2. INTRODUCTION
• Huygen’s Theory proposes light as wavemotion propagated as an electromagnetic wave of sinusoidal form.
• The maximum disturbance of wave is called amplitude and velocity of transmission is called frequency.
• The higher points of a wave are called Crests and lower points are called Troughs.
• The distance between two Crests/Troughs is called Wavelength.
• The time taken by light in covering one wavelength is called Time Period.
3. INTERFEROMETRY:
• The phenomenon of interaction of light is called Interference.
• Under ordinary conditions, the wave nature of light is not apparent. But when two waves interact with
each other, the wave effect is visible and it can be made useful for measuring applications.
• For example, when light is made to interfere, it produces a pattern of dark bands which corresponds to a
very accurate scale of divisions.
• This particular characteristic of this entity is the unit value of the scale, which is exactly one-half
wavelength of light used. As this length is constant, it can be used as a standard of measurement.
• Use of Interferometry technique enables the determination of size of end standards(slip gauges & end
bars) directly in terms of wavelength of light source.
• Based on this, the wavelength standards have been established in 1960. Wavelength of orange light from
krypton-86 spectrum was used.
5. PRINCIPLE OF INTERFERENCE:
• The following figure explains the effect of two light rays A and B which are of the same wavelength.
• When they happen to be in phase, it results into increased amplitude called Resultant Amplitude. It is the
addition of the amplitudes of the combined rays.
• Hence, if two rays of equal intensity are in phase, they augment each other and produce increased brightness.
• If rays A and B differ by a phase of 180 ̊ , then the combined result R will be very small, may be zero, if the
amplitudes aA and aB are equal.
• Therefore, if two rays of equal intensity differ in phase by λ/2, they nullify each other and result into
darkness.
• The above discussion reflects that interference can occur only when two rays are coherent, that is, their phase
difference is maintained for an appreciable length of time. This could be possible only when two rays
originate from the same point of light source at the same time.
6.
7. PROCEDURE TO PRODUCE INTERFERENCE BANDS:
1. Monochromatic light is allowed to pass through a very narrow slit (S), and then allowed to pass through
the other two narrow slits (S1) and (S2), which are very close to each other.
2. Two separate sets of rays are formed which pass through one another in the same medium.
8. 3. If path S1 B2 and S2 B2 are exactly equal then the rays on these paths will be in phase which results in
constructive interference, producing maximum intensity or bright band. The phenomenon remains same
for B1 and B3 .
4. If at the same point D, the ray path difference is equal to half the wavelength (S2 D1 - S1 D1 = λ/2), it
results into an out-of-phase condition producing zero intensity or a dark band due to destructive
interference. The phenomenon remains the same for D2 .
5. Thus, a series of bright and dark bands are produced. The dark bands are called Interference fringes. The
central bright band is flanked on both the sides by dark bands, which are alternatively of minimum and
maximum intensities and are known as Interference Bands.
9. INTERFERENCE BANDS USING OPTICAL FLATS:
1. Another simple method of producing interference fringes is by illuminating an Optical Flat over a plane
reflecting surface. They are made up of Quartz or Glass.
2. An optical flat is a disc of glass or quartz whose faces are highly polished and flat within a few microns.
3. When it is kept on the surface nearly flat, dark bands can be seen. These are cylindrical pieces whose
diameters range from 25mm to 300mm with thickness of 1/6th of the diameter.
4. For measuring flatness, in addition to optical flat, a monochromatic light source is required. The yellow-
orange light radiated by helium gas can be satisfactorily used.
5. Optical flats are of two types, namely, Type A- It is a single flat surface and is used for testing precision
measuring surfaces, Eg: Surfaces of Slip Gauges, Measuring Tables, etc., Type B – It has both the working
surfaces flat and parallel to each other and is used for testing the measuring surfaces of instruments like
Micrometers, measuring anvils and similar other devices for their flatness and parallelism.
10. • They are also classified as:
1. Grade 1 – It is a reference grade whose flatness is 0.05 micron.
2. Grade 2 – It is used as a working grade with tolerance for flatness as 0.10 micron.
11.
12. • Monochromatic Light Source:
• For length measurement by interferometry, monochromatic light source is used. A ray of light having a
single frequency and wave length produces monochromatic light.
• It should be noted that white light cannot be used for interferometry because white light is a combination of
all colors of a spectrum.
• The selection of proper source for an application depends on the results to be obtained by interferometer,
cost and convenience.
