For manufacturers of large and complex components, precision is not simply a quality objective : it is a decisive factor in customer confidence and business success. As component dimensions increase and geometries become more sophisticated, particularly in demanding applications such as power generation and gas turbines, manufacturers must ensure that every critical dimension, position and tolerance is verified accurately and efficiently.
C.P.S. Fisciano, which specialises in the production of components for power generation among other applications, has made quality an integral part of its manufacturing philosophy since its foundation. As customer expectations continue to rise, the company recognises that reliable measurement data and complete documentation of tight tolerances are essential to guaranteeing product quality.
To meet these demands, C.P.S. has invested in advanced quality control capabilities and selected ZEISS as its metrology partner. Two coordinate measuring machines from the ZEISS MMZ family are used to assure the quality of large components, providing the measuring volume and payload capacity required for heavy and complex workpieces.
The Challenge: Precision on a Large Scale
Producing large components presents a unique metrology challenge. Components used in power generation can be extremely large and heavy, while their geometries can contain complex structures and demanding dimensional and positional requirements.
For C.P.S., the challenge is not only to manufacture these components accurately but also to measure dimensional and positional parameters within short inspection times.
The increasing complexity of parts, combined with increasingly stringent customer requirements, means that measurement data has become a critical element of the manufacturing process.
Customers expect the highest quality standards, together with reliable documentation demonstrating compliance with tight tolerances.
This makes conventional inspection approaches insufficient for many applications. C.P.S. needed a metrology solution capable of performing high precision, close to production inspection of complex, large volume components, while also providing flexibility for future requirements.
In the C.P.S. measuring room, dimensional and positional parameters on power generation components, for example, have to be recorded in a short time. In addition, tighest tolerances must be adhered to when manufacturing complex, large volume, and usually heavy objects. This is why ZEISS systems were chosen. The metrology met all the requirements for high precision, close to production inspection of complex structures, and was also designed to meet the requirements for continuity and support for future growth.
Multi Sensor Capability for Complex Inspection Requirements
Large components often require different measurement technologies depending on the geometry and inspection requirement. For C.P.S., flexibility was therefore an important consideration when selecting its metrology systems.
The ZEISS multiapplication sensor technology (ZEISS MASS) enables different ZEISS sensors to be used on the same measuring machine. Sensors can be changed quickly when required, allowing the CMM to adapt to different inspection tasks.
The ZEISS VAST sensor technology provides additional flexibility, with sensor configurations ranging from standard and large probe systems to tilt and swivel units.
This is particularly valuable when inspecting complex structures containing difficult to reach measurement points.
By combining different sensor options with large measuring volumes, the ZEISS MMZ systems allow C.P.S. to achieve high accuracy while maintaining efficient detection times.
The result is a flexible metrology environment capable of handling the varied inspection requirements associated with large power generation components.
Complementing Tactile Inspection with Optical Measurement
C.P.S.’s quality strategy extends beyond coordinate measurement.
The company also uses ZEISS optical measurement technology to acquire full surface 3D measurement data. This provides another layer of information that can be particularly useful during casting and pre machining stages.
The tactile and optical measurement technologies therefore complement each other.
While the ZEISS coordinate measuring machines provide high precision dimensional and positional inspection, optical systems can capture comprehensive three dimensional information across the component surface.
Together, these technologies give C.P.S. a broader view of component quality across different manufacturing stages.
As Antonio Olivieri, Sales & Operation Manager, C.P.S., explains:
“Our primary goal is to reliably supply our customers with top quality products. That is why we have invested heavily in quality control systems and rely on the ZEISS portfolio for both 2D and 3D inspection.”
This philosophy highlights the company’s commitment to making quality assurance an integral part of its manufacturing operation.
ZEISS CALYPSO: Turning Measurement Data into Quality Insights
The hardware is complemented by ZEISS CALYPSO metrology software, which helps C.P.S. maximise the capabilities of its coordinate measuring machines.
The software analyses measurement data acquired through tactile and optical measurement and enables users to measure geometrical elements efficiently.
Inspection plans can be programmed by selecting the desired features, simplifying the preparation of measurement tasks.
CALYPSO also provides functions for recording components and analysing measurement results, supporting users throughout and after the measurement process.
For a manufacturer working with complex and high value components, this ability to systematically capture and analyse measurement information is essential.
Reliable data provides the basis for demonstrating conformity, identifying deviations and maintaining consistent quality.
Quality Assurance Designed for Future Growth
For C.P.S., investing in metrology is not simply about addressing today’s inspection requirements. The company selected its ZEISS systems with continuity and future growth in mind.
The combination of large format CMMs, multi sensor technology, optical measurement and software provides a scalable quality assurance platform capable of supporting increasingly complex components.
This is particularly important in industries such as power generation, where component value is high and manufacturing tolerances can be demanding.
The ability to perform accurate inspection close to production can also support faster decision making and help manufacturers maintain greater control over their processes.
