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Metris became a member of the Nikon group
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Formula 1 teams are a key reference when it comes to fast development and rigorous testing of new cars and prototypes. To keep pace with the continuous ambition to deliver faster and more reliable cars, F1 teams are relying on the latest technologies in various application domains. Also, in the field of dimensional measurement, F1 teams are adopting new technologies to win the race against time.
That’s why the new Spyker F1 Team* has started in 2006 an industrial sponsorship with Metris, the market leader for optical dimensional measurement solutions.
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James Key, Technical Director at Spyker explains: “It is a fairly simple equation. If we want to perform successfully at the races, we need the best metrology equipment support to enable us to outperform our competitors. We were particularly looking for a system that besides 3D point and laser scanning measurement, could also be used for dynamic measurements such as chassis stiffness or suspension compliance. Of course everything packaged in an easy to mount and portable configuration. The dynamic testing application is a very important element during the development of the car and, in particular, this application is where the Metris system provides an advantage compared to similar metrology-only solutions. The flexible multi-tasking capabilities, together with the top accuracy measurement technology, are the most important decision parameters for selecting Metris as a partner.”
The Metris Optical CMM
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The Metris Optical CMM uses a linear CCD-based camera that accurately detects infra-red moving LEDs in its 6 meter long measurement volume. A combination of these LEDs is mounted on a touch probe, the SpaceProbe, to uniquely define the exact location of the probe and its measuring tip. When the LEDs are used in combination with a Laser Scanner device, - the K-Scan - it can be used as a handheld laser scanner to digitise parts to obtain 3D pointclouds. An important advantage of the Optical CMM is the so-called dynamic referencing: When the measured object is equipped with LED’, it can change position during a measurement, since the changes are tracked by the camera and compensate the measurement data. |
Another application and as such differentiating from a classical measurement system, is to mount these LED’s on a car or component to measure its movement in space.
A myriad of measurement applicationsThe Metris Optical CMM covers many applications where F1 teams can benefit.
A first example is the FIA legality check, where the cars and bodywork are measured to verify compliance with the strict FIA regulations. This legality check is performed before and after every race in the FIA box to ensure that all competing cars are tuned within the regulations. Gauges are still used to quickly check wing positions. The rules have become more stringent though and more intelligent methods were needed to cope with it. Especially in the field of bodywork deformation under load (flexible wings) the system has proven its added-value.
The system also proves its value during wind tunnel tests that are performed to quantify and optimise the down force on the car and other aerodynamic capabilities. Setting the car up in a wind tunnel is a very precise challenge that traditionally can take several hours. The wheels aren’t attached to the car but need to be set-up within a millimetre to simulate the exact wind flow. As different car designs need to be tested, this set-up phase can lead to reduced efficiency of the expensive wind tunnel use. Using the Metris system the time to set the car model up can be downsized with a factor 4, so much more time can be dedicated to effective testing. Another wind tunnel application is the recording of changes applied to the car during wind tunnel optimisation. Often small manual adjustments are made to the car model and using the SpaceProbe, the user can measure and store the different set-ups for evaluation of the best circumstances.
Another important application is the 3D digitising of bodywork for inspection or reverse engineering. This scanning is performed using a handheld 3D scanner (K-Scan) and results in a pointcloud, i.e. a digital copy of the part. This 3D pointcloud can be used for comparison of the physical part against the CAD model, reverse engineering or rapid prototyping purposes. As such, design optimisations or actual changes to the bodywork can be fed back to the original CAD model.
Bringing motion in metrologyIn the race to produce ever stiffer and lighter composite structures, the Metris Optical CMM also proves its benefits. The cars are mounted on a multi-poster shaker rig where suspension and chassis are subject to the various race track profiles to test the dynamic behaviour, such as stiffness and compliance of chassis and suspension. Various LEDs (up to 256 3D positions are measured) are now attached to wheels or structure and tracked by the Optical CMM. As such, all motions are captured in 3D, enabling a detailed stiffness and modal analysis.
The same dynamic testing technique is also applied in static stiffness and compliance tests to nearly all individual components, such as rods, rockers, connectors, suspension parts. These tests are held to optimise their performance against weight. A typical test where the Metris system is used is the testing of kinematics and compliance (K&C testing) of the suspension. The suspension is fully compressed to analyse the behaviour of the chassis by tracking the LED’s that are mounted on the suspension and chassis.
ConclusionIt is a major benefit that so many measurement applications can be handled by a single system. The Metris system can also facilitate many other applications such as geometry definition for modal analysis, crash test analysis or CMM aid during build of cars. This not only is beneficial for the system cost, but also minimizes the investment in user training and system knowledge. Also, the fact that the Metris system is adopted by various other F1 teams, as well by the FIA, is a top reference.
* Midland F1 Racing was sold to Spyker Cars at the end of the 2006 Formula One World Championship. Metris equipment continues to play an essential role in the research and development of the team's chassis and drive train design during Spyker MF1 Racing’s assault on the 2007 Formula 1 World Championship.
Download: Spyker F1 Team & Metris: Partners in the Paddock (PDF file)
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