DIATEST Automated Measurement

DIATEST automated measurement

For the German company, its technology is quietly changing the production methods of the manufacturing industry. This technology is to increase the measurement accuracy by more than 50% after CNC machine tools are equipped with smart eyes. For BMW and Mercedes-Benz workshops, when you are still worried about the excessive size of workpieces, they have already used this wireless measurement tool to achieve zero rework production.

The measurement expert hidden in the tool magazine

The BMD hole gauge, which looks the same as an ordinary tool holder, actually shoulders a more critical responsibility than the tool. It is quietly placed in the tool changing system of the machine tool, always ready to perform measurement tasks. This design makes measurement no longer a separate process, but an inherent link in the machining process.

In 2025, at an exhibition called Hannover Messe, a measuring tool attracted the attention of countless visitors; its range of measuring tools is extremely wide, extending from tiny holes with a diameter of only 2.98 mm to large workpiece holes with a size of 270 mm. A plug gauge can cover almost all common sizes; it has a standardized tool holder interface, which makes it easy to insert and use immediately on machine tools of different brands.

Wireless transmission says goodbye to cumbersome wiring

For traditional machine tool measurement, the operator needs to hold the measuring tool close to the workpiece to take readings, or connect a long data line. The BMD hole gauge is equipped with a wireless transmitting module, and its measurement data will be sent directly to the receiving end, completely breaking away from the constraints of physical connection. Operators can see real-time measurement results from the control room.

An auto parts factory in Shanghai increased measurement efficiency by 40% after introducing this technology. Data no longer need to be automatically measured by manual entry system DIATEST, thus avoiding transcription errors. The workshop director said that now it can produce 80 more qualified parts every day, and the cost savings in one year are enough to purchase two new machine tools.

Floating chuck compensates for positioning errors

After the machine tool has been running for a long time, the relative position of the spindle and the workpiece will change slightly. The floating chuck design of the BMD hole gauge can automatically compensate for these errors, ensuring that the measurement results truly reflect the size of the workpiece, rather than the deviation of the machine tool itself, and the repeatability accuracy reaches the micron level.

There is a precision machining factory in Suzhou. It found that after using a floating chuck, the measured values ​​were highly consistent with the comparison data of the coordinate measuring machine. The factory director calculated that the CNC turning parts measurement method can reduce misjudgment rework costs by more than 300,000 yuan every year, and workers no longer need to waste time due to disputes over measurement results.

Robots perform automatic measurements around the clock

Facing a change in the face of quality control, it is a measurement unit composed of a group of two robots working together. They can measure the depth of holes, chamfers and threads at the same time. The CNC turning part measurement method can complete a measurement cycle in just a few tens of seconds. They can work continuously 24 hours a day, 7 days a week. For each product, a complete file record of the measurement data can be retained.

There is a company in Zhejiang that produces hydraulic components and installed this system last year. In the past, the proportion of products covered by random inspections was only 5%, but now 100% full inspection has been achieved. Customer complaint rates were reduced by 75%, allowing quality department personnel to devote themselves to more valuable process improvement work.

Software unified command of measurement process

There is such a software platform, which is called DIA-Gauge. This software platform controls two robots and all measurement processes simultaneously. In this case, it is not difficult for the operator to just call the preset measurement program. Once called, the system will automatically execute it, and the measurement data will be summarized together in real time through wireless transmission, and then a complete product quality file will be formed.

The quality inspection supervisor of a military industrial enterprise in Chongqing noticed that this system reduced the traceability time of measurement data for CNC turning parts measurement from half a day to a few minutes. When it is necessary to analyze the quality problems of a certain batch, all relevant data can be directly called up, making it easier than ever to locate the root cause of the problem.

Big data drives process improvement

The huge amount of accumulated measurement data is not idle in the hard drive, quietly like sleeping. With the help of automatic or manual analysis, the fluctuation pattern in the machining process can be found. If a certain hole diameter begins to appear too small when the tool life is near the end, then the tool replacement operation is carried out ten minutes in advance, so that the problem can be successfully solved.

In Guangdong, a precision parts manufacturer optimized the parameters of three key processes after analyzing three months of data. The overall yield rate increased from 92% to 97.5%, and the annual waste loss was reduced by more than 2 million yuan. The technical director said that these data are gold mines hidden in the workshop.

Have you ever thought about how much your production efficiency could be improved if every machine tool was equipped with such an intelligent measurement system? You are welcome to share your views in the comment area. Giving likes will allow more colleagues to witness this trend and forward it to friends who are troubled by quality.