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UNIT-5 Advances in Metrology

Laser metrology tools like laser scan micrometers and laser interferometers provide advantages for precision measurement tasks. Computer-aided metrology uses coordinate measuring machines (CMMs) which have three axes and probes to accurately measure geometries. CMMs capture coordinate data that can be analyzed to evaluate features and dimensions in manufacturing. They provide flexibility, reduced setup times, improved accuracy, and greater productivity over traditional measurement methods.

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SURESH KUMAR AP
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428 views45 pages

UNIT-5 Advances in Metrology

Laser metrology tools like laser scan micrometers and laser interferometers provide advantages for precision measurement tasks. Computer-aided metrology uses coordinate measuring machines (CMMs) which have three axes and probes to accurately measure geometries. CMMs capture coordinate data that can be analyzed to evaluate features and dimensions in manufacturing. They provide flexibility, reduced setup times, improved accuracy, and greater productivity over traditional measurement methods.

Uploaded by

SURESH KUMAR AP
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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UNIT-5

ADVANCES IN METROLOGY

Lasers in metrology - Advantages of lasers – Laser scan micrometers; Laser interferometers –


Applications – Straightness, Alignment; Ball bar tests, Computer Aided Metrology - Basic
concept of CMM – Types of CMM – Constructional features – Probes – Accessories –
Software – Applications – Multi sensor CMMs.
Machine Vision - Basic concepts of Machine Vision System – Elements – Applications - On-
line and in-process monitoring in production - Computed tomography – White light Scanners.
PRECISION INSTRUMENTS BASED ON LASER

 Laser stands for “Light Amplification by Stimulated Emission of Radiation”. Laser


instruments are devices to produce powerful, monochromatic collimated beam of light in
which the waves are coherent

 Properties of laser
 Monochromatic

 Collimated beam

 Coherent waves

 Powerful

 A typical helium-neon laser source produces a 1 to 2 mm diameter beam of pure red light
having power of 1MW. So, this type of a beam is focused at a point. It means, beam has very
high intensity. The laser is used extensively for interferometer. Upto a great distance beam
has no divergence but then it begins to expand at a rate of about 1mm/m.

 This is used for very accurate measurements in the order of 0.1 µm in 100m.
PRECISION INSTRUMENTS BASED ON LASER

 Laser are extensively used for interferometry

 Metrology laser are low power instrument that emit visible pr infrared light.

 Light at a wave length of 0.6m m is produced by He-Ne lasers.

 Laser are used for dimensions measurements and surface inspection.


LASER TELEMETRIC SYSTEM
 In general , telemetry means measurement made from distance.
 To detect change in dimension of the moving components. As the output
of the system is in digital form.
 Laser telemetric system is a non contact gauge that measures with a
collimated laser beam. It measures at the rate of 150 scans per second.
CONTRUCTION
The laser telemetric system consists of mainly three components namely
1. Transmitter
2. Receiver
3. Processor electronics.
 The transmitter produces a collimated parallel scanning laser beam
moving at a high constant linear speed. The beam appears as red line
after scanning.
 The receiver collects the laser beam and photo electrically senses the
laser light transmitted through the objects being measured. The
processor receivers the signal and converts it into convenient from.
The transmitter has the following components.
1. Low power helium neon gas laser.
2. Synchronous motor.
3. Collimating lens.
4. Reflector prism
5. Synchronous pulse photo detector.
6. Replaceable window
WORKING
• The object to be measured is placed in the measurement region. High
constant and linear speed laser beams from transmitter which is focused on
the object to be measured. The receiver module collects and senses the
laser light transmitted past the object to be measured.
• After sensing, the processor electronics take the received signals and
convert them into a convenient from and then display the dimensions
being gauged.
ADVANTAGES:
• It is possible to detect changes in dimensions when components are
moving
• It is possible to detect changes in dimensions when product is in
continuous processes.
• There is no need to wait for taking measurements when the product is in
hot conditions
• It can be applied on production machines and controlled them with
feedback loops
• It is possible to write programs for the microprocessor to take care of
smoke, dust and other airborne interference around the work piece being
measured.
Laser scan micrometers
• A laser is emitted onto a spinning polygon mirror which traverses the beam throughout the sensors
measurement range at a constant speed. Measurements such as the outer diameter are determined by
measuring the amount of time the light is blocked from the receiver.
A.C LASER INTERFEROMETER
Basic Principles of Coordinate
Measuring machines
A coordinate measuring machine (CMM) is a
device for measuring the physical geometrical
characteristics of an object.

This machine may be manually controlled by an


operator or it may be computer controlled.

Measurements are defined by a probe attached


to the third moving axis of this machine. Probes
may be mechanical, optical, laser, or white light,
among others.
DESCRIPTION

CMM is composed of three axes, an X, Y and Z. These axes are orthogonal to


each other in a typical three dimensional coordinate system.
• Each axis has a scale system that indicates the location of that axis. The
machine will read the input from the touch probe, as directed by the
operator or programmer.
• The machine then uses the X,Y,Z coordinates of each of these points to
determine size and position. Typical precision of a coordinate measuring
machine is measured in Microns, or Micrometers, which is 1/1,000,000 of a
meter.
• A coordinate measuring machine (CMM) is also a device used in
manufacturing and assembly processes to test a part or assembly against the
design intent. By precisely recording the X, Y, and Z coordinates of the target,
points are generated which can then be analyzed via regression algorithms
for the construction of features.
• These points are collected by using a probe that is positioned manually by an
operator or automatically via Direct Computer Control (DCC). DCC CMMs can
be programmed to repeatedly measure identical parts, thus a CMM is a
specialized form of industrial robot.
Parts

• Coordinate-measuring machines include four main


components:
1. The main structure which include three axes of
motion
2. Probing system
3. Data collection and Reduction system - typically
includes a machine controller, desktop computer.
4. Application software
Uses

They are often used for:


• Dimensional measurement
• Profile measurement
• Angularity or orientation measurement
• Depth mapping
• Digitizing or imaging
• Shaft measurement
Feature Based Measurement
• Form
• straightness, flatness, roundness, cylindricity, sphericity
• Orientation
• parallelism, perpendicularity, concentricity, angularity
• Profile
• profile (scanning), surface (manual), output (graphics)
ADVANTAGES OF USING CMM
FLEXIBILITY:

 Co-ordinate measuring machines are essentially universal measuring machines and do not
need to be dedicated to any single or particular measuring task.