• Mercury, Mercury 198, cadmium, krypton-86, thallium, helium, potassium, zinc, sodium and Laser Beams
are used as light sources for Interferometry.
13. LASER
1. A laser is a device that emits light through a process of optical amplification based on the stimulated
emission of electromagnetic radiation. The term "LASER" originated as an acronym for "Light
Amplification by Stimulated Emission of Radiation".
2. Theodore Maiman made the first laser operate on 16 May 1960 at the Hughes Research Laboratory in
California, by shining a high-power flash lamp on a ruby rod with silver-coated surfaces.
3. laser principle.mp4
4. How Lasers Work.mp4
14.
15. WORKING PRINCIPLE OF LASER
A LASER work in the form of the processes that consists of four important processes:
1. Absorption
2. Spontaneous Emission
3. Pumping and Population Inversion
4. Stimulated Emission of Electromagnetic Radiation
16. 1. ABSORPTION:
When a photon of energy (E2 –E1 ) is incident on the atom it may be excited into the higher energy state E2
through absorption of photon. This process is called as stimulated absorption.
An Atom consists of different energy states. Let us consider two energy states of an electron.
When electromagnetic energy falls on an atom, in the form of light photon of frequency ‘υ’, then
Electromagnetic energy is equal to the difference of E2 –E1 = hυ.
When its energy falls on the electron, it absorbs the energy and jumps from the ground state E2 to the excited
state E1.
Energy E
υ
17. 2. SPONTANEOUS EMISSION:
Spontaneous Emission is defined as the process in which the electrons in the excited state are released on their own
from higher energy state to the ground state.
As we already said, electrons jumps from ground state to excited state. But the excited electrons that jumped to
higher energy state, doesn’t remain for longer period in that state and it comes back to its original ground state by
losing its energy in the form of photons.
The photons do not have any correlation in phase and thus considered as Incoherent Light.
Thus , the release of energy by electrons on their own is known as Spontaneous Emission. Transition from one
state to another state occurs randomly in time.
Energy E
υ
18. 3. PUMPING AND POPULATION INVERSION:
The transitioned electrons don’t stay for longer time in the excited state.
There are electrons of some substances or systems, where they remain in the excited state for longer period.
Such systems are called ACTIVE Systems or ACTIVE Media.
These are generally compounds or mixtures of different elements. When electrons turn into active systems,
their electronic energy levels are also modified and thus it acquires some special properties.
Energy E
υ
19. Now let us consider that an atom has three electronic states say E1 , E2 , E3 in active medium.
Generally electrons exist in lower state called as Ground State E1 .
Let the number of electrons in the ground state be N1 .
Due to the process of absorption when electromagnetic energy equal to the difference of E3 - E1 are incident
on atom, electrons jumps from state 1 to the excited state 3.
Due to the process of spontaneous emission, the excited electron in the E3 state remains for less period, in
the order of 10−8 seconds. Usually most of the electrons loses its energy due to spontaneous emission and
returns from E3 state to E1 state.
20. But some of the electrons may lose very less energy E3 - E2 and jump to state E2. This less energy emitted by the
electrons is called as Thermal Energy. This energy is absorbed by the medium itself.
The transition or jumping of electrons from E3 to E2 state is called as non-radiative transition or invisible
transition.
The electrons in this state E2 remains for longer period compared to state E1 , in the order of 3 x 10−3
milli
seconds. This electronic state is called as Metastable State.
The number of electrons in this state is said to be N2 . The number of electrons N2 in the state E2 is increasing
rapidly. At the same point the number of electrons N2 is more than the number of electrons N1 . i.e., N2 > N1 . This
stage is called as Population Inversion.
The process in which the number of electrons (N2) in a higher energy state called ‘Metastable State’ of an active
medium is increased to a value greater than the number (N1) in the ground state (i.e., N2 > N1 ) is called as
“Population Inversion”.
This Population Inversion is achieved by the supply of sufficient and appropriate energy to the active medium from
an external source. Thus, the process of achieving Population Inversion is called as Pumping.
21. 4. INDUCED AND STIMULATED EMISSION:
We know that electrons in the metastable state for a longer period of time in the order of 3 x 10−3 milli
seconds.
Now let us assume, coherent beam of light energy hυ = E2 –E1 incident from an external source on the active
system. The light energy in the form of photon stimulates electrons in the metastable state (N2) to undergo
transition to the ground state (N1).
Thus, large number of photons of same energy is simultaneously emitted.
