSUMPTIONS ..................................................................... 11 Tractor Scanning and Modeling Assumptions .......................................................................... 11 Trailer Scanning and Modeling Assumptions ........................................................................... 14

FINAL MODELS ......................................................................................................................... 15

PROJECT MANAGEMENT NOTES .......................................................................................... 16

### INTRODUCTION In support of the aerodynamic analysis effort for EPA’s SmartWay Tran sportation Partnership program, Southwest Research Institute ® 

### (SwRI ® 

### ) and its subcontracto r, Nikon Metrology, provided 3D laser scanning and modeling services , capturing the exteriorgeometry of a highroof, aero sleeper cab Class 8 trac tor and its 53-ft. trailer (Figure 1). This document describes the equipment and methods used, modeling techni ques, and illustrations that capture the chronological sequence of digitization activities. Finally, so me discussion is provided regarding project management aspects of the truck digiti zation, including informa tion about productivity and suggestions for future digitiz ation efforts of this nature.

Figure 1. High-roof aero sleeper cab Class 8 tractor and its 53 ft. trailer prior to scanning.



### OBJECTIVE The objective was to digitize a Class 8 truck (tractor and trai ler) for the dual purpose of computational fluid dynamic analysis and to enab le fabrication of a rapid prototype scale model for wind tunnel testing (closed-grill model). The output file format was to be STL, which is compatible with common computational flui d dynamics software including Star CCM, PowerFlow, and FLUENT, and is also compatible with additive rapid prototyping machines.

1

### DELIVERABLES The contractual deliverables for the truck digitization effort in cluded the following:

• 3D models in STL format for the
o Trailer including aero kit
o Trailer excluding aero kit
o Tractor

• Technical report (this document) SwRI also provided (not contractual):

• A photo archive of the whole process

• Laser scanner point cloud data

• 3D models in IGES and Sldprt (SolidWorks) formats

APPROACH To avoid error stack-up due to instrument l eap-frogging, the truck was scanned using a twoinstrument approach. An iGPS (infrared laser positioning) system was first used to probe coordinate frame nests, acquiring their X,Y, Z positions in a single encompassing coordinate frame. An articulated arm with laser scanner was then used to scan the exteri or of one side of the truck, including the underbody. The opposite side of the truck was mode led as a mirrored copy of the scanned side, except where asymmetries existed (e.g., tractor exhaust manifold). The nominal resolution of the point cloud was 1.5 mm. La ser scan data patches we re stitched together using the coordinate frame nests whose positions we re determined with the iGPS system. In this way, the maximum incurred error did not exceed the combined error of the iGPS and CMM laser scanner arm, plus any errors related to small va riations in the temperature of the building and mounting flexure. Local error when matching iGPS and scanner data was observed to be better than 1 mm. Global error, which could be additio nally influenced by temperature variation, is estimated to have been better than 2 mm. For this size vehicle, errors of this scale were assumed to have negligible influence on the outcome of aerodynamic analysis.

SETUP The truck was moved to SwRI building 9800, which is a large temperature-controlled building with approximately 20 ft. of clea rance to the roof support structur e. The tractor and trailer were scanned sequentially as separate entities to im prove physical access to the surface of both. The sub-sections that follow (pages 3 - 8) describe the equipment used, and the particular setup for the tractor and trailer. The setup of the iGPS equipment is also described.

Equipment List The following tables provide th e tractor and trailer specs.

2

### Table 1. Tractor Specifications

Manufacturer MY International Model ProStar Premiun Sleeper Cab Type Class 8 Sleeper Cab VIN 2HSCUAPR6AC168660 Tractor ID 1660-HD-01

Table 2.Trailer Specifications

Manufacturer Great Dane Owner ID 123458 Model SSL-1313-02053 VIN Number 1GRAA06219J628785 Manufacture Date December 2007 Model Year 2008 GVWR 68,000 Lbs. Rear Axle Tires Bridgestone R195 Tire Size 295 / 75 /22.5 Rims/Make Accuride DOT T

The following hardware tools were used to acquire the surface data (refer to the Appendices for more information about the metrology tools used):

• Nikon Metrology (formerly Me tris) iGPS G5 system, including the following subcomponents:
o 8 laser transmitters, each on Brunson instrument tripods
o 2-meter Invar calibration bar
o Hand-held vector bar w/ 5m m ball tip and wireless PCE
o Dell laptop workstation

• Nikon Metrology MCA 2 meter scanning arm w/ MDD 200mm laser scanner

• Set of synchronized portable 220V electric wheel lifts

• Jack stands

• Battery powered ~18 ft. scissor lift

• Battery powered ~12 ft. vertical man lift

• Movable ~15 ft. stair case

• 3 Large I-beams for mounting th e scanning arm under the truck

• Step ladder

• Safety equipment including harnesses, ha rd hats, gloves, and safety glasses.

3

### The following software programs were used for ac quiring and then post-processing the scan data to generate STL models:

• Nikon Metrology Surveyor 1.4 software to bundle, configure, and run the iGPS

• New River Kinematics Spatial Analyzer software to collect, visualize, and analyze nest data points and inte rface with the iGPS.

• Nikon Focus Handheld to calibrate the laser sc anner, collect the data, and decimate the data down to useable resolution.

• SolidWorks 2011 to generate reverse-engineered model of the trailer and to generate the combined model.

• Polyworks to generate reverse-e ngineered model of the tractor

Configuration of the Tractor for Scanning The tractor was prepared for scanning first. Four portable electric wheel lifts were used to lift the tractor ~31⁄2 ft. off the ground. The lifts were placed under the front wheels and under the forward rear axle based on the fact that weight would be more evenly distributed. Once the tractor was suspended, jack stands were pla ced at hard points along the center frame rails (Figures 2 and 3). I-beams were secured to the floor underneath the tractor using hot glue to provide a mounting flange for the scanning arm (Figure 3). Standoffs were also glued to the I-beams every couple of feet to provide rigid nests for the scanning arm to locate itself with reference to the iGPS absolute coordinate frame. A #6 threadless alum inum standoff makes a highly repeatable 5 mm probe tip nest for about 1/100 of the pr ice of nests sold for that purpose. Figure 4 illustrates many of the nuances of scanning a Class 8 tr uck. Because the laser scanner has difficulty with reflective (e.g. chrome) or tr ansparent surfaces, developer spray was used to coat these surfaces, making them frosty white. Th e laser scanning arm cannot be mounted to the same apparatus that supporting its human operato r, because the shifting weight of the operator can introduce large errors in sca nner’s base position. Therefore, the scanning arm was frequently mounted to an I-beam clamped to a two-story scaffo lding (far right side of the image). Also, the front wheel was removed at the very end of the scanning job, so that the wheel well could be scanned. The final model of the truck used geometry from 23 scan data point clouds.

4Figure 2. The tractor was scanned in a temperature controlled high bay. Two of the eight iGPS laser transmitters are visible on the white tripods. The yellow scale bar is on the black tripod in the center of the image.

Figure 3. The tractor was suspended off the ground so that the underside could be scanned.



### 5Figure 4. The front wheel of the tractor wa s removed to provide laser scanning access.



### Configuration of the Trailer for Scanning The setup for the trailer was much simpler than fo r the tractor. The trailer was scanned separately from the tractor, sitting on its built-in jack stand (Figure 5). Due to its in herent ground clearance, it could be scanned without need to jack it up off the ground (F igure 6). This also simplified mounting for the scanning arm. A large portion of the trailer’s broad side and top surface did not need to be scanned due to the fact that they were featureless (large flat planes), so the scanning arm was moved along the ground, capturing the featur es of the lower edge, aero kit, and underside (Figure 7). The final model of the trai ler used geometry from 13 scanned point clouds.

6Figure 5 . The trailer was scanned from front to back, separated from the tractor. The scanning arm was mounted to a tall Brunson tripod (center) to access the high surfaces of the trailer.

Figure 6. The inherent ground clearanc e of the trailer enabled scanning without need for jack stands.



### 7Figure 7. Since the variable geometry of the trailer was mostly found along the lower edges and underside, the scanner was able to collect needed geometry for th e broad side from a short tripod.