 They can measure practically any dimensional characteristic of virtually any part configuration,
including cams, gears, and contoured surfaces.

 No special fixtures or gages are required; because electronic probe contact is light, most parts
can be inspected without being clamped to a surface plate.

REDUCED SETUP TIME:

 Establishing part alignment and appropriate reference points are very time consuming with
conventional surface-plate inspection techniques.

 These procedures are greatly simplified or virtually eliminated through software available on
computer-assisted or computer-controlled CMMs.
IMPROVED ACCURACY:

 All measurements on a CMM are taken from a common geometrically fixed measuring system,
eliminating the introduction and accumulation of errors that can result with hard gage
inspection methods and transfer techniques.

 Moreover, measuring all significant features of a part in one setup prevents the introduction of
errors due to setup changes.

 In the part-program-assisted mode, the operator positions the machine; once the initial position
has been set, the machine is under the control of a program that eliminates operator choice.

 In the Computer Numerically Controlled (CNC) mode, motor-driven machines run totally
unattended by operators.

 Also, automatic data recording, available on most machines, prevents errors in transcribing
readings to the inspection report.

 This all adds up to the fact that less skilled operators can be readily instructed to perform
relatively complex inspection procedures.
IMPROVED PRODUCTIVITY:

 All the factors previously mentioned help to make CMMs more productive than
conventional inspection techniques.

 Further dramatic productivity improvements are realized through the computational


and analytical capabilities of associated data handling systems, including calculators
and all levels of computers.
• All CMMs will have three moving elements of which one is capable of moving in x-axis,
another in y-axis and another in z-axis with respect to each other.

• Each moving element is also fitted with a linear measurement transducer for positional
feedback, with the help of which we can have the co-ordinate of a particular position
with respect to a reference.

• The moving elements can be moved by means of frictionless air bearings or mechanical
bearings.

• The Job to be measured will be mounted over a table made of granite because of its
stability in various temperatures.

• The work table of the machine generally consists of tapped holes to facilitate clamping
and locating of parts.

• A total of 11 different machine configurations exist; however, some of these


configurations are modifications of one of the five primary configurations:
MACHINE CONFIGURATIONS

A variety of machine configurations is available from the


manufacturers of CMMs.

Each configuration has advantages that make it suitable


for particular applications.

A total of 11 different machine configurations exist;


however, some of these configurations are modifications
of one of the four primary configurations: bridge,
column, gantry, and horizontal arm.
TYPES OF CMM

1. Cantilever type
2. Bridge type
3. Column type
4. Gantry type
5. Horizontal type.

CANTILEVER TYPE

• The probe is attached to the vertical quill that moves in a Z-axis direction relative to a
horizontal arm that over hangs the work table.
• The quill can be moved along the length of the arm to achieve y-axis motion, and the arm can
be moved to the work table to achieve x-axis motion.

Advantages
• Convenient access to the work table and its relatively small floor space requirements
Disadvantages
• Lower rigidity than some of the other CMM construction

Types of cantilever
1. Moving Table Horizontal Arm CMM
2. Moving Arm Horizontal Arm CMM
3. Column CMM
4. Fixed Table Horizontal Arm CMM
Types of CMM

Moving Arm Horizontal Arm Moving Table Horizontal Arm


Coordinate Measuring Machine Coordinate Measuring Machine
Types of CMM

Fixed Table Cantilever Coordinate Moving Bridge Coordinate Measuring


Measuring Machine Machine
COLUMN:
Column-type CMMs are similar in construction to
accurate jig boring machines.
The column moves in a vertical (Z) direction only, and a
two-axis saddle permits movement in the horizontal (X
and Y) direction.
Column-type CMMs are often referred to as universal
measuring machines rather than CMMs by
manufacturers and are considered gage-room
instruments rather than production-floor m/c.
Horizontal arm CMMs

Moving ram Moving table

Fixed table
Machine Vision
What is Machine Vision – Machine vision is the substitution of the human visual sense and judgment capabilities with a
video camera and computer to perform an inspection task. It is the automatic acquisition and analysis of images to obtain
desired data for controlling or evaluating a specific part or activity.
The components of a vision system include the following basic seven elements.
Although each of these components serves its own individual function and can be
found in many other systems, when working together they each have a distinct role to
play. To work reliably and generate repeatable results it is important that these critical
components interact effectively.
•The machine vision process starts with the part or product being inspected.
•When the part is in the correct place a sensor will trigger the acquisition of the digital
image.
•Structured lighting is used to ensure that the image captured is of optimum quality.
•The optical lens focuses the image onto the camera sensor.
•Depending on capabilities this digitizing sensor may perform some pre-processing to
ensure the correct image features stand out
•The image is then sent to the processor for analysis against the set of pre-
programmed rules.
•Communication devices are then used to report and trigger automatic events such as
part acceptance or rejection.

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