Energy E
υ
22. Thus the emitted photons have the property called as ‘Temporal Coherence’ and this process is called as
‘Induced or Stimulated Emission’.
When an active medium is in enclosed state, multiple reflections of emitted light occur, where stimulated
emission dominates spontaneous emission.
Thus, the incident beam of light gets amplified and results in output as LASER (Light Amplification by
Stimulated Emission of Radiation).
23. INTERFEROMETERS
• Interferometers are optical instruments used for measuring flatness and determining the
length of slip gauges by direct reference to the wavelength of light.
• The interferometer incorporates the extension of the application of the optical flat.
• It overcomes some of the disadvantages of the optical flats used in ordinary daylight or
diffused source of monochromatic light by having some refined arrangements.
• In interferometers the lay of the optical flat can be controlled and the fringes can be
oriented to the best advantage.
• Also there is arrangement to view the fringes directly from top and above the fringes thus
avoiding any distortion due to incorrect viewing.
25. • This is one of the oldest type of Interferometers.
• However, Michelson using this Interferometer, established exact relationship between meter and red
wavelengths of cadmium lamp.
• The basic Michelson Interferometer consists of a monochromatic light source, a beam splitter and two
mirrors.
• It relies on the principle of constructive and destructive interference as one mirror remains fixed and the
other is moved.
• It uses a monochromatic light(single wavelength) from an extended source.
• This light falls on the beam splitter(which is a plain parallel plate having a semi-transparent layer of silver
at its back) which splits the light into two rays of equal intensity at right angles.
• One ray is transmitted to Mirror M1 and other is reflected through beam splitter to Mirror M2 .
26. • From both these mirrors, the rays are reflected back and these reunite at the semi-reflecting surface
from where they are transmitted to the eye of the observer.
• Mirror M2 is fixed and the reflected ray from M1 serves as a reference beam. Mirror M1 is movable. i.e.
it is attached to the object whose dimension is to be measured.
• If both the mirrors are at same distance from beam splitter, then light will arrive in phase and observer
will see bright spot due to constructive interference.
• If movable mirror shifts by quarter wavelength, then beam will return to observer 180̊ out of phase and
darkness will be observed due to destructive interference.
• Each half wavelength of mirror travel produces a change in the measured optical path of one
wavelength and the reflected beam from the moving mirror shifts through 360° phase change.
• When the reference beam reflected from the fixed mirror and the beam reflected from the moving
mirror re-join at the beam splitter, they alternately reinforce and cancel each other as the mirror moves.
27. • Thus each cycle of intensity at the eye represents λ/2 of mirror travel.
• It may be noted that when monochromatic light source is used then fringes can be seen over a range of
path difference that may vary from a few to a million wavelengths, depending on the source.
• However, when white light is used, then fringes can be seen only if both ray paths are exactly equal to a
few wavelengths in total length in glass and air.
• The lengths themselves are not important, but only their differences affect fringe formation.
• So when white light source is used then a compensator plate is introduced in the path of mirror M 1 so
that exactly the same amount of glass is introduced in each of the paths. (In the path of mirror M 2, the
glass was coming due to rays passing through beam splitter back surface).
• The various sophistications which have undergone to improve the Michelson’s basic apparatus are :
28. 1. Use of laser as the light source, which means that the measurements can be made over longer
distances ; and also the beam laser compared to other monochromatic sources has exact and pure
wavelength thus enabling highly accurate measurements.
2. Mirrors are replaced by cube-corner reflectors (retro-reflectors) which reflect light parallel to its
angle of incidence regardless of retroreflector alignment accuracy.
3. Instead of observing the interference phenomenon by eye, photocells are employed which convert
light-intensity variations in voltage pulses which are processed by electronic instruments to give the
amount and direction of position change.
30. • It is much improved system over the Michelson simple interferometer.
• It uses a single frequency circular polarised laser beam.
• On reaching the polarising beam splitter, the beam splits into two components, the reflected beam being vertically
polarised light and the transmitted beam being horizontally polarised light.
• These two beams referred to as reference arm and measurement arm respectively travel to their retroreflectors and
are then reflected back towards the beam splitter.
• The recombined beam at beam splitter consists of two superimposed beams of different polarisation; one
component vertically polarised having travelled around reference arm and other component horizontally polarised
having travelled around the measurement arm.
• These two beams being differently polarised do not interfere.
• The recombined beam then passes through a quarter wave plate which causes the two beams to interfere with one
another to produce a beam of plane polarised light.