### Configuration of the iGPS System for Scanning The iGPS system was set up on one side of the trac tor/trailer in an arc configuration to ensure signal coverage over the entire si de. The iGPS Vector Probe was used to measure feature touchpoints and coordinate frame nest s (Figure 8). The probe accuracy filter was set to 0.015 inches. This meant that the operator had to hold the probe very still in order to acquire a measurement. The system does not collect points if the calculated accuracy is wors e than the filter limit. Each nest was tagged with a number to uniquely iden tify it. Once the nest positions were acquired with the iGPS system through the Spatial Analyzer software interface (Figures 9-12), the nest data was exported to a spreadsheet then lase r scanning began. For each base position of the scanning arm, five or six nests were first measured to establish the coordinate frame of the arm. In the Focus Handheld software, which serves as the user interface for the arm, each nest was labeled with its unique identifier number. In post processing, the nest coordinates were assigned in the Focus Handheld software and a least squares fit was used to transform the point cloud data from the coordinate frame of the scanner to the global coordinate frame of the iGPS. The scanner was used to capture the geometry of all hidden (non-lin e-of-sight) areas like the underside of the vehicle.

8Figure 8. The author used the iGPS system to acquire nest locations.

Figure 9. Profile view of the tractor nest point data. The silhouette of the tractor is apparent from the points along the top of the image. The points along the bottom are ground reference points used to localize the scanner when it was beneath the tractor.



### 9Figure 10. Top view of the tractor iGPS constellation and nest data points. Here the intent is to show the relatively large transmitter constellation, shown as small black dots with serial numbers around the perimeter of the image, needed to see all of the reference nests on the tracto r. It is not readily apparent, but the front of the tractor is at left, and the rear of the tractor is at right. 

### 100 ft. 41 ft. tractor nest points

iGPS transmitters

Figure 11. Rear isometric view of the trailer ne st points. The pink points (left) are at the back end of the trailer. The green po ints are along the lower edge and

skirt, and the blue points (right) are on the front face of the trailer.



### 10Figure 12. Top view of the trailer iGPS conste llation and nest positions. Here, the small black dots at the periphery are the location s of the iGPS transmitters (8 total), the pink points (left) are from the rear face of the trailer, the g reen points (center) are from the right side face, and the blue points (right) are from the front face of the trailer. 

### 42 ft. trailer nest points

iGPS transmitters

113 ft.

SCANNING AND MODELING ASSUMPTIONS Efficient reverse engineering requires a methodology to identify important design features and to discard superfluous design features. In the case of digitization for an aerodynamic study, the decision to keep or discard features cannot be s implified to a simple rule based only on size or cross sectional area. (We had started with th e goal of capturing everything larger than 3 mm based on CFD literature). There are many considerat ions including the accessibility of the feature to line-of-sight, cost of modeling irregular/asymme trical curved surfaces, and the need to close the model to make it a “water tight” solid. The subsections that follow describe how SwRI and its subcontractors chose which features to s can and model for the tr actor and trailer.

Tractor Scanning and Modeling Assumptions The following list summarizes the assumptions. To illustrate these considerations, Figures 13-16 are provided.

• Half of the tractor was scanned, the othe r half was generated by mirror-copying the model in post processing. Asym metric features that were pr eserved in the model include:
o Exhaust system manifold and stack.
o Pneumatic air tanks (underside)
o Transaxles
o Engine oil pan

• The model is a closed-grill model, which doe s not allow for airflow through the radiator and over the engine. The effort to reverse engineer the engine and under-hood geometry would double or triple the cost of this overall project.

11

### • To close the underside of the engine compar tment, a plane was inserted, approximately co-planar with the top of the main beams beneath the tractor. Only items below this plan were modeled.

• Items that were obviously symmetric were not scanned in their entirety. For instance, the tires were assumed to be axisymme tric and only a patch was scanned.

• The ride height of the front and rear axle s was adjusted in the model to account for suspension loading/unloading while the tractor was on jack stands.

• Cowling sheet metal was modeled as a zero-thickness surface.

• Small gaps between body sheet metal were bridged to close the surface.

• The interior hollow of the roof dome was a ssumed to follow the exterior contour, except where scan data was accessible.

• Pneumatic hoses and electrical harnesses were ignored due to thei r small size and high complexity.

• Mud flaps were modeled as flat.

• Most fasteners were not modeled.

• The steering gear for th e front wheels was ignored.

12Figure 13. Front view of the scan data overlaid on the final model. From this perspective, nearly every exterior surface feature from the scan data has a modeled counterpart.

Figure 14. Top rear isometric view of the scan data (grey) overlaid on the final

tractor model (red). Note that the rea r wheel data doesn ’t overlay perfectly because the suspension preload had to be compensated in post processing.



### 13Figure 15. Bottom view of the scan data (grey ) overlaid on the final tractor model (red). 

### Trailer Scanning and Modeling Assumptions The following list summarizes the assumptions for scanning and modeling the trailer:

• Half of the trailer was scanned, the other half was generated by mirror-copying the model in post processing. Asymmetric features th at were preserved in the model include:
o Rear ladder
o Pneumatic tank for the air brakes (underside)
o Hazard diamonds

• The trailer model was provided in two variants : one that includes the as-built aero kit and one for which the aero kit had been digitally subtracted.

• The main body of the trailer was modeled with flat sides that meet at right angles. The physical trailer sides bow or curve slightly in a manner that is unique to that trailer.

• Certain areas were not captured entirely in the scanning process because symmetry or patterning was assumed. These areas include:
o The driver’s side of the trailer (mirro red from the passenger’s side, which was scanned)
o The hazard diamonds on the flanks of the trailer (assumed planar)
o The band feature around the lower edge ofthe trailer (assumed constant crosssection)
o The rivets and panel struct ures (patterned array)
o The tire treads (simplified pattern used)
o The rib structures on the unde rside of the trailer (patte rned from single scanned rib)

• A few areas of the trailer could not be sca nned due to access limitations and are therefore less accurate. The features in these areas we re extrapolated from existing scan data or modeled from hand measurements and observa tions. The areas of reduced accuracy include:
o The undercarriage features between the wheels (some hand measurements were taken to augment scan patches)
o The crown feature around the upper edge of the trailer (hand-measured and assumed to be constant cross-section)

14

### FINAL MODELS Figures 16-18 show various perspe ctives of the completed model.

Figure 16. Front isometric perspect ive of the completed model. H ere the attention to detail in the tractor body and cowling is evident from the number of surface parting lines.

Figure 17. Rear top isometric view of th e completed model. The model of the

trailer relied heavily on assumption s of symmetric and repeated patterns.



### 15Figure 18. Front bottom isometric view of the completed model. This view highlights the detail of the underside of the trailer model.



### PROJECT MANAGEMENT NOTES One of the goals of the truck digitization proj ect was to evaluate the feasibility and cost effectiveness of using the iGPS system as an ab solute coordinate frame, enabling repositioning of the arm scanner without error stack-up, to co ver the whole surface of the truck including the underside. From a technical perspective, the iGPS worked extremely well, knitting together scan data patches with an accuracy that exceeded the resolution of the decimated scan data (0.38 mm vs. 1.5 mm). From a cost perspective, the efficiency of the iGPS depends on the throughput of the particular scanning job (note that no iGPS equipment charges were assessed to the project, as it was used on a trial basis). Two other alternativ es, a laser tracker or la ser radar, could also provide similar functionality. The laser tracker would be much less expensive to own/operate, but would require multiple setups to gather the e quivalent data. Laser radar could also have been used. Like the laser tracker, it is only a single piece of equipment (though similar in price to iGPS). The advantage of the laser radar is that it could capture point clouds and nest locations both. The scanning arm would still be needed if the laser radar was used, due to accessibility restrictions under th e truck and inside the rear fairing. In answer to the bottom line question of the cost efficiency of the iGPS, it costs more th an the laser tracker and it takes longer to setup than either of the alternatives. If a high thr ough-put of scanning jobs was expected and setup only had to be done once, the iG PS would be cost effective. For infrequent large scale laser scanning jobs, the laser tracker is probab ly the most cost effective solution.

