Geometry Under Load: Measuring Right at the Test Bench with the KEYENCE XM-5000

Since 2014, deineMaschine GmbH has developed highly specialized test benches for components that must be tested under real operating conditions, with a focus on extreme temperatures, pressures and rotational speeds. Customers from demanding sectors such as aerospace, mechanical engineering, energy technology and the automotive industry rely on the precision and reliability of these systems. The company is especially valued for its ability to develop individual test benches tailored exactly to specific requirements.

Before adopting the XM-5000, deineMaschine worked with a range of measurement methods: hand measuring tools, external service providers, and the predecessor model of the XM Series. Measurement therefore ran alongside the actual test workflow — with additional effort for re-clamping and transport.

Upgrading to the XM-5000 Handheld Probe Coordinate Measuring Machine made it possible to integrate the measurement process into the ongoing test workflow. Today, measurement takes place directly at the test bench, often immediately after the test cycle. The time spent re-clamping and transporting parts is eliminated. An added advantage: operation is through an intuitive interface, so technically skilled employees without a metrology qualification can also carry out reliable 3D measurements.

"It was important for us that the measurement simply works — without lengthy training or specialist knowledge."

— Benedikt Fröhlich, Sales Director

In deineMaschine's day-to-day development, geometry measurement follows a clear four-step sequence around the load test:

• Before the test: A component, such as an impeller, is measured in its initial state. Cylinder forms, coaxialities, roundness, flatness, symmetries and reference points are captured and documented.
• Loading in the test bench: The component is subjected to high loads — rotation at over 30,000 rpm, heat, pressure and vibration. These tests simulate the real operating conditions.
• After the test: The second measurement takes place after the test cycle. The XM-5000 now reveals deviations, for example minimal deformations, positional shifts or symmetry breaks. The results are shown in color and compared against the defined tolerances.
• Analysis & conclusions: The data flows directly back into quality evaluation and design. Especially for customers in aerospace and energy technology, such data is indispensable for material and process decisions.

Introducing the XM-5000 did not just replace existing measurement processes — it raised them to a new level, technologically and economically. The biggest improvements show up in these areas:

• Integration into existing processes: Measurement happens right where the action is. Separate measuring rooms or transfers are no longer required. This saves time, reduces complexity and increases transparency.
• Real-time target-actual comparison with a color map: Deviations between expected and measured geometry are visualized directly in the software — for immediate evaluation after the measurement.
• Fully digital data flow: All results are stored, documented and available for evaluation. This simplifies traceability and supports quality assurance.
• Scalable and future-proof: The system can also be used in other parts of the business. Mobility and easy integration make the XM-5000 a viable standard solution for geometry-related measurement tasks.
• Temperature resistance: The XM-5000 delivers reliable results even with fluctuating ambient temperatures — a major advantage in a dynamic test environment where high thermal loads can occur.
• Intuitive operating interface: The system is quick to learn. Even without special metrology training, reproducible results can be achieved — providing flexibility in daily operations.

Since introducing the XM-5000, deineMaschine has been able to standardize and accelerate the entire measurement process. Components no longer need to be moved or elaborately prepared. The data is available faster and can be interpreted unambiguously. Design, test engineers and customers all receive the same data basis in consistent quality.

The decision for this measurement system was not only technical but also strategic. Being able to bring testing and measurement together in time and space significantly increases flexibility in everyday development. Thanks to the digital documentation, series comparisons, long-term trends or recurring inspections can also be represented efficiently.

The XM-5000 has cleared the way at deineMaschine for integrated, fast and reliable geometry measurement under real conditions. The system delivers reproducible data right where it is needed: immediately after the load test. The combination of easy handling, technical precision and digital evaluability makes the system a fixed component of the entire test process.

"With the XM-5000 we can now measure components directly after the test run. It saves time and gives us reliable data exactly where we need it."

— Benedikt Fröhlich, Sales Director