“As I have said before the world is expanding and becoming even more connected. New markets are opening and environmental pressure is being put on governments and multi-national companies. As a result, it is changing the way components and products are manufactured. There is no place to hide and lack of knowledge is not taken lightly, especially when there are many tools that are now available that will aid companies in their manufacturing processes,” said George Sansoni of Apex Metrology Solutions.
“Almost everyone is aware of the electric vehicle (EV) revolution in the automotive industry. The switch from diesel and petrol engines to electric power is constantly in the news, and despite some obstacles to widespread adoption, the clock is ticking to a total switch by 2035,” continued Sansoni.
“Metrology and quality are now an integral part of an organisation and provide opportunities for sales, training, implementation, support and professional services as well as product development in the manufacturing space.”
This is an example of a 40-year-old Ferranti CMM before it was upgraded with new technology
“CMM failures remain one of the most disruptive events, production halts and suddenly manufacturers face decisions that will impact operations for years to come. For decades, the available alternative, generally speaking, has been a full machine replacement. But recent advancements have re-shaped how the industry thinks about retrofit feasibility. Technological developments are creating new possibilities that challenge this traditional framework.”
Full machine replacement
“Modern CMMs offer advanced features, improved accuracy, and reliable performance for years to come. These machines come in various configurations, including touch probes, scanning probes, and optical laser scanners. But investing in a new CMM is a significant expenditure, facing weeks of downtime and requires calibration after installation. It is always worth questioning whether controller failure truly justifies replacing everything when your frame, part programmes, inspection software and operator knowledge are lost, unless you buy a new CMM from the same OEM, preserving CMM OEM exclusivity and captivity.”
OEM retrofit
“A retrofit performed by the original manufacturer benefit from deep machine knowledge and guaranteed software combability, but they remain structurally limited, as they maintain single-vendor dependency and captivity, tie users to specific software ecosystems, and typically require mandatory inspection software upgrades that adds a significant cost. Manufacturers should understand they’re entering a long-term relationship along with predetermined costs and limited flexibility.”
Retrofit with generic I++ communication protocol software
“The term “I++” in communication protocols primarily refers to the I++ DME (Dimensional Measuring Equipment) protocol, a standard used for unifying metrology software and coordinate measuring machines (CMMs). I++ DME is an open standard, managed by the I++ Working Group, and is widely adopted by some of the major metrology OEM companies.”
The 40-year-old Ferranti CMM upgraded by Apex Metrology Solutions with new technology. It is still able to measure to less than 0.010mm
“These retrofits offer some flexibility in software choices but require giving away the existing inspection software (e.g. PC-DMIS, Calypso, Mcosmos, PolyWorks ) and rewriting existing inspection programmes, which may require an enormous amount of time. The I++ communication protocol used by these controllers often limits or downgrades advanced inspection software functionality. Licenses for I++ client connections are typically required and can be expensive. In most cases, rewiring the machine is necessary, and a full CMM calibration must be performed afterward, turning the retrofit into a time-consuming and costly process.”
“The question for manufacturers is whether these trade-offs truly support long-term operational needs, or simply replace one set of limitations with another.”
The emerging alternative – Advanced plug and play controllers
“Advanced controller retrofits designed to maintain native connectivity with existing CMM hardware and full compatibility with established inspection software come with features and benefits.”
Key characteristics of this approach include native software compatibility, hardware-level integration, continuity of part programmes, reuse of existing error map, future-ready architecture for touch probes, scanning probes, optical probes, laser scanners and more and controllers that are built specifically around the philosophy of true native compatibility, zero rewiring, immediate programme continuity, reuse of existing calibration, and one-day CMM return to production.”
“From experience working with manufacturers and retrofitters worldwide, this category of retrofit has matured into a practical and reliable alternative.”
“As controller electronics age while mechanical structures continue to perform well, solutions that preserve compatibility while modernising capability make economic and operational sense.”
CMM retrofits a refurbishments adoption
“We at Apex Metrology Solutions have adopted this emerging alternative and returning CMMs to the quality floor that were about to be sent to the scrap dealer. We upgrade and modernise legacy coordinate measuring machines (CMMs) with advanced controls and software, extending equipment life and enhancing performance at a fraction of replacement costs.”
“For CMM owners seeking to preserve value, avoid downtime, and retain full control over their equipment choices, native-compatibility controllers provide a compelling path forward.”
“Founded with a deep understanding of industrial quality demands, Apex Metrology Solutions has evolved into a leading metrology service provider in South Africa. Our journey began in dimensional inspection and has expanded into a full-service offering, covering contract measurement, 3D scanning, reverse engineering, and CMM technologies,” concluded Sansoni.
For further details contact Apex Metrology Solutions on TEL: 064 073 5612 or visit https://www.apexmetsol-sa.co.za
