Compact system designed for high-precision, robot-based surface measurements
Researchers have developed a lightweight optical system for 3D inspection of surfaces with micron-scale precision. The new measurement tool could greatly enhance quality control inspection for high-tech products including semiconductor chips, solar panels and consumer electronics such as flat panel televisions.
Because vibrations make it difficult to capture precision 3D measurements on the production line, samples are periodically taken for analysis in a lab. However, any defective products made while waiting for results must be discarded.
To create a system that could operate in the vibration-prone environment of an industrial manufacturing plant, researchers headed by Georg Schitter from Technische Universität Wien in Austria combined a compact 2D fast steering mirror with a high precision 1D confocal chromatic sensor.
“Robot-based inline inspection and measurement systems such as what we developed can enable 100% quality control in industrial production, replacing current sample-based methods,” said Ernst Csencsics, who co-led the research team with Daniel Wertjanz. “This creates a production process that is more efficient because it saves energy and resources.”
As described in The Optical Society (OSA) journal Applied Optics, the new system is designed to be mounted on tracking platform placed on a robotic arm for contactless 3D measurements of arbitrary shapes and surfaces. It weighs just 300 grams and measures 75 x 63 x 55 millimeters cubed, which is about the size of an espresso cup.
“Our system can measure 3D surface topographies with unprecedented combination of flexibility, precision, and speed,” said Wertjanz, who is pursuing a PhD on this research topic. “This creates less waste because manufacturing problems can be identified in real-time, and processes can be quickly adapted and optimized.”
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