16

### 17 Another project management interest is the cost comparison of digital aerodynamic drag calculation with empirical testi ng as it relates to compliance with future EPA fuel economy regulations. SwRI was not involve d with the CDF analysis and ca nnot address the cost of that portion, but we can help to quantify the labo r involved in digitization of a truck. Table 3 documents the labor involved in scanning and mode ling the tractor and trailer for this project. Note that report writing hours ar e excluded and subcontractor hours are estimated. Also note that the modeling labor would be at least twice as high if the engine/under-hood was reverse engineered to a similar degree of detail as the rest of the truck. Some cost savings could be realized if multiple trucks were scanned at once, but these savings would mostly be in the area of setup and breakdown labor, which were not dominant in the total cost. Table 3. Truck Digitization Labor Hours Description Est. Engineering Hours Est. Technician Hours Setup and Scanning 148 175 Reverse Engineering/Modeling 203 0 Total 351 175

### Appendix A: iGPS Product Data SheetsiSpace setups, configurations, tools and options

4 series 6 series 8 series Transmitter count 4 6 8 Available configurations x, s x, s, i x, s, i Typical measurement volume footprint from 10x10m up to 40x40m Typical use case Smaller volume / Unobstructed line of sight / Lower accuracy General purpose / Standard system size / Moderate line of sight obstructions Larger volumes / Obstructed line of sight / Maximum accuracy

x s i Hardware configuration Free network of transmitters Transmitters plus base stations Transmitters plus monuments Calibration method Traceable scale-bar Traceable scale-bar Traceable reference network Accuracy 1,2 <250 μm over 3x scale-bar length 3 <250 μm over 3x scale-bar length <200 μm uniformly over monument volume Typical use case Portable/Deployable setup Short term measurement and tracking Engineering or R&D focused Less health monitoring Semi-portable or semi-fixed installations Longer term measurement and tracking Production focused High level of health monitoring Fixed installation Always-on production system Maximum system robustness accuracy and reliability

1 For optimum performance, it is recommended to keep the distance between sensors and transmitters between 3 and 35m and guarantee individual sensors to be within line of sight of at least 4 transmitters. 2 System performance testing according to B89 and ISO10360 in conjunction with an independent accredited measurement standards lab. iSpace is a network based metrology system that does not follow traditional uncertainty models. Coordinate uncertainties are interdependent, do not scale with range and are repeatable within the volume. 3 Requires stable transmitter positions and environmental conditions Tools and options Available series Description Metrology server 6, 8 Allows multiple independent clients to be used in the same iSpace network leveraging scalability Dynamic Tracking Kit 4, 6, 8 Kit of 4 vector bar sensors allowing 6DOF tracking of an object in the iSpace volume Handheld vector bar (5DOF) 4, 6, 8 2 sensor vector tool providing handheld inspection capability iProbe (6DOF) 4, 6, 8 4 sensor 6 DOF tool providing handheld inspection capability with customizable probe tips iMCA 6, 8 Support base for MC4 articulated arm that utilizes the iSpace system for automatic alignment Related products

• Hardware: iGPS / Laser Radar / MCA articulated arms
• Supported software: Nikon Metrology Surveyor / NRK Spatial Analyzer / Tango!3D / Verisurf
• Software development kit (SDK) for 3 rd party integrations Environmental requirments Operating temperature (standard performance) 10°C to 30°C (50°F to 86°F) Storage temperature -20°C to 50°C (-4°F to 122°F) Relative humidity 10% to 75% (non-condensing) 

# Full freedom operation in large volumes

iGPS technology provides the building blocks for the iSpace systems iGPS is a scalable measurement concept that converts a workspace into a metrology enabled work volume. The operation of an iGPS system is comparable to a global positioning system (GPS) in a car, but it is designed for industrial applications on a facility-wide scale. GPS satellites are replaced by infrared iGPS laser transmitters that activate a measurement field as large as an entire room or facility.
iGPS features accuracies that are roughly a hundred thousand times higher than consumer GPS systems. Tools, parts, probes and equipment, such as AGVs, can be equipped with iGPS receivers that are tracked by the transmitters. As such, positions can be measured or dynamically tracked with a high degree of confidence in order to provide accurate metrology data or to facilitate tracking and positioning applications.
To obtain accurate positioning, receivers need line of sight from minimum 2 transmitter fields. Adding more transmitters enlarges the measurement area, improves robustness by guaranteeing line of sight, and further increases measurement accuracy. iGPS is a flexible metrology solution that offers full freedom operation for indoor and outdoor use. The iSpace systems are standardized configurations built with iGPS components focusing on ease of installation and use. 

# Configurations and specifications

Niko N M E t R olo G y NV Geldenaaksebaan 329 B-3001 Leuven, Belgium phone: +32 16 74 01 00 fax: +32 16 74 01 03 info@nikonmetrology.com

More offices and resellers at www.nikonmetrology.com Niko N Co RP o R atio N Shin-Yurakucho Bldg., 12-1, Yurakucho 1-chome Chiyoda-ku, Tokyo 100-8331 Japan phone: +81 3 3773 9026 fax: +81 3 3773 9062 www.nikon-instruments.jp/eng/

Niko N M E t R olo G y Eu R o PE NV tel. +32 16 74 01 01 sales_europe@nikonmetrology.com Niko N M E t R olo G y G M bH tel. +49 6023 91733-0 sales_germany@nikonmetrology.com Niko N M E t R olo G y S a R l tel. +33 1 60 86 09 76 sales_france@nikonmetrology.com Niko N M E t R olo G y, iNC

. tel. +1 810 2204360 sales_us@nikonmetrology.com us.nikonmetrology.com www.nikoninstruments.com Niko N M E t R olo G y uk l td. tel. +44 1332 811349 sales_uk@nikonmetrology.com Niko N iNS t R u MEN t S (S H a NGH ai) Co. l td. tel. +86 21 5836 0050 tel. +86 10 5869 2255 (Beijing office) tel. +86 20 3882 0550 (Guangzhou office) Niko N Si NG a P o RE Pt E

. l td. tel. +65 6559 3618 Niko N Malay S ia Sd N

. bH d. tel. +60 3 7809 3609 Niko N iNS t R u MEN t S k o RE a Co. l td. tel. +82 2 2186 8400 

### ni KO n M e T r O l OG y i VISION BEYOND PRECISION 

# Turn your shopfloor into a metrology enabled workspace

iSpace delivers significant value to the customer, right from the start!iSpace_EN_0410 – Copyright Nikon Metrology NV 2010. All rights reserved. The materials presented here are summary in nature and intended for general information only. 

# iSpace Large volume metrology, tracking and positioning

iSpace_EN_0410.indd 1 4/23/10 11:14 AMHandheld iProbe (6DOF)

Carbon scale bar iMCA Metrology grade transmitter Metrology
server 

# iSpace drives Metrology a ssisted Production Expandable measurement volume... ... with countless applications

Scalable systems for large volume metroloy iSpace systems can be scaled from small work cells to facility-wide installations by just adding more transmitters. The measurement volume is configured to the size of the application, resulting in 360° part coverage.
u niform accuracy for industrial large scale application The typical accuracy of an iSpace system is 200μm. Where traditional metrology equipment accuracy decreases with distance and as a result of leapfrogging-related measurement errors, iSpace accuracy is uniform across the entire measurement volume, regardless of the size of the metrology enabled area.

i nherent robustness Unlike traditional laser-based metrology tools, iSpace offers 360° part coverage without line-of-sight issues thanks to transmitter redundancy. Continuous health monitoring including on-line compensation in case of transmitter displacement and drift, guarantees optimum system performance without user intervention. Easy to deploy and straightforward to use Installing iSpace on the shop floor is easy and straightforward: just set up the transmitters on their portable tripods and calibrate the system by walking around in the measurement volume while holding a calibrated scale bar. As such, shopfloor measurement eliminates the need to transport large heavy parts to/from the measurement room. Multi-user for concurrent applications iSpace has the unique ability to serve multiple users simultaneously without performance loss. Once a work cell is iSpace-enabled, additional users and new applications can be added with minimum additional investment. Next to supporting a range of handheld metrology devices, iSpace positions tools or tracks multiple objects simultaneously, such as automated guided vehicles (AGVs) in a manufacturing environment.

