Module IV: COMPUTER AIDED AND LASER METROLOGY:

1.0 Tool Makers Microscope

2.0 Coordinate Measuring Machines – Applications
3.0 Laser Micrometre,
4.0 Laser scanning gauge,
5.0 Computer Aided Inspection techniques - In-process inspection,
6.0 Machine Vision system-Applications.
1.0 TOOL MAKER’S MICROSCOPE:
Theory:
A large tool maker’s microscope, shown in Fig. C.30, essentially consists of a cast base, the main lighting unit,
the upright with carrying arm, and the sighting microscope.
The rigid cast base rests on three foot screws by means of which the equipment can be levelled with
reference to the build-in box level.
The base carries the coordinate measuring table, consisting of two measuring slides, one along the X and
the other along the Y direction, and a rotary circular table provided with a glass plate. The slides run on
precision balls in hardened guideways warranting reliable travel.
Two micrometer screws, each of them measuring a specified range given by the equipment manufacturer,
permit the measuring table to be displaced in the directions X and Y. The range of movement of the carriage
can be widened up to 150 mm in the X direction and up to 50 mm in the Y direction with the use of gauge
blocks.

Construction:

The general view of a tool maker’s microscope, giving its design, optical systems, and measuring techniques, is as
shown in Fig. C.31.
It consists of an optical head having various interchangeable eyepieces, which moves along the guideways
of a vertical column. The optical head can be clamped in any position by a screw. The working table on which the
part to be inspected is placed, is secured on a heavy hollow base. The table has a compound slide, by means of
which the measured part can have longitudinal and lateral movements. The slight movement given to these
screws can be easily determined using scales and verniers.
Cross-lines are engraved on the ground glass screen, which can be rotated through 360°, and measurements
are made using these cross-lines. The optical eyepiece/head tube is adjusted in height for focusing purposes, until
a sharp image can be seen on the ground glass screen. The magnification obtained depends on the objectives
of the microscope, but instruments are commonly supplied with facilities to give a magnification of 10–100×.
In order to adapt the apparatus to deal with a variety of works, various attachments may be fitted to the work
table, such as clamp attachment and light arrangement.
Linear movement of the table is controlled by micrometer screws having an accuracy of 0.0025 mm.

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 Fig. : Tool maker’s microscope

Applications of Tool Maker’s Microscope:

A tool maker’s microscope can be used for the following purposes:

1. Measurement of the parts of complex forms, for example, profile of external threads, tools, gauges, and
templates
2. Determination of relative position of various points on a workpiece
3. Measurement of angle
4. Length measurement in Cartesian and polar coordinates
5. Angle measurements of tools, threading tools, punches, gauges, templates, etc.
6. Thread measurements, including measurements of profile of major and minor diameters, height of lead, thread
angle, profile position with respect to the thread axis, and the shape of thread (rounding, flattering, and
straightness of flanks)
7. Comparison between centres and drawn patterns, and drawing of projected profiles

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 2.0 COORDINATE MEASURING MACHINES
The term coordinate measuring machine refers to the instrument/machine that is capable of measuring
in all three orthogonal axes. Such a machine is popularly abbreviated as CMM. A CMM enables the
location of point coordinates in a three-dimensional (3D) space.
Another remarkable feature of a CMM is its integration with a computer. The computer provides additional
power to generate 3D objects as well as to carry out complex mathematical calculations. Complex objects
can be dimensionally evaluated with precision and speed.

Fig. : CNC CMM

Types of CMM:

Fig. : Basic configuration of a CMM

(a) Moving lever cantilever arm type (b) Moving bridge type (c) Column type (d) Moving RAM horizontal
arm type (e) Gantry type
Depending on the geometry of the workpiece being measured, the user can choose any one
among the five popular physical configurations.
Cantilever:

The vertically positioned probe is carried by a cantilevered arm. The probe moves up and down along the
Z-axis, whereas the cantilever arm moves in and out along the Y-axis (lateral movement). The longitudinal
movement is provided by the X-axis, which is basically the work table. This configuration provides easy
access to the workpiece and a relatively large work volume for a small floor space.
Bridge:

A bridge-type configuration is a good choice if better rigidity in the structure is required. The probe
unit is mounted on a horizontal moving bridge, whose supports rest on the machine table.
Column:

This configuration provides exceptional rigidity and accuracy. It is quite similar in construction to a jig boring
machine. Machines with such a configuration are often referred to as universal measuring machines.
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 Horizontal arm:

In this type of configuration, the probe is carried by the horizontal axis. The probe assembly can also move
up and down along a vertical axis. It can be used for gauging larger workpieces since it has a large work
volume. It is often referred to as a layout.
Gantry:

In this configuration, the support of the workpiece is independent of the X- and Y-axis. Both these
axes are overhead and supported by four vertical columns from the floor. The operator can walk along
with the probe, which is desirable for large workpieces.

