Laser tracked from stem to stern

The recent purchase of two complementary, laser-based technologies from FARO UK has enabled renowned superyacht builder, Sunseeker to significantly reduce its build times and further develop the company’s quality standards.

Poole, Dorset-based Sunseeker’s composite development manager, Stuart Jones, was aware of the advantages FARO’s laser-based technologies deliver and was confident that FARO products could provide improved levels of speed and precision throughout all stages of each boat’s build. A successful on-site demonstration of a FARO Laser Tracker and a FARO Laser Projection System validated his opinion.

Put through their paces, the FARO equipment proved its accuracy and speed of use. As the demonstration verified the FARO systems’ ability to considerably reduce boat build times, a rapid return on investment was calculated and an order placed for a FARO Vantage^E Laser Tracker, four FARO Tracer^M Laser Projectors and FARO’s CAM2 software. Now in use across a variety of tasks, as anticipated Sunseeker’s advanced new FARO products are making a major contribution to the precision and efficiency of its boat building activities.

“Having previously utilised conventional, time-consuming means of measurement and inspection, we’ve made a quantum leap by using our advanced new FARO Vantage Laser Tracker,” says Jones. “We’re now able to rapidly and accurately capture the 3D base geometry of, for example our superyacht hulls and our large composite components and ensure they adhere to the designs generated with the help of our in-house design and manufacturing software. Once obtained, this data is used by our four new FARO Laser Projectors to project a variety of key datums, templates and location positions onto our hulls, allowing the precise fitting of key components during build.

“Having successfully applied it to capturing the base geometry of hulls and large composite components, the ease of use, accuracy and flexibility of our FARO Vantage Laser Tracker, meant that within days of its delivery, we discovered a multitude of other uses for it. We found we could use it to accurately compare other key components against their original software models. Also, because of its relatively low weight, portability and robust construction, we’re able to bring our FARO Vantage Laser Tracker to our suppliers to assist in problem identification and take the relevant measures.

“As many of our parts have extremely tight tolerances, our tracker routines allow us to accurately detect and quantify any deflection or change in the geometrical shape of components that could cause later assembly issues. The use of the precise data gathered by our Vantage Laser Tracker means we’re able to take early corrective actions and avoid more problematic issues later in the build process.”

The advantage of precision

Ideal for large-scale 3D measurement applications, FARO’s Vantage is a high-performance laser tracker that enables users to maximise productivity and reduce inspection cycle times by 50% to 75%.

Compact, portable and robust, the FARO Vantage offers an array of class-leading features, including ActiveSeek technology that allows the laser trackers to find and follow the target, even after the user passes behind obstructions. In addition, what’s said to be the widest field of view in the industry gives the user complete freedom to move throughout a large measurement envelope.

FARO’s sixth generation integrated Absolute Distance Measurement System (iADM) ensures exceptional accuracy, whilst a data output rate of 1,000 points/second, means the Vantage provides feedback for high-speed motion control and high-density scanning making it ideal for automated applications.

The Vantage S and E series Laser Trackers are the only portable CMM machines that measures angle and distances with a single, Class 1 (eye-safe) laser. Whilst measurement reliability is improved as errors and drift associated with two-beam tracker technology are eliminated.

Jones explains Sunseeker’s purchase and use of the company’s four new FARO Tracer^M Laser Projectors: “Having identified several key potential applications for FARO’s Tracer^M, an impressive practical demonstration of the laser projection system operating in these areas proved its precision and speed capabilities.

“We now use our Tracer^M Laser Projectors to project precise, virtual templates that enable datums to be marked. This process allows the accurate location of components, such as bulkheads, longitudinal elements, stringers and engine beds. The benefits the FARO projections are that we’re able to quickly and accurately complete the ‘right-first-tine’ positioning of these important features in all three dimensions.

“The installation of wire-looms located on our deck liners is a typical example of the time-savings we’ve achieved. Previously two people would have manually marked out the cable routes with a tape measure and marker pens, returning later to then fit the looms in-situ. Now, our Tracer^M’s projects our wire-loom design model onto the deck liner surface and the cable mounts and looms are then fitted in one rapid, accurate procedure. The fitting of our liners, which had previously been a bottleneck in the build, were subsequently reduced by two days. Added to this, the use of our laser projectors has been instrumental in avoiding problems, such as cable pinching during final assembly.”

Projections of accuracy

FARO launched the Tracer^M laser projection system with the intentions of removing the need for physical templates, increasing users’ precision capabilities, eliminating the risk of human errors and reducing the delays associated with the alignment and assembly of large components.

FARO’s Tracer^M uses customers’ existing 3D CAD models to projects a 0.5mm wide laser line onto a 2D or 3D target surface or object, creating an accurate virtual template that enables fast, accurate positioning of components with absolute confidence. Users can rapidly create virtual and collaborative 3D templates that help streamline assembly and production applications, improve productivity and enhance quality functions.

The system features precise, variable and long-range projection capabilities that cover an envelope of up to 15.2 x 15.2m. For larger assemblies and space-constrained areas, multiple Tracer^M projectors can be controlled from a single workstation to provide large-scale virtual templates within a single coordinate system. Advanced Trajectory Control (ATC) is use by the Tracer^M to deliver fast projections. ATC provides superior dynamic accuracy and a rapid refresh rate which minimises flicker.

The Tracer^M uses BuildIT Projector, an easy to use, intuitive software solution that is able to be operated by both knowledgeable or less inexperienced staff. BuildIT Projector can import native CAD from all major formats. The software’s capabilities cover the creation of the projections together with the configuration and operation of the projectors and their alignment features.

Sunseeker’s manufacturing engineering manager, Steve Efford concludes: “Our association with FARO has been extremely productive. Not only have we been very impressed with the efficiency and precision gains through the use of FARO’s technology, we’ve also been impressed with the levels of service we’ve received from their staff. We’ve quickly become proficient in our new FARO equipment’s use. FARO helped us quickly develop a range of manufacturing methodologies that have improved our precision capabilities and also reduced our build times. By using FARO’s large range scanner, we can capture data from boat moulds or hulls and have a full colour map of points all in under an hour.

“Every application we’ve used our new FARO equipment on has sparked new thoughts for additional tracking and projecting opportunities. To further exploit the potential of our new FARO equipment we are already working on several future projects.”

www.faro.com