o pen solution that grows along with your measurement needs As a modular and scalable solution, iSpace offers a broad application reach. Using off-the-shelf iSpace components, tailor-made tooling and the software development kit (SDK), all elements are present to build a custom solution that perfectly meets your needs. t ailored configurations for each application The iSpace portfolio consists of 3 standard setups, with 4, 6 or 8 transmitters. More transmitters create a larger measurement volume and further improve line of sight. The 4-series iSpace setup is easy to deploy, providing a smaller and unobstructed measurement volume. The 6-series setup is typically used where left/right measurements are taken on a vehicle body, for example, while the 8-series preserves the best line of sight in a measurement volume with a footprint up to 1.200m2. Each iSpace setup is available in different configurations: the x-series configuration is a portable lightweight system that is easy to set up. The s-series are delivered with base stations that provide reference detectors for continuous health monitoring. The top-line i-series inherently provide highest accuracy and system robustness. They utilize fixed iSpace monuments to capture position and scale reference points throughout the workspace. After having determined the positions of the reference points during system setup using an external measurement device, iSpace continuously monitors these monuments to be able to maintain transmitter positions at highest accuracy.

a ircraft fuselage inspection

• Measure individual points on a fuselage using iMCA
• iMCA allows for easy measurement of hidden points in the workspace Full car body inspection

• Operators use iProbe to measure multiple car bodies without leap-frogging
• Ideal for concurrent measurement of jigs/tooling Measurement of features on large turbine casting

• iProbe is used to measure surface features across the entire casting
• Full freedom measurement through wireless connection between PDA and portable client 

# Metrology applications

d ynamic tracking of ship models in towing tank applications

• Ship models are equipped with iSpace receivers
• iSpace dynamic measuring to monitor real-time ship behavior

t

racking and monitoring of industrial robots

• Sensors are embedded into robot and fixtures
• Single setup to monitor robots on a factory-wide scale

a ligning and joining large subassemblies

• Fuselage sections, wings and body components are equipped with iSpace sensors to track their position
• Monitoring of drilling and riveting robotic machining systems iSpace offers dynamic tracking in support of precision assembly of large parts and continuous monitoring of tools and objects. As such, closed-loop iSpace measurements are directly integrated into the production and assembly stages, realizing a first-time-right Metrology Assisted Production process. iProbe - lightweight 6 do F metrology probe The iProbe is a wireless handheld measurement device that provides exchangeable and inclinable 6DOF measurements within an iSpace or iGPS enabled workspace. Equipped with a stylus probe tip, the iProbe allows for accurate large volume inspection in the most flexible way. The iProbe can also be configured as a 6DOF localizer for 3 rd party instruments. Accuracy is dependent on the iSpace setup, but is equal throughout the complete measurement volume. The system’s ergonomic design and wireless operation make iProbe suitable for long duration measurement.

iMC a – iSpace enabled articulated arm The moveable iMCA tripod stand is designed to support a metrology grade MCA articulated measuring arm to operate anywhere within the iSpace enabled workspace. The iSpace determined position and orientation of the iMCA stand is combined with the coordinate information received from the MCA arm in order to measure a single point within the iSpace coordinate system. This ‘extends’ the working volume of the articulated arm and provides a large, continuous working cell without having to ‘leapfrog’ measurements.

d ynamic tracing kit The Dynamic Tracking Kit (DTK) is an add-on to any iSpace system to support dynamic referencing and 6DOF part tracking. The DTK can be semi-permanently fixed to a part or jig and used for 6DOF tracking or dynamic referencing within an iSpace volume. The DTK can be configured to track a part’s local coordinate system by following a straightforward alignment procedure. Standalone or metrology server based In a single application, data processing and system monitoring is handled by a portable, combined client/server workstation that runs the Surveyor control software and a (3 rd party) application. In case of concurrent applications, the data streams and system monitoring are controlled by a metrology server that manages the connectivity between the measurement systems and multiple portable client applications. t

ransmitter assembly with intgrated detector units

Positioning of subassemblies to align for final ship assembly

• Robust operation guaranteed for outdoor application
• Components are equipped with iSpace receivers to support computer-guided assembly

a pplying marker positions for final machining purposes

• iProbe is equipped with a miniature drill to mark positions
• Operator is guided to correct position to create a mark Coating thickness measurement in aerospace applications

• iProbe is equipped with a coating thickness tool
• Exact position recording of coating measurement Acquiring real-time positioning information is essential in a wide range of large volume applications. iSpace can determine the exact position of large objects or parts, but can also measure the exact location of tools to suit 3 rd party applications, such as coating thickness measurement, drill marking, robot-guided painting, etc. i deally, large parts or components are verified on the shop floor where they are produced. Measuring large heavy parts using traditional metrology tools may require transportation overhead to bring the parts to the measurement equipment. iSpace overcomes these challenges by converting your workspace into a metrology enabled facility where users can easily measure multiple parts. 

# t racking applications Positioning applications

iSpace_EN_0410.indd 2 4/23/10 11:15 AMHandheld iProbe (6DOF)

Carbon scale bar iMCA Metrology grade transmitter Metrology
server 

# iSpace drives Metrology a ssisted Production Expandable measurement volume... ... with countless applications

Scalable systems for large volume metroloy iSpace systems can be scaled from small work cells to facility-wide installations by just adding more transmitters. The measurement volume is configured to the size of the application, resulting in 360° part coverage.
u niform accuracy for industrial large scale application The typical accuracy of an iSpace system is 200μm. Where traditional metrology equipment accuracy decreases with distance and as a result of leapfrogging-related measurement errors, iSpace accuracy is uniform across the entire measurement volume, regardless of the size of the metrology enabled area.

i nherent robustness Unlike traditional laser-based metrology tools, iSpace offers 360° part coverage without line-of-sight issues thanks to transmitter redundancy. Continuous health monitoring including on-line compensation in case of transmitter displacement and drift, guarantees optimum system performance without user intervention. Easy to deploy and straightforward to use Installing iSpace on the shop floor is easy and straightforward: just set up the transmitters on their portable tripods and calibrate the system by walking around in the measurement volume while holding a calibrated scale bar. As such, shopfloor measurement eliminates the need to transport large heavy parts to/from the measurement room. Multi-user for concurrent applications iSpace has the unique ability to serve multiple users simultaneously without performance loss. Once a work cell is iSpace-enabled, additional users and new applications can be added with minimum additional investment. Next to supporting a range of handheld metrology devices, iSpace positions tools or tracks multiple objects simultaneously, such as automated guided vehicles (AGVs) in a manufacturing environment.

o pen solution that grows along with your measurement needs As a modular and scalable solution, iSpace offers a broad application reach. Using off-the-shelf iSpace components, tailor-made tooling and the software development kit (SDK), all elements are present to build a custom solution that perfectly meets your needs. t ailored configurations for each application The iSpace portfolio consists of 3 standard setups, with 4, 6 or 8 transmitters. More transmitters create a larger measurement volume and further improve line of sight. The 4-series iSpace setup is easy to deploy, providing a smaller and unobstructed measurement volume. The 6-series setup is typically used where left/right measurements are taken on a vehicle body, for example, while the 8-series preserves the best line of sight in a measurement volume with a footprint up to 1.200m2. Each iSpace setup is available in different configurations: the x-series configuration is a portable lightweight system that is easy to set up. The s-series are delivered with base stations that provide reference detectors for continuous health monitoring. The top-line i-series inherently provide highest accuracy and system robustness. They utilize fixed iSpace monuments to capture position and scale reference points throughout the workspace. After having determined the positions of the reference points during system setup using an external measurement device, iSpace continuously monitors these monuments to be able to maintain transmitter positions at highest accuracy.

a ircraft fuselage inspection

• Measure individual points on a fuselage using iMCA
• iMCA allows for easy measurement of hidden points in the workspace Full car body inspection

• Operators use iProbe to measure multiple car bodies without leap-frogging
• Ideal for concurrent measurement of jigs/tooling Measurement of features on large turbine casting

• iProbe is used to measure surface features across the entire casting
• Full freedom measurement through wireless connection between PDA and portable client 