• The angular orientation of the plane of this polarised light depends on the phase difference between the light in the
two returned beams.
31. • The direction of plane of polarisation spin is dependent on the direction of movement of the moving
retroreflector.
• The beam after quarter wave plate is split into three polarisation sensitive detectors.
• As the plane of polarised light spins, each detector produces a sinusoidal output waveform.
• The polarisation sensitivity of the detectors can be set so that their outputs have relative phases of 0°, 90°, and
180°.
• The outputs of three detectors can be used to distinguish the direction of movement and also the distance moved
by the moving retroreflector attached to the surface whose displacement is to be measured.
• For linear measurements (positional accuracy or velocity), the retroreflector is attached to the body moving along
the linear axis. For angular measurement (For pitch and yaw), the angular beam splitter is placed in the path
between the laser head and the angular reflector.
• In this way it is possible to measure flatness, straightness, rotatory axis calibration.
• Arrangements also need to be made for environmental compensation because the refractive index of the air
varies with temperature, pressure and humidity.
• Interferometry is now an established and well developed technique for high accuracy and high resolution
measurement.
33. • Twyman-Green modified Michelson interferometer utilises a pin-hole source diaphragm and collimating lenses.
• In this way, all rays are rendered parallel to the central rays and thus all rays describe the same path.
• All modern two-beam interferometers are based on this arrangement. The mirrors M1 and M2 are arranged
perpendicular to the optical axis.
• If mirror M1 is kept fixed, and M2 is moved slowly exactly parallel to itself, the observer will note periodic
changes in the intensity of the field being viewed, from bright to dark for every λ/2 movement of the mirror.
• In fact intensity variation is found to be sinusoidal.
• It may also be noted that if one of the mirrors is even slightly inclined to the optical axis then parallel fringes will
be seen moving parallel to themselves by just one fringe for every λ/2 (half the wavelength of the light source
used) mirror motion.
• Usually it is quite difficult to count such fringes by eye.
• However, photo detectors connected to high speed counters can do this job very accurately (accuracy of one part
in million being obtainable).
• It is possible to calibrate the output of counter directly in terms of the linear movement of the mirror M2, but
several conditions must be met to achieve these results.
35. • This interferometer was designed by National Physical Laboratory and is commercially manufactured by Hilger
and Watts Ltd.
• The flatness of any surface is judged by comparing with an optically flat surface which is generally the base plate
of the instrument.
• This instrument essentially consists of a mercury vapour lamp.
• As we are interested in having single monochromatic source of light, the radiations of the mercury lamp are
passed through a green filter.
• The wavelength of the resulting monochromatic radiation is of the order or 0.0005 mm.
• This radiation is then brought to focus on pinhole in order to obtain an intense point source of light.
• A mirror is used in order to deflect the light beam through 90°.
• The pinhole is placed in the focal plane of a collimating lens, thus the radiations out of the lens will be parallel
beam of light.
• This beam is directed on the gauge to be tested via an optical flat.
• The fringes formed are viewed directly above by means of a thick glass plate semi-reflector set at 45° to the
optical axis.
36. • The gauge to be tested is wrung on the base plate whose surface is finished to a degree comparable to that
of the highest quality gauge face.
• As the optical flat is placed above it in a little tilted position, interference fringes are formed; one between
rays reflected from the under surface of the optical flat and those reflected from the surface of the gauge,
and the other between rays reflected from the under surface of the optical flat and those reflected from the
base plate.
• If the gauge face is flat and parallel to the base plate, then the optical flat being equally inclined on both the
surfaces the fringe pattern from both the gauge face and the base plate will consist of straight, parallel and
equally spaced fringes as shown in Fig. 6.22 (a).
• When the gauge is flat but not parallel to the base plate, then straight and parallel fringes of different pitch
above the gauge face as compared with those of the base plate are seen [Fig. 6.22 (b)].
37. • In such case, to determine the amount of unparallelism, provision is made to rotate the base plate by 180°
and this method is covered in detail after discussing the various other possible cases.
• In case taper is present in some other direction, i.e. surface of the gauge is flat but its surface is inclined to
the base plate at some other angle, then fringe pattern obtained is as shown in Fig. 6.23.
• Here the error is indicated by the amount by which the fringes are out of parallel with those on the base
plate.
• When the gauge surface is convex or concave then fringe pattern as shown in Fig. 6.24 is obtained, i.e. the
fringes on the gauge are curved lines.
