Precision measurement is the core link of quality control in modern industrial production, directly determining the product
qualification rate, production efficiency and enterprise competitiveness. The significance of precision measurement is
reflected in multiple dimensions such as quality assurance, cost control, technological progress and safety guarantee.
In the aerospace field, the measurement accuracy requirement reaches the micron level, and a deviation of 0.001mm
may lead to losses of millions.
I. The fundamental guarantee of product quality assurance
Dimension accuracy control is the basic requirement for product quality.
1. In mechanical processing, the diameter tolerance of shaft parts is IT6-IT9 level, corresponding to a deviation of
0.009-0.052mm; the tolerance of hole parts is IT7-IT10 level, with a deviation of 0.015-0.084mm.
2. Precision measuring equipment such as digital calipers has an accuracy of 0.01mm, micrometers have an accuracy
of 0.001mm, dial indicators have an accuracy of 0.001mm, and three-coordinate measuring machines have an accuracy
of up to 0.0005mm.
3. For electronic products, the measurement accuracy of PCB board hole diameters requires ±0.025mm, and the
assembly gap of mobile phone shells is controlled within 0.1-0.2mm. For optical components such as lens lenses,
the thickness tolerance is ±0.01mm, and the curvature radius accuracy is 0.1%. The accuracy of dimension measurement
directly affects the assembly performance of parts, and the accumulation of tolerance chains may lead to product
functional failure.
Shape and position accuracy measurement ensures the functional performance of the product.
Flatness measurement controls the quality of the sealing surface, with an accuracy requirement of
0.005 - 0.05mm; Roundness measurement guarantees the accuracy of the bearing raceway, requiring an accuracy
of 0.0005 - 0.002mm; Axiality measurement ensures the smooth operation of the transmission shaft system, with an
accuracy of 0.01 - 0.1mm; Verticality measurement ensures the accuracy of the assembly reference, with a requirement
of 0.02 - 0.2mm.
Gear tooth profile deviation measurement has an accuracy of ±0.005mm, affecting the transmission noise
and efficiency. Thread minor diameter measurement has an accuracy of ±0.002mm, determining the strength of the
threaded connection. Deviation in shape and position tolerances can cause problems such as loose fit, increased
vibration, and accelerated wear, seriously affecting the reliability of the product.
Surface quality inspection is crucial for product appearance and performance.
The measurement range of surface roughness is from Ra0.005 to 80 μm. For aircraft engine blades, the Ra value
is 0.1 - 0.4 μm; for the inner walls of car cylinder liners, it is 0.1 - 0.8 μm; for precision optical components, it is
0.005-0.05μm. Surface defect detection includes cracks, pores, scratches, and depressions, with detection accuracy
at the micrometer level. The measurement accuracy of coating thickness is ±1 μm, which affects the anti-corrosion
performance and appearance quality. Surface quality control is achieved through precise measurement, directly relating
to product lifespan and user satisfaction. Advanced technologies such as laser interferometry and white light
interferometry enable nanometer-level surface topography detection.
II. Technical Support for Improving Production Efficiency
1. Online measurement system enables real-time monitoring of the production process. The accuracy of the
on-machine online measurement probe is ±0.001mm, and the measurement time is 2-10 seconds. It automatically
compensates for processing errors, increasing processing accuracy by 50%-80%. The integrated measurement
system of the automated production line synchronizes the detection cycle with the production cycle, and the
measurement efficiency is increased by 3-5 times. The laser measurement system performs non-contact detection,
which is suitable for soft materials and high-temperature workpieces. The measurement accuracy is ±0.01mm,
and the detection speed is several thousand points per second. Real-time measurement feedback enables closed-loop
control, reducing the scrap rate by 60%-90% and increasing equipment utilization by 15%-25%.
2. Automated measurement equipment reduces labor costs. The three-coordinate measuring machine is equipped
with an automatic head-changing system, which can operate without human intervention for 8 to 24 hours. The
measurement efficiency is 3 to 8 times that of manual measurement. The visual measurement system uses image
recognition technology to detect hundreds of pieces per minute with an accuracy of ±0.005mm, making it suitable for
mass production. The laser scanning measurement equipment acquires millions of measurement points to complete the
detection of complex surfaces, reducing the measurement time by 80% to 95%.
Automation measurement reduces human errors, improves measurement consistency, and lowers detection costs by
30% to 50%. The robot integrated measurement system enables flexible inspection and is suitable for multi-variety
and small-batch production.
3. Analyze data to optimize production process parameters. SPC statistical process control collects measurement
data, analyzes the process capability indices Cp and Cpk, and guides process improvement. The measurement data
is uploaded in real time to the MES system, establishing a quality product archive and enabling quality traceability.
Big data analysis identifies quality trends, predicts equipment maintenance needs, and reduces failure rates by
20%-40%. The value of measurement data is mined through artificial intelligence algorithms, optimizing processing
parameters and increasing product qualification rates by 5%-15%. Cloud measurement data services provide functions
such as benchmark comparison, uncertainty assessment, and calibration reminders.
The significance of precise measurement is becoming increasingly prominent in modern industrial production
and has become an important component of an enterprise's core competitiveness. Starting from the fundamental
need for product quality assurance, precise measurement ensures that product dimensions, shape and position
accuracy, and surface quality meet design requirements, directly affecting product functionality, performance,
and user satisfaction.
In terms of production efficiency improvement, online measurement systems, automated measurement equipment,
and data analysis optimization significantly enhance production efficiency and reduce labor costs. Cost control
and economic efficiency optimization are achieved through measures such as waste rate control, equipment
utilization improvement, and customer satisfaction enhancement, with an investment return rate typically
ranging from 500% to 1500%.
Technological innovation and industrial upgrading cannot be separated from the support of precise measurement,
and new product development, process improvement, and intelligent manufacturing transformation all rely on
high-precision measurement data. Safety guarantees and risk management require precise measurement
to provide reliable assurance, especially in critical fields such as aerospace, automotive, and medical.
As the manufacturing industry moves towards high-end development, precise measurement technology
is also constantly advancing, with new technologies such as nanoscale measurement, multi-sensor fusion,
and artificial intelligence applications constantly emerging. Enterprises should establish a precise measurement
system suitable for their stage of development, gradually enhance measurement capabilities, and achieve a dual
improvement in quality and efficiency. In the future, precise measurement will become more intelligent, networked,
and standardized, and become an important infrastructure for intelligent manufacturing.