# Metrology applications

d ynamic tracking of ship models in towing tank applications

• Ship models are equipped with iSpace receivers
• iSpace dynamic measuring to monitor real-time ship behavior

t

racking and monitoring of industrial robots

• Sensors are embedded into robot and fixtures
• Single setup to monitor robots on a factory-wide scale

a ligning and joining large subassemblies

• Fuselage sections, wings and body components are equipped with iSpace sensors to track their position
• Monitoring of drilling and riveting robotic machining systems iSpace offers dynamic tracking in support of precision assembly of large parts and continuous monitoring of tools and objects. As such, closed-loop iSpace measurements are directly integrated into the production and assembly stages, realizing a first-time-right Metrology Assisted Production process. iProbe - lightweight 6 do F metrology probe The iProbe is a wireless handheld measurement device that provides exchangeable and inclinable 6DOF measurements within an iSpace or iGPS enabled workspace. Equipped with a stylus probe tip, the iProbe allows for accurate large volume inspection in the most flexible way. The iProbe can also be configured as a 6DOF localizer for 3 rd party instruments. Accuracy is dependent on the iSpace setup, but is equal throughout the complete measurement volume. The system’s ergonomic design and wireless operation make iProbe suitable for long duration measurement.

iMC a – iSpace enabled articulated arm The moveable iMCA tripod stand is designed to support a metrology grade MCA articulated measuring arm to operate anywhere within the iSpace enabled workspace. The iSpace determined position and orientation of the iMCA stand is combined with the coordinate information received from the MCA arm in order to measure a single point within the iSpace coordinate system. This ‘extends’ the working volume of the articulated arm and provides a large, continuous working cell without having to ‘leapfrog’ measurements.

d ynamic tracing kit The Dynamic Tracking Kit (DTK) is an add-on to any iSpace system to support dynamic referencing and 6DOF part tracking. The DTK can be semi-permanently fixed to a part or jig and used for 6DOF tracking or dynamic referencing within an iSpace volume. The DTK can be configured to track a part’s local coordinate system by following a straightforward alignment procedure. Standalone or metrology server based In a single application, data processing and system monitoring is handled by a portable, combined client/server workstation that runs the Surveyor control software and a (3 rd party) application. In case of concurrent applications, the data streams and system monitoring are controlled by a metrology server that manages the connectivity between the measurement systems and multiple portable client applications. t

ransmitter assembly with intgrated detector units

Positioning of subassemblies to align for final ship assembly

• Robust operation guaranteed for outdoor application
• Components are equipped with iSpace receivers to support computer-guided assembly

a pplying marker positions for final machining purposes

• iProbe is equipped with a miniature drill to mark positions
• Operator is guided to correct position to create a mark Coating thickness measurement in aerospace applications

• iProbe is equipped with a coating thickness tool
• Exact position recording of coating measurement Acquiring real-time positioning information is essential in a wide range of large volume applications. iSpace can determine the exact position of large objects or parts, but can also measure the exact location of tools to suit 3 rd party applications, such as coating thickness measurement, drill marking, robot-guided painting, etc. i deally, large parts or components are verified on the shop floor where they are produced. Measuring large heavy parts using traditional metrology tools may require transportation overhead to bring the parts to the measurement equipment. iSpace overcomes these challenges by converting your workspace into a metrology enabled facility where users can easily measure multiple parts. 

# t racking applications Positioning applications

iSpace_EN_0410.indd 2 4/23/10 11:15 AMHandheld iProbe (6DOF)

Carbon scale bar iMCA Metrology grade transmitter Metrology
server 

# iSpace drives Metrology a ssisted Production Expandable measurement volume... ... with countless applications

Scalable systems for large volume metroloy iSpace systems can be scaled from small work cells to facility-wide installations by just adding more transmitters. The measurement volume is configured to the size of the application, resulting in 360° part coverage.
u niform accuracy for industrial large scale application The typical accuracy of an iSpace system is 200μm. Where traditional metrology equipment accuracy decreases with distance and as a result of leapfrogging-related measurement errors, iSpace accuracy is uniform across the entire measurement volume, regardless of the size of the metrology enabled area.

i nherent robustness Unlike traditional laser-based metrology tools, iSpace offers 360° part coverage without line-of-sight issues thanks to transmitter redundancy. Continuous health monitoring including on-line compensation in case of transmitter displacement and drift, guarantees optimum system performance without user intervention. Easy to deploy and straightforward to use Installing iSpace on the shop floor is easy and straightforward: just set up the transmitters on their portable tripods and calibrate the system by walking around in the measurement volume while holding a calibrated scale bar. As such, shopfloor measurement eliminates the need to transport large heavy parts to/from the measurement room. Multi-user for concurrent applications iSpace has the unique ability to serve multiple users simultaneously without performance loss. Once a work cell is iSpace-enabled, additional users and new applications can be added with minimum additional investment. Next to supporting a range of handheld metrology devices, iSpace positions tools or tracks multiple objects simultaneously, such as automated guided vehicles (AGVs) in a manufacturing environment.

o pen solution that grows along with your measurement needs As a modular and scalable solution, iSpace offers a broad application reach. Using off-the-shelf iSpace components, tailor-made tooling and the software development kit (SDK), all elements are present to build a custom solution that perfectly meets your needs. t ailored configurations for each application The iSpace portfolio consists of 3 standard setups, with 4, 6 or 8 transmitters. More transmitters create a larger measurement volume and further improve line of sight. The 4-series iSpace setup is easy to deploy, providing a smaller and unobstructed measurement volume. The 6-series setup is typically used where left/right measurements are taken on a vehicle body, for example, while the 8-series preserves the best line of sight in a measurement volume with a footprint up to 1.200m2. Each iSpace setup is available in different configurations: the x-series configuration is a portable lightweight system that is easy to set up. The s-series are delivered with base stations that provide reference detectors for continuous health monitoring. The top-line i-series inherently provide highest accuracy and system robustness. They utilize fixed iSpace monuments to capture position and scale reference points throughout the workspace. After having determined the positions of the reference points during system setup using an external measurement device, iSpace continuously monitors these monuments to be able to maintain transmitter positions at highest accuracy.

a ircraft fuselage inspection

• Measure individual points on a fuselage using iMCA
• iMCA allows for easy measurement of hidden points in the workspace Full car body inspection

• Operators use iProbe to measure multiple car bodies without leap-frogging
• Ideal for concurrent measurement of jigs/tooling Measurement of features on large turbine casting

• iProbe is used to measure surface features across the entire casting
• Full freedom measurement through wireless connection between PDA and portable client 

# Metrology applications

d ynamic tracking of ship models in towing tank applications

• Ship models are equipped with iSpace receivers
• iSpace dynamic measuring to monitor real-time ship behavior

t

racking and monitoring of industrial robots

• Sensors are embedded into robot and fixtures
• Single setup to monitor robots on a factory-wide scale

a ligning and joining large subassemblies

• Fuselage sections, wings and body components are equipped with iSpace sensors to track their position
• Monitoring of drilling and riveting robotic machining systems iSpace offers dynamic tracking in support of precision assembly of large parts and continuous monitoring of tools and objects. As such, closed-loop iSpace measurements are directly integrated into the production and assembly stages, realizing a first-time-right Metrology Assisted Production process. iProbe - lightweight 6 do F metrology probe The iProbe is a wireless handheld measurement device that provides exchangeable and inclinable 6DOF measurements within an iSpace or iGPS enabled workspace. Equipped with a stylus probe tip, the iProbe allows for accurate large volume inspection in the most flexible way. The iProbe can also be configured as a 6DOF localizer for 3 rd party instruments. Accuracy is dependent on the iSpace setup, but is equal throughout the complete measurement volume. The system’s ergonomic design and wireless operation make iProbe suitable for long duration measurement.

iMC a – iSpace enabled articulated arm The moveable iMCA tripod stand is designed to support a metrology grade MCA articulated measuring arm to operate anywhere within the iSpace enabled workspace. The iSpace determined position and orientation of the iMCA stand is combined with the coordinate information received from the MCA arm in order to measure a single point within the iSpace coordinate system. This ‘extends’ the working volume of the articulated arm and provides a large, continuous working cell without having to ‘leapfrog’ measurements.

d ynamic tracing kit The Dynamic Tracking Kit (DTK) is an add-on to any iSpace system to support dynamic referencing and 6DOF part tracking. The DTK can be semi-permanently fixed to a part or jig and used for 6DOF tracking or dynamic referencing within an iSpace volume. The DTK can be configured to track a part’s local coordinate system by following a straightforward alignment procedure. Standalone or metrology server based In a single application, data processing and system monitoring is handled by a portable, combined client/server workstation that runs the Surveyor control software and a (3 rd party) application. In case of concurrent applications, the data streams and system monitoring are controlled by a metrology server that manages the connectivity between the measurement systems and multiple portable client applications. t

ransmitter assembly with intgrated detector units

Positioning of subassemblies to align for final ship assembly

• Robust operation guaranteed for outdoor application
• Components are equipped with iSpace receivers to support computer-guided assembly

a pplying marker positions for final machining purposes

• iProbe is equipped with a miniature drill to mark positions
• Operator is guided to correct position to create a mark Coating thickness measurement in aerospace applications

• iProbe is equipped with a coating thickness tool
• Exact position recording of coating measurement Acquiring real-time positioning information is essential in a wide range of large volume applications. iSpace can determine the exact position of large objects or parts, but can also measure the exact location of tools to suit 3 rd party applications, such as coating thickness measurement, drill marking, robot-guided painting, etc. i deally, large parts or components are verified on the shop floor where they are produced. Measuring large heavy parts using traditional metrology tools may require transportation overhead to bring the parts to the measurement equipment. iSpace overcomes these challenges by converting your workspace into a metrology enabled facility where users can easily measure multiple parts. 