Features of CMM:
Multiple features:
More the number of features (both dimensional and geometric) can be controlled.
If many measurements are to be made on a complex part, and many contact locations are required, then
the cycle time of a CMM will be significantly less than the corresponding time for a manual procedure.
Flexibility:
It offers flexibility in measurement, without the necessity to use accessories such as jigs and fixtures.
Automated inspection:
Whenever inspection needs to be carried out in a fully automated environment, CMM can meet the
requirements quite easily.
A wide variety of parts can be inspected.
A CMM is a programmable machine, capable of dealing with high parts variety.
Interface to CAD software

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3.0 LASER MICROMETRE:

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A scanning laser micrometer uses a rotating optical element to reflect or refract a laser beam through a measurement area
and across the path of an object to measure. The part obstructs the laser light, creating a shadow that persists for a time
proportional to the size of the part.
Optics in the receiver collect the unobstructed laser light and focus it on a photocell. The output of the photocell is analysed
by electronics to detect the precise time at which the laser crosses each part edge. Software converts timing data into
meaningful measurements.
All scanning laser micrometers operate by the same fundamental principle, whether they use a rotating mirror, prism,
hologram, tuning fork, or some other mechanism to scan the laser beam through the measurement field. Scanning laser
micrometers have used a variety of light sources: laser diodes, helium-neon (HeNe) laser tubes, and LEDs.
The electrical interface—power, signal, and status lines—to a scanning laser micrometer also varies amongst this class of
devices. However, since they all operate on the same fundamental principle, the electrical signals encode the same
fundamental information.

Reference:

http://laserlinc.com/laser_micrometer_operating_principle.html
https://www.aeroel.it/technology/how-does-a-laser-micrometer-works/38-inglese/tecnologia.html

4.0 LASER SCANNING GAUGE:

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5.0 COMPUTER AIDED INSPECTION (CAI) TECHNIQUES - IN-PROCESS INSPECTION
Introduction

Computer Aided Inspection (CAI) is a new technology that enables one to develop a comparison of a physical part
to a 3D CAD model. The inspection device uses several multiplexed sensors, each composed of a camera and a
structured light source, to measure all sides of the object in a single pass.
This process is faster, more complete, and more accurate than using a Coordinate Measuring Machine (CMM) or
other more traditional methods.
Process details:

An automatic inspection method and apparatus using structured light and machine vision camera is used to
inspect an object in conjunction with the geometric model of the object.
Camera images of the object are analysed by computer to produce the location of points on the object's
surfaces in three dimensions. Point-cloud data is taken from a laser scanner or other 3-D scanning device.
During a setup phase before object inspection, the points are analysed with respect to the geometric model of
the object.
The software provides a graphical comparison of the manufactured part compared to the CAD model.
Many points are eliminated to reduce data-taking and analysis time to a minimum and prevent extraneous
reflections from producing errors.
When similar objects are subsequently inspected, points from each surface of interest are spatially averaged
to give high accuracy measurements of object dimensions.

Advantages:

The CAI process saves both time and money.

The computer software processes data from a 3-D point cloud from a laser scanner, eliminating the need for slower
and more time-consuming CMM measurements.
Inspecting with CMMs requires that designers create a 2-D drawing in addition to the 3-D CAD model of a part. The
drawing is used to inspect the part at specific locations to verify that it matches the design.
Point-cloud data is taken from a laser scanner or other 3-D scanning device. The software provides
a graphical comparison of the manufactured part compared to the CAD model.
By producing point clouds of the entire part, measurement of the part can be done everywhere and not be limited
to the specific locations on a drawing.

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6.0 MACHINE VISION SYSTEM:
Introduction:

Machine vision consists of the acquisition of image data, followed by the processing and interpretation of these data by
computer for some industrial application. Machine vision is a growing technology, with its principal applications in automated
inspection and robot guidance.
Operation of a machine vision system

The operation of a machine vision system can be divided into the following three functions:
(1) Image acquisition and digitization,
(2) Image processing and analysis, and
(3) Interpretation.

Fig. : Basic functions of a machine vision system.

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