Stepper, one of the technological leaders in the stamping sector, is known worldwide for its modular tool construction, producing up to several billion connector parts per year. For quality control, the tooling expert has relied on Alicona for many years. Stepper continues to develop its production automation with Alicona measurement systems in use 24/7.
When a tool is used to simultaneously manufacture seven connector contacts at 2,300 strokes per minute, 16,100 of these contacts are produced every minute. For Marcel Heisler, Head of Laser Ablation and High-Speed Cutting at Stepper, there's one thing above all that's essential to keep up with this output: " We have to measure, measure, measure, measure! "The demands of its customers, who mainly come from the automotive sector, are high. " The automotive industry has always demanded maximum precision and productivity. "says Heisler. This has to coincide with tool life, because only tools that are exceptional in terms of material, surface quality and precision can manufacture the demanding geometries of microcomponents with consistently high and repeatable accuracy. Marcel Heisler sums it up in a few words: " A tool only pays off when it works! "To ensure the quality of its cutting and bending dies, Stepper has relied on Alicona quality control for many years.
3D measurement technology for final inspection and development of high-performance cutting tools
" We use Alicona for continuous quality control of manufactured parts, as well as for tool development in terms of materials, surface quality and precision. This is only possible with absolutely reliable measurement results. "explains German tool manufacturer Fritz Stepper GmbH. Since 2010, the manufacturer of high-performance cutting tools has been relying on Alicona's Focal Variation measurement systems. " Before using Alicona, we had enormous difficulty measuring steep sides, smooth surfaces and tools with reflectivity variations. The knowledge we've gained with Alicona since the outset has taken us an incredible step forward "adds Heisler. Repeatable, connected measurement of even complex, curved surfaces is one of the reasons why Stepper has invested in a third Alicona system. The investment is also justified by the wide range of applications that can be measured on a single measuring system. Stepper checks both dimensional tolerances and surface quality by measuring the roughness of parts of different types, shapes and sizes. His conclusion: " We know of no other system that offers such a wide range of applications. We can measure anything! "
Automation from design to measurement technology
Precision and innovation are requirements that Stepper and Alicona have in common. Both companies are regarded as pioneers and driving forces in their industries, and they are proving it once again. Stepper organizes its production according to the latest technologies and production concepts. Digitization, networking and optimized communication of all production systems are becoming increasingly important. Part of a modern production strategy is also to consider measurement technology as an integral part of production, and to position it accordingly. Measurement technology is not only used at the end of a production line, but also as part of the production process. For this, it is essential to have fully automated measuring systems that can be used without any prior knowledge of metrology. Alicona offers this automation with the AutomationManager software interface. It enables user-specific configuration of measurement series by an administrator on a reference part, which is started by a production operator at the touch of a button. Acquisition and evaluation are fully automatic, and the programmed parameters are measured without any user influence. Stepper is in the process of introducing the AutomationManager software module into its production. " The measurement of parts in each new production batch does not need to be programmed; measurements are programmed once and for all on a reference part, and each additional part is then automatically checked. "Heisler explains. " This will multiply our efficiency gains ".
When it comes to increasing efficiency through automation, Stepper has further plans with Alicona. The optional connection of the automation software to an existing CAD-CAM program makes it possible to integrate measurement technology as early as the design phase, by defining series of measurements in the CAD dataset of a part. This simulation provides an overview of the measurement process to be carried out, enabling reliable measurement planning. The Alicona measurement system's functional simulation covers the entire handling process, from part positioning to the determination of the 3D measurement range. For Stepper, the benefits are obvious: " We expect to save a considerable amount of time. Thanks to the CAD-CAM connection, I no longer need the measuring system to learn my measurement series, which can be transferred to another workstation. This means we'll be able to use the measuring device 24 hours a day, 7 days a week, without interrupting production, and use it to its full potential. ".
With the implementation of measurement technology in production and design, Stepper continues its strategy of integrating the best technologies into its products with the most appropriate partners. Marcel Heisler confirms: " As a high-tech company, we're looking for partners who share our passion for precision. That's what we've found in Alicona! ".
Learn more: www.alicona.com