# t racking applications Positioning applications

iSpace_EN_0410.indd 2 4/23/10 11:15 AMiSpace setups, configurations, tools and options

4 series 6 series 8 series Transmitter count 4 6 8 Available configurations x, s x, s, i x, s, i Typical measurement volume footprint from 10x10m up to 40x40m Typical use case Smaller volume / Unobstructed line of sight / Lower accuracy General purpose / Standard system size / Moderate line of sight obstructions Larger volumes / Obstructed line of sight / Maximum accuracy

x s i Hardware configuration Free network of transmitters Transmitters plus base stations Transmitters plus monuments Calibration method Traceable scale-bar Traceable scale-bar Traceable reference network Accuracy 1,2 <250 μm over 3x scale-bar length 3 <250 μm over 3x scale-bar length <200 μm uniformly over monument volume Typical use case Portable/Deployable setup Short term measurement and tracking Engineering or R&D focused Less health monitoring Semi-portable or semi-fixed installations Longer term measurement and tracking Production focused High level of health monitoring Fixed installation Always-on production system Maximum system robustness accuracy and reliability

1 For optimum performance, it is recommended to keep the distance between sensors and transmitters between 3 and 35m and guarantee individual sensors to be within line of sight of at least 4 transmitters. 2 System performance testing according to B89 and ISO10360 in conjunction with an independent accredited measurement standards lab. iSpace is a network based metrology system that does not follow traditional uncertainty models. Coordinate uncertainties are interdependent, do not scale with range and are repeatable within the volume. 3 Requires stable transmitter positions and environmental conditions Tools and options Available series Description Metrology server 6, 8 Allows multiple independent clients to be used in the same iSpace network leveraging scalability Dynamic Tracking Kit 4, 6, 8 Kit of 4 vector bar sensors allowing 6DOF tracking of an object in the iSpace volume Handheld vector bar (5DOF) 4, 6, 8 2 sensor vector tool providing handheld inspection capability iProbe (6DOF) 4, 6, 8 4 sensor 6 DOF tool providing handheld inspection capability with customizable probe tips iMCA 6, 8 Support base for MC4 articulated arm that utilizes the iSpace system for automatic alignment Related products

• Hardware: iGPS / Laser Radar / MCA articulated arms
• Supported software: Nikon Metrology Surveyor / NRK Spatial Analyzer / Tango!3D / Verisurf
• Software development kit (SDK) for 3 rd party integrations Environmental requirments Operating temperature (standard performance) 10°C to 30°C (50°F to 86°F) Storage temperature -20°C to 50°C (-4°F to 122°F) Relative humidity 10% to 75% (non-condensing) 

# Full freedom operation in large volumes

iGPS technology provides the building blocks for the iSpace systems iGPS is a scalable measurement concept that converts a workspace into a metrology enabled work volume. The operation of an iGPS system is comparable to a global positioning system (GPS) in a car, but it is designed for industrial applications on a facility-wide scale. GPS satellites are replaced by infrared iGPS laser transmitters that activate a measurement field as large as an entire room or facility.
iGPS features accuracies that are roughly a hundred thousand times higher than consumer GPS systems. Tools, parts, probes and equipment, such as AGVs, can be equipped with iGPS receivers that are tracked by the transmitters. As such, positions can be measured or dynamically tracked with a high degree of confidence in order to provide accurate metrology data or to facilitate tracking and positioning applications.
To obtain accurate positioning, receivers need line of sight from minimum 2 transmitter fields. Adding more transmitters enlarges the measurement area, improves robustness by guaranteeing line of sight, and further increases measurement accuracy. iGPS is a flexible metrology solution that offers full freedom operation for indoor and outdoor use. The iSpace systems are standardized configurations built with iGPS components focusing on ease of installation and use. 

# Configurations and specifications

Niko N M E t R olo G y NV Geldenaaksebaan 329 B-3001 Leuven, Belgium phone: +32 16 74 01 00 fax: +32 16 74 01 03 info@nikonmetrology.com

More offices and resellers at www.nikonmetrology.com Niko N Co RP o R atio N Shin-Yurakucho Bldg., 12-1, Yurakucho 1-chome Chiyoda-ku, Tokyo 100-8331 Japan phone: +81 3 3773 9026 fax: +81 3 3773 9062 www.nikon-instruments.jp/eng/

Niko N M E t R olo G y Eu R o PE NV tel. +32 16 74 01 01 sales_europe@nikonmetrology.com Niko N M E t R olo G y G M bH tel. +49 6023 91733-0 sales_germany@nikonmetrology.com Niko N M E t R olo G y S a R l tel. +33 1 60 86 09 76 sales_france@nikonmetrology.com Niko N M E t R olo G y, iNC

. tel. +1 810 2204360 sales_us@nikonmetrology.com us.nikonmetrology.com www.nikoninstruments.com Niko N M E t R olo G y uk l td. tel. +44 1332 811349 sales_uk@nikonmetrology.com Niko N iNS t R u MEN t S (S H a NGH ai) Co. l td. tel. +86 21 5836 0050 tel. +86 10 5869 2255 (Beijing office) tel. +86 20 3882 0550 (Guangzhou office) Niko N Si NG a P o RE Pt E

. l td. tel. +65 6559 3618 Niko N Malay S ia Sd N

. bH d. tel. +60 3 7809 3609 Niko N iNS t R u MEN t S k o RE a Co. l td. tel. +82 2 2186 8400 

### ni KO n M e T r O l OG y i VISION BEYOND PRECISION 

# Turn your shopfloor into a metrology enabled workspace

iSpace delivers significant value to the customer, right from the start!iSpace_EN_0410 – Copyright Nikon Metrology NV 2010. All rights reserved. The materials presented here are summary in nature and intended for general information only. 

# iSpace Large volume metrology, tracking and positioning

iSpace_EN_0410.indd 1 4/23/10 11:14 AMiSpace setups, configurations, tools and options

4 series 6 series 8 series Transmitter count 4 6 8 Available configurations x, s x, s, i x, s, i Typical measurement volume footprint from 10x10m up to 40x40m Typical use case Smaller volume / Unobstructed line of sight / Lower accuracy General purpose / Standard system size / Moderate line of sight obstructions Larger volumes / Obstructed line of sight / Maximum accuracy

x s i Hardware configuration Free network of transmitters Transmitters plus base stations Transmitters plus monuments Calibration method Traceable scale-bar Traceable scale-bar Traceable reference network Accuracy 1,2 <250 μm over 3x scale-bar length 3 <250 μm over 3x scale-bar length <200 μm uniformly over monument volume Typical use case Portable/Deployable setup Short term measurement and tracking Engineering or R&D focused Less health monitoring Semi-portable or semi-fixed installations Longer term measurement and tracking Production focused High level of health monitoring Fixed installation Always-on production system Maximum system robustness accuracy and reliability