• Slight rounding off at the corners of an otherwise generally flat and parallel surface will give a fringe
pattern as shown in Fig. 6.25 having closely curved lines at the ends, and straight and parallel fringes of
equal pitch in the middle.
39. • This is also called the gauge length interferometer and used for determining actual dimensions or absolute
length of the gauges.
• As the mechanical sub-division of end standards length tends to be laborious when small lengths are
considered, and due to liability of error in that method, direct measurement interferometer based on the
design of N.P.L. is most commonly used.
• Since this involves very precision work, it is important to see that the physical conditions surrounding the
measuring equipment are standardised and controlled.
• The standard conditions being temperature of 20°C, barometric pressure of 760 mm of mercury with water
vapour at a pressure of 7 mm and containing 0.33% by volume of carbon dioxide.
• In case conditions are different, then correction factors have to be applied.
• The diagrammatic arrangement of the instrument is shown in Fig.
• S is suitable source of light and light form it is brought to focus on the illuminating aperture in the plate by
passing it through a condensing lens.
40. • This plate is placed at the focal plane of a collimating lens.
• Thus light from this plate acts as a point source of light and after collimating lens, rays of light in the form
of parallel beam of light move into a constant deviation prism.
• The constant deviation prism disperses the light into its constituent colours.
• The beams of different colours are thus reflected downwards by the prism in slightly different directions.
• In case of cadmium source of light, the various colours of beam available are red, green, blue and violet.
• Any one of these coloured beams can be directed vertically downward on the gauge and the base plate
through the optical flat by slightly rotating the constant deviation prism about a certain axis.
• The rays reflected at the gauge face and at the face of the base plate return along the same path
approximately as the incident rays, but their axis is tilted slightly due to inclination of optical flat and thus
brought to focus at some other point on the plate, where they are incident on a reflecting prism.
• Reflecting prism then reflects the rays into the eyepiece at normal to these rays.
• The fringe pattern obtained is shown in the field of view in Fig. 6.27.
41. • Actually two interference systems are produced.
• One set of fringes is due to the upper surface of the gauge and the other is due to the base plate’s reflecting
surface.
• It is essential that the gauges being calibrated by this method possess a very high degree of flatness and
parallelism.
• Only then the fringe pattern from the gauge and the base plate will consist of straight, parallel and equally
spaced fringes of the same frequency.
• Generally two fringe patterns cannot be in phase and will be displaced as shown in Fig. 6.28.
• The amount of this displacement varies for each colour and, therefore, wavelength of light used.
• The displacement observed a, is expressed as a fraction of the fringe spacing b, i.e. ‘f = a/b’.
• In order to determine the length of the gauge an estimation of f is made for each of the four radiations from
the cadmium lamp.
43. • In case of AC laser interferometer (ACLI) position information is carried as phase deviation rather than as a
signal amplitude deviation, thus giving a much improved signal to noise ratio over amplitude modulation,
because the noise sources that affect signal amplitude have little effect on phase.
• In this way, ACLI is much more tolerant of environmental factors that attenuate the intensity of a laser beam,
such as dust, smoke, air turbulence etc.
• It requires no warm-up time or standby power. Thus ACLI has the following advantages: high repeatability
and resolution of displacement measurement (0.1 um), high accuracy, long-range optical path (60 m), easy
installation, and no change in performance due to ageing or wear and tear.
• A single laser source can be used for as many as six simultaneous measurements in different axes.
• However, it is very much expensive ; since the basic instrument measures physical displacement in terms of
wavelength instead of traditional units, conversion instrumentation is required for conventional read out.
• Highest possible accuracy is obtainable only by compensating changes in air pressure and temperature which
affect wavelength of the laser beam.
44. • It uses two frequency laser system, thus overcoming the shortcoming of d.c. laser interferometer. Whereas
the d.c. system mixes out of phase light beams of the same frequency, the a.c. system mixes beams of two
different frequencies thus permitting the distance information to be carried on a.c. waveform.
• Use is made of the fact that the AC amplifiers are insensitive to d.c. variation of a.c. inputs.
• Two frequency Zeeman laser generates light of two slightly different frequencies with opposite circular
polarisations.
• These beams get split up by beam splitter B1: one part travels towards B2 and from there to external cube
corner where the displacement is to be measured.
• It may be noted that mirror is not employed here like Michelson Interferometer, because mirror alignment
is a critical procedure.
• This interferometer, instead, uses cube-corner reflectors (retroreflectors) which reflect light parallel to its
angle of incidence regardless of retroreflector alignment accuracy.