1 For optimum performance, it is recommended to keep the distance between sensors and transmitters between 3 and 35m and guarantee individual sensors to be within line of sight of at least 4 transmitters. 2 System performance testing according to B89 and ISO10360 in conjunction with an independent accredited measurement standards lab. iSpace is a network based metrology system that does not follow traditional uncertainty models. Coordinate uncertainties are interdependent, do not scale with range and are repeatable within the volume. 3 Requires stable transmitter positions and environmental conditions Tools and options Available series Description Metrology server 6, 8 Allows multiple independent clients to be used in the same iSpace network leveraging scalability Dynamic Tracking Kit 4, 6, 8 Kit of 4 vector bar sensors allowing 6DOF tracking of an object in the iSpace volume Handheld vector bar (5DOF) 4, 6, 8 2 sensor vector tool providing handheld inspection capability iProbe (6DOF) 4, 6, 8 4 sensor 6 DOF tool providing handheld inspection capability with customizable probe tips iMCA 6, 8 Support base for MC4 articulated arm that utilizes the iSpace system for automatic alignment Related products

• Hardware: iGPS / Laser Radar / MCA articulated arms
• Supported software: Nikon Metrology Surveyor / NRK Spatial Analyzer / Tango!3D / Verisurf
• Software development kit (SDK) for 3 rd party integrations Environmental requirments Operating temperature (standard performance) 10°C to 30°C (50°F to 86°F) Storage temperature -20°C to 50°C (-4°F to 122°F) Relative humidity 10% to 75% (non-condensing) 

# Full freedom operation in large volumes

iGPS technology provides the building blocks for the iSpace systems iGPS is a scalable measurement concept that converts a workspace into a metrology enabled work volume. The operation of an iGPS system is comparable to a global positioning system (GPS) in a car, but it is designed for industrial applications on a facility-wide scale. GPS satellites are replaced by infrared iGPS laser transmitters that activate a measurement field as large as an entire room or facility.
iGPS features accuracies that are roughly a hundred thousand times higher than consumer GPS systems. Tools, parts, probes and equipment, such as AGVs, can be equipped with iGPS receivers that are tracked by the transmitters. As such, positions can be measured or dynamically tracked with a high degree of confidence in order to provide accurate metrology data or to facilitate tracking and positioning applications.
To obtain accurate positioning, receivers need line of sight from minimum 2 transmitter fields. Adding more transmitters enlarges the measurement area, improves robustness by guaranteeing line of sight, and further increases measurement accuracy. iGPS is a flexible metrology solution that offers full freedom operation for indoor and outdoor use. The iSpace systems are standardized configurations built with iGPS components focusing on ease of installation and use. 

# Configurations and specifications

Niko N M E t R olo G y NV Geldenaaksebaan 329 B-3001 Leuven, Belgium phone: +32 16 74 01 00 fax: +32 16 74 01 03 info@nikonmetrology.com

More offices and resellers at www.nikonmetrology.com Niko N Co RP o R atio N Shin-Yurakucho Bldg., 12-1, Yurakucho 1-chome Chiyoda-ku, Tokyo 100-8331 Japan phone: +81 3 3773 9026 fax: +81 3 3773 9062 www.nikon-instruments.jp/eng/

Niko N M E t R olo G y Eu R o PE NV tel. +32 16 74 01 01 sales_europe@nikonmetrology.com Niko N M E t R olo G y G M bH tel. +49 6023 91733-0 sales_germany@nikonmetrology.com Niko N M E t R olo G y S a R l tel. +33 1 60 86 09 76 sales_france@nikonmetrology.com Niko N M E t R olo G y, iNC

. tel. +1 810 2204360 sales_us@nikonmetrology.com us.nikonmetrology.com www.nikoninstruments.com Niko N M E t R olo G y uk l td. tel. +44 1332 811349 sales_uk@nikonmetrology.com Niko N iNS t R u MEN t S (S H a NGH ai) Co. l td. tel. +86 21 5836 0050 tel. +86 10 5869 2255 (Beijing office) tel. +86 20 3882 0550 (Guangzhou office) Niko N Si NG a P o RE Pt E

. l td. tel. +65 6559 3618 Niko N Malay S ia Sd N

. bH d. tel. +60 3 7809 3609 Niko N iNS t R u MEN t S k o RE a Co. l td. tel. +82 2 2186 8400 

### ni KO n M e T r O l OG y i VISION BEYOND PRECISION 

# Turn your shopfloor into a metrology enabled workspace

iSpace delivers significant value to the customer, right from the start!iSpace_EN_0410 – Copyright Nikon Metrology NV 2010. All rights reserved. The materials presented here are summary in nature and intended for general information only. 

# iSpace Large volume metrology, tracking and positioning

iSpace_EN_0410.indd 1 4/23/10 11:14 AM

### Appendix B: MCA Arm Product Data SheetsNikon Metrology offer 110523-DBERRYM-93659-4 Page 4 of 11 

### Description offer 

## MCA II Articulated Arm

The MCA II is a portable manual CMM arm that offers accurate, repeatable and operator-independent insp ection results for a broad range of applications, along wi th maximum productivity and maneuverability. It is a precise, reliable and comfortable portable measuring system available in 6- or 7-axis versions. Its wireless operation a nd battery power make it feel perfectly at home in the metrology lab , on the shop floor and in the field.
The MCA II can be equipped with a wide range of pro bing systems for laser scanning, touch trigger meas urements and continuous scanning. Its flexibility makes this mea surement arm the perfect partner for a wide range o f measurement tasks.

Fig 1: 7 axis MCA II (shown with optional MMDx scanner) Fig 2: 6 axis MCA II



### Features

 Advanced carbon fiber arm tubes offer strength, li ght weight, thermal stability and feature a lifetim e warranty.

 Patented infinite rotation of principle axes allow s inspection in difficult-to-reach areas.

 Heidenhain encoders offer “wide-track” bearing sup port that enhances performance.

 Rotating grips at elbow and forearm provide low fr iction grip positions for better ergonomics.

 An integrated counterbalance reduces operator fati gue and delivers effortless control in all position s.

 An 802.11g WiFi connection is provided for tactile measuring applications allowing the operator to po sition the computer where it is most convenient.

 An integrated, rechargeable Li-ION battery allows on-site inspection without AC power or cables.

 Quick and repeatable change of automatically recog nized probes thanks to the TESA kinematic joint ada ptor.

 Ergonomic wrist, incorporating tactile selection b uttons with pistol grip on 7-axis arms and integrat ed camera and LED work light on 6-axis arms.

 The 3.5" x 8 universal mounting system attaches to a variety of tripods and bases - including the sta ndard magnetic mount.

 Accuracy certified according to ASME B89.4.22 stan dard.

 “In-the-field” system verification using a NIST-tr aceable certified length standard included with eve ry arm. 

### Technical Specifications The MCA II comes in both 7-axis and 6-axis variants with diametrical measuring volumes up to 3.6m. The 6-axis MCA II comes in two accuracy specifications - Metrology for all applications and Metrology Plus for jobs d emanding the very highest accuracy. The 7-axis MCA II is available in Metrology-grade spec.Nikon Metrology offer 110523-DBERRYM-93659-4 Page 5 of 11

MCA II 7-axis Metrology-grade Model Size SPAT 1 Vol length accuracy 2 Weight
MCA II 1800 M7 1.8m (6ft) 0.024mm (0.0009in) 0.035mm (0.0014in) 9.7kg (21.3lbs)
MCA II 2400 M7 2.4m (8ft) 0.028mm (0.0011in) 0.040mm (0.0016in) 10.1kg (22.4lbs)
MCA II 2800 M7 2.8m (9ft) 0.045mm (0.0018in) 0.064mm (0.0025in) 10.4kg (22.8lbs)
MCA II 3000 M7 3.0m (10ft) 0.050mm (0.0020in) 0.071mm (0.0028in) 10.5kg (23.2lbs)
MCA II 3600 M7 3.6m (12ft) 0.070mm (0.0028in) 0.100mm (0.0040in) 10.9kg (24.1lbs)

MCA II 6-axis Metrology-grade Model Size SPAT 1 Vol length accuracy 2 Weight
MCA II 1800 M6 1.8m (6ft) 0.016mm (0.0006in) 0.023mm (0.0009in) 9.1kg (20.0lbs)
MCA II 2400 M6 2.4m (8ft) 0.020mm (0.0008in) 0.029mm (0.0011in) 9.5kg (21.0lbs)
MCA II 2800 M6 2.8m (9ft) 0.029mm (0.0011in) 0.041mm (0.0016in) 9.8kg (21.6lbs)
MCA II 3000 M6 3.0m (10ft) 0.034mm (0.0013in) 0.050mm (0.0020in) 9.9kg (21.9lbs)
MCA II 3600 M6 3.6m (12ft) 0.050mm (0.0020in) 0.068mm (0.0027in) 10.3kg (22.8lbs)

MCA II 6-axis Metrology Plus-grade Model Size SPAT 1 Vol length accuracy 2 Weight
MCA II 2400 MP6 2.4m (8ft) 0.017mm (0.0007in) 0.025mm (0.0010in) 9.5kg (21.0lbs)
MCA II 3600 MP6 3.6m (12ft) 0.043mm (0.0017in) 0.058mm (0.0023in) 10.3kg (22.8lbs)

(1) Point repeatability Test (also known as Single Point Articulation Test, or S.P.A.T.): results anal yzed via range/2 method. The probe is placed within a trihedral seat or conical socket, and individual points are measured from multiple approach angles with maximum articula tion of all of the principal joints. Each individua l point measurement is analyzed as a range of deviations ab out the average value for the point locations. This test is to assess the arm’s ability to provide sim ilar values of a point co-ordinate when the arm is articulated throu gh the maximum possible range of motion for that si ngle point. Accuracies are certified according to A SME B89.4.22 standard.

(2) Volumetric Length Accuracy Test (Volumetric Per formance Test): results analyzed via range/2 method . Volumetric Length Accuracy is determined by using certifed length standards (included with all arms) that are measured at various locations and orientations thro ughout the measuring volume. This test most accurat ely represents the reasonable expectations for machine performance in practical measuring applications. The Volumetri c Length Accuracy Test is the most appropriate test for determining machine accuracy and repeatability sinc e it involves measuring a certifed length standard many times in several locations and orientations an d compares the resultant measurements to the actual length. Accura cies are certified according to ASME B89.4.22 stand ard.



### General specifications Operating temperature: 0° to 46°C (32° to 115°F) Humidity: 5% - 95% non-condensing Vibration (55 to 2000Hz): less than 100ms/s2 (EN 60 068-2-6) Shock & Impact (6ms): less than 1000ms/s2 (EN 60 068-2-27) Permissible angular acceleration: 105rads/s2 Power requirement: Universal worldwide voltage 110-240V, Li-ION 7.2V battery (included) Connection to PC: USB / Wireless Ethernet Communication (IEEE802.11b /g 54Mbps) Certification: CE compliant

### Appendix C: MMD Laser Scanner Product Data Sheets

### PRODUCT DESCRIPTION The ModelMaker D is the sixth generation of laser scanner from Metris, featuring "True Digital Camera Technology", which is a leap forward in 3D laser scanning technology and includes several groundbreaking innovations that have never previously been available on any laser scanner. The ModelMaker D is the premium hand-held scanning solution from Metris.



### KEY FEATURES

 Ultimate productivity



###  No interface box for maximum portability & simple setup



###  Total thermal stability – no warming time



###  Twin pod design



###  Integrated to the latest Metris, Faro and Cimcore articulated arms. Integrated to the Metris K-scan.



###  Choice of 3 stripe widths (50 mm ,100 mm, 200 mm)



###  Scanning rate up to 80 stripes/sec.



###  Variable data collection, optimise for speed or resolution



###  Manual stripe selection 100/200mm (D200 sensor)



###  Arm controlled menu operation



###  Real time visualization of scanned data



###  Laser spot for stand-off indication



###  Lap-top compatible



###  Enhanced Sensor Performance (ESP2) for the ultimate in improved scanning of non-ideal surfaces (dark or shiny)



### APPLICATIONS In general the ModelMaker D is designed for the scanning of freeform surfaces of component s ranging from approximately 10cm up to 4meters in the sub 100micron accuracy range. Feature capture capability is also possible. Application segmentation:



###  Inspection – any application where the objective is to check or verify the dimensional info rmation of the component being scanned against a reference 

### O Surface inspection 

### O Section inspection 

### O Feature inspection



###  Reverse Engineering – any application where the objective is the re-create the precise 3D data of the physical part for a further process 

### O Manufacture 

### O CFD, FEA 

### O Visualisation 

### O Digital archiving



### TECHNICAL SPECIFICATIONS
D50 D100 D200 Sensor weight (g) 395 Range Z (mm) 50 100 150 Max stripe length Y (mm) 50 100 200 Min point spacing Y (mm) 0.05 0.075 0.100 Stand-off distance (1) (mm) 100 100 55 Max stripes / second 80 Max points / stripe 1000 Laser power Class 2M Sensor dimensions (mm) 179.5 x 75 x 137.5 (1) Stand-off distance is calculated fr om the sensor to the beginning of the Field of View

TYPICAL SYSTEM ACCURACY (1)

System Flat plane measurement (2) (2 sigma – 95%) Plane to plane measurement (3) (3 sigma – 99.5%) D50 0.030 0.050 D100 0.050 0.075 D200 0.100 0.100

(1) Typical result based upon sensor mounted on FARO Platinum 08-05 or Cimcore 3028i localiser scanning matt white surface (2) Using Certified scanning setti ngs and Flat Plane measurement (3) Using Certified scanning settings and Plane to Plane measurement MMZ figures are based upon 'Merged' data

ENVIRONMENTAL CONDITIONS

Operating temperature (ambient) 0oC to +50 oC Storage temperature -20oC to +80 oC Relative humidity 80% maximum (non condensing) 

# ModelMaker D

DATA SHEET V1.6 25 OCTOBER 2007DS-MMD-1007 SYSTEM DIAGRAM

PC SPECIFICATIONS The recommended PC specifications for an MMD scanner are:

- CPU: Intel Core Duo 2.0 GHz or higher

- Video Card:
o NVidia: GeForce with 256 Mb RAM, or
o ATI: Radeon with 256 Mb RAM

- 20GB Hard disk

- Dedicated Ethernet connection

- 3 x USB port

- 2048MB RAM

- CD-ROM drive

- Windows XP Professional

- Internet Explorer 6.0 or later Non Metris PC’s require an onsite installation.

LOCALISER COMPATIBILITY

MMD

Metris articulated arms Metris MCA 6 and 7 axis (1,8m) D Metris MCA 6 and 7 axis (2,4m) D Metris MCA 6 and 7 axis (3,0m) D Metris MCA 6 and 7 axis (4,0m) D Metris MCA 6 and 7 axis (5,0m) D Metris Optical CMMs Metris K-Scan on K500 D Metris K-Scan on K600 D Metris K-Scan on K610 D 3 rd Party articulated arms Faro Platinum/Titanium 7axis 6ft (1.8m) D Faro Platinum/Titanium 7axis 8ft (2.4m) D Faro Platinum/Titanium 7axis 10ft (3.0m) D Faro Platinum/Titanium 7axis 12ft (3.7m) D Romer-Cimcore Infinite 7axis 2.4m D Romer-Cimcore Infinite 7axis 2.8m D Romer-Cimcore Infinite 7axis 3.0m D Romer-Cimcore Infinite 7axis 3.6m D 

### SYSTEM INCLUDES

 Sensor (either D50, D100, D200)



###  Power supply



###  Alignment cube with 6mm probe calibration piece



###  Alignment cube extension (two-piece)



###  Surface mount datum cones (24)



###  Heavy duty carry case with protective foam insert



### MANDATORY ITEMS

 Arm interface for Metris MCA, Faro, Cimcore or K-scan (trigger cable and arm mount)



###  KUBE Scan software: User friendly data capture with ESP2 tracking of scan surface and automated optimisation of sensor settings for each individual point, real-time rendered scan visualisation, arm driven scan menu, online point processing, play and record macro’s, support for multi-site measurements.



### OPTIONAL ITEMS

 KUBE Tools+ Tactile measurements, advan ced datuming & coordinate system creation and transformati on, data set registration, advanced online and offline point processing, mesh creation, mesh tools and cross sectioning.



###  KUBE Inspect+ Import of CAD (IGES), surface, section and tactile to CAD inspection, online inspection, feature measurement and dimensioning, colour plot report generation with fly-outs.



###  KUBE Inspect+ CAD importers for 

### O VDA 

### O STEP 

### O ProEngineer 

### O CATIA V4 

### O CATIA V5



###  Battery and charger kit



###  Numbered floor mount datum cones (24)



###  Metris offers competitive pricing on twin or triple MMD laser scanner packages. MMD system diagram

Lap t op Laptop Bulky Interface Box

Scanner & Arm Data & Power 

### ~

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