• Beam splitter B2 optically separates the frequency f1 which alone is sent to the movable cube-corner
reflector.
45. • The second frequency f2 (optically separated) from B2 is sent to a fixed reflector which then re-joins f1 at
the beam splitter B2 to produce alternate light
• and dark interference flicker at about 2 Mega cycles per second.
• Now if the movable reflector (external cube corner) moves, then the returning beam frequency will be
Doppler-shifted slightly up or down by ∆f1.
• Thus the light beams moving towards photo-detector P2 have frequencies f1 and (f1 ± ∆ f1) and P2 changes
these frequencies into electrical signal. (Photocells convert light-intensity variations into voltage pulses
which can be processed by electronic instruments to give the amount and direction of position change).
• Photo detector P1 receives signal from beam splitter B1 and changes the reference beam frequencies f1 and
f2, into electrical signal.
• An A.C. amplifier A1 separates frequency difference signal f2 – f1 and A2 separates frequency difference
• signal [(f2 - (f1 ± ∆ f1)].
46. • The pulse converter extracts ∆ f, one cycle per half wavelength of motion.
• The up-down pulses from the pulse converter are counted electronically and displayed in analog or digital
form on the indicator.
• It may be noted that output in case of ACLI is in the form of pulses, whereas in d.c. systems, the output is in
the form of a sinusoidal wave, the amplitude (intensity) of which depends upon laser aging, air turbulence or
air pollutant and thus the change of amplitude leads to improper triggering and counting errors.
47. BRIEF DESCRIPTION OF COMPONENTS INVOLVED
(i)Two frequency laser source. It is generally He—Ne type that generates stable coherent light beams of
two frequencies, one polarised vertically and one horizontally relative to the plane of the mounting feet. The
frequency stabilisation is based on Zeeman splitting of the atomic levels involved in the laser action. Laser
oscillates at two slightly different frequencies by a cylindrical permanent magnet around the cavity. The two
components of frequencies are distinguishable by their opposite circular polarisations. Beam containing both
frequencies passes through a quarter wave and half wave plates which change the circular polarisations to
linear perpendicular polarisations, one vertical and other horizontal. Thus the laser can be rotated by 90°
about the beam axis (roll) without affecting transducer performance. If the laser source is deviated in roll
from one of the four optimum positions, the photo-receiver signal will decrease. At a deviation of 45°, the
signal will decrease to zero. The linearly polarised beam is expanded in a collimating telescope, after which
most of the beam is transmitted through a 45° beam splitter and out of laser head.
48. • (ii) Optical Elements:
• (a) Beam splitters. These, (like partially silvered mirrors) divide the laser beam into separate beams along
different axes. It is possible to adjust the splitted laser’s output intensity by having a choice of beam splitter
reflectivities. To avoid attenuation it is essential that the beam splitters must be oriented so that the reflected
beam forms a right angle with the transmitted beam, so that these two beams are coplanar with one of the
polarisation vectors of the input beam.
• (b) Beam benders. These are used to deflect the light beam around corners on its path from the laser to each
axis. These are actually just flat mirrors, but having absolutely flat and very high reflectivity. Normally these
are restricted to 90° beam deflections to avoid disturbing the polarising vectors.
• (c) Retro-reflectors. These can be plane mirrors, roof prisms or cube-corners. Cube corners are three
mutually perpendicular plane mirrors, and in these devices the reflected beam is always parallel to the
incidental beam. Each ACLI transducer axis needs at least two retro-reflectors. All ACLI measurements are
made by sensing differential motion between two retroreflectors relative to an interferometer. Plane mirrors
used as retroreflectors with the plane-mirror interferometer must be flat to within 0.06 micron per cm.
49. • (iii) Laser head’s measurement receiver. During a measurement, the laser beam is directed through optics
in the measurement path and then returned to the laser head’s measurement receiver which will detect part
of the returning beam as f1 – f2 and a doppler
• shifted frequency component bf.
• (iv) Measurement display. It contains a microcomputer to compute and display results. The signals from
reference receiver and measurement receiver located in the laser head are counted in two separate pulse
counters and subtracted. Necessary calculations are made and the computed value is displayed. Other input
signals for correction are temperature, coefficient of expansions, air velocity etc. which can also be
displayed.
50. COORDINATE MEASURING MACHINES
• Coordinate metrology is concerned with measuring the actual shape and dimensions of an object and
comparing these results with the desired shape and dimensions, as might be specified on the part drawing.
• In this sense, coordinate metrology consists of the evaluation of the location, orientation, dimensions and
geometry of the part or object.
• A Coordinate Measuring Machine (CMM) is an electromechanical system designed to perform coordinate
metrology.
• A CMM has a contact probe that can be positioned in three dimensions relative to the surfaces of the
workpart.
• The x, y and z coordinates of the probe can be accurately and precisely recorded to obtain dimensional data
about the part geometry.
• This technology of CMMs dates from the mid 1950s.CMM Measuring Machine.mp4
51. • To accomplish measurements in three-dimensional space, the basic CMM consists of the following
components:
1. Probe Head and Probe to contact the work part surfaces.
2. Mechanical structure that provides motion to the probe in three Cartesian axes and displacement
transducers to measure the coordinate values of each axis.
• In addition, many CMMs have the following components:
1. Drive system and control unit to move each of the three axes.
2. Digital computer system with application software.
52. CMM CONSTRUCTION:
• In the construction of a CMM, the probe is fastened to a mechanical structure that allows movement of the
probe relative to the part.
• The part is usually located on a worktable that is connected to the structure.
• Let us examine the two basic components of the CMM: (1) Its probe and (2) lts mechanical structure,
• Probe: The contact probe is a key component of a CMM. lt indicates when contact has been made with the
part surface during measurement.
• The tip of the probe is usually a ruby ball. Ruby is a form of corundum (aluminium oxide), whose desirable
properties in this application include high hardness for wear resistance and low density for minimum inertia.
Probes can have either a single tip or multiple tips.
53. • Most probes today are touch-trigger probes, which actuate when the probe makes contact with the part surface.
• Commercially available touch-trigger probes utilize any of various triggering mechanisms, including the following:
1. The trigger is based on a highly sensitive electrical contact switch that emits a signal when the tip of the probe is deflected
from its neutral position.
2. The trigger actuates when electrical contact is established between the probe and the (metallic) part surface.
3. The trigger uses a piezoelectric sensor that generates a signal based on tension or compression loading of the probe.
• Immediately after contact is made between the probe and the surface of the object, the coordinate positions of the probe are
accurately measured by displacement transducers associated with each of the three linear axes and recorded by the CMM
controller.
• Common displacement transducers used on CMMs include optical scales, rotary encoders, and magnetic scales.
• Compensation is made for the radius of the probe tip, as indicated in our Example 23.1, and any limited over travel of the probe
quill due to momentum is neglected.
• After the probe has been separated from the contact surface, it returns to its neutral position.
54. • EXAMPLE: Dimensional Measurement with Probe Tip Compensation
• The part dimension L in Figure 23.5 is to be measured. The dimension is aligned with the x-axis, so it can be
measured using only x-coordinate locations. When the probe is moved toward the part from the left, contact
made at x = 68.93 is recorded (mm). When the probe is moved toward the opposite side of the part from the
right, contact made at x = 137.44 is recorded. The probe tip diameter is 3.00 mm. What is the dimension L?
55. • Solution: Given that the probe tip diameter D, = 3.00 mm, the radius R, = 1.50 mm
• Each of the recorded x values must be corrected for this radius.
• X1 = 68.93 + 1.50 = 70.43mm
• X2 = 137.44 - 1.50 = 135.94 mm
• L = X2 – X1 = 135.94 - 70.43 = 65.51 mm
• Mechanical Structure: There are various physical configurations for achieving the motion of the probe, each with its
relative advantages and disadvantages. Nearly all CMMs have a mechanical configuration that fits into one of the
following six types. They are:
1. Cantilever Type
2. Moving Bridge Type
3. Fixed Bridge Type
4. Horizontal Arm Type
5. Gantry Type
6. Column Type
56. CANTILEVER TYPE
• In the cantilever configuration, the probe is attached to a vertical quill that moves in the z-axis direction relative
to a horizontal arm that overhangs a fixed worktable.
• The quill can also be moved along the length of the arm to achieve y-axis motion, and the arm can be moved
relative to the worktable to achieve y-axis motion.
• The advantages of this construction are: (1) convenient access to the worktable, (2) high throughput-the rate at
which parts can be mounted and measured on the CMM, (3) capacity to measure large work parts (on large
CMM,). and (4) relatively small floor space requirements.
• Its disadvantage is lower rigidity than most other CMM constructions.
57. MOVING BRIDGE TYPE
• In the moving bridge design, the probe is mounted on a bridge structure that is moved relative to a stationary
table on which is positioned the part to be measured.
• This provides a more rigid structure than the cantilever design, and its advocates claim that this makes the
moving bridge CMM more accurate.
• However, one of the problems encountered with the moving bridge design is yawing (also known as walking), in
which the two legs of the bridge move at slightly different speeds, resulting in twisting of the bridge.
• This phenomenon degrades the accuracy of the measurements. Yawing is reduced on moving bridge CMMs
when dual drives and position feedback controls are installed for both legs.
• The moving bridge design is the most widely used in industry.
• It is well suited to the size range of parts commonly encountered in production machine shops.
58.
59. FIXED BRIDGE TYPE
• In this configuration, the bridge is attached to the CMM bed, and the worktable is moved in the x-direction
beneath the bridge.
• This construction eliminates the possibility of yawing, hence increasing rigidity and accuracy.
• However, throughput is adversely affected because of the additional mass involved to move the heavy worktable
with part mounted on it.
60. HORIZONTAL ARM TYPE
• The horizontal arm configuration consists of a cantilevered horizontal arm mounted to a vertical column.
• The arm moves vertically and in and out to achieve y-axis and a-axis motions.
• To achieve x-axis motion, either the column is moved horizontally past the worktable (called the moving ram
design), or the worktable is moved past the column (called the moving table design).
• The moving ram design is illustrated in Figure.
• The cantilever design of the horizontal arm configuration makes it less rigid and therefore less accurate than
other CMM structures.
• On the positive side, it allows good accessibility to the work area.
• Large horizontal arm machines are suited to the measurement of automobile bodies, and some CMMs are
equipped with dual arms so that independent measurements can be taken on both sides of the car body at the
same time.
61.
62. GANTRY TYPE
• This construction, is generally intended for inspecting large objects.
• The probe quill (z-axis) moves relative to the horizontal arm extending between the two rails of the gantry.
• The workspace in a large gantry type CMM can be as great as 25 m (82 ft) in the x-direction by 8 m (26 ft) in the
y-direction by 6 m (20 ft) in the z-direction.
63. COLUMN TYPE
• This configuration, is similar to the construction of a machine tool.
• The x- and y-axis movements are achieved by moving the worktable, while the probe quill is moved vertically
along a rigid column to achieve z-axis motion.
64. CMM OPERATION AND PROGRAMMING
• Positioning the probe relative to the part can be accomplished in several ways, ranging from manual
operation to direct computer control (DCC).
• Computer-controlled CMMs operate much like CNC machine tools, and these machines must be
programmed.
• CMM Controls. The methods of operating and controlling a CMM can be classified into four main categories: (1)
manual drive, (2) manual drive with computer-assisted data processing, (3) motor drive with computer-
assisted data processing, and (4) DCC with computer-assisted data processing.
1. In a manual drive CMM, the human operator physically moves the probe along the machine's axes to
make contact with the part and record the measurements. The three orthogonal slides are designed to be
nearly frictionless to permit the probe to be free floating in the x-, y-, and z-directions. The measurements
are provided by a digital readout, which the operator can record either manually or with paper printout.
Any calculations on the data (e.g., calculating the center and diameter of a hole) must be made by the
operator.
65. • A CMM with manual drive and computer-assisted data processing provides some data processing and
computational capability for performing the calculations required to evaluate a given part feature. The types
of data processing and computations range from simple conversions between U.S. customary units and
metric to more complicated geometry calculations, such as determining the angle between two planes. The
probe is still free floating to permit the operator to bring it into contact with the desired part surfaces.
• A motor-driven CMM with computer-assisted data processing uses electric motors to drive the probe
along the machine axes under operator control. A joystick or similar device is used as the means of
controlling the motion. Features such as low-power stepping motors and friction clutches are utilized to
reduce the effects of collisions between the probe and the part. The motor drive can be disengaged to permit
the operator to physically move the probe as in the manual control method. Motor-driven CMMs are
generally equipped with data processing to accomplish the geometric computations required in feature
assessment.
66. • A CMM with direct computer control (DCC) operates like a CNC machine tool. It is motorized. and the
movements of the coordinate axes are controlled by a dedicated computer under program control. The
computer also performs the various data processing and calculation functions and compiles a record of the
measurements made during inspection. As with a CNC machine tool, the DCC CMM requires pari
programming.
• DCC Programming. There are two principle methods of programming a DCC measuring machine: (1)
manual lead through and (2) off-line programming. In the manual lead through method, the operator leads
the CMM probe through the various motions required in the inspection sequence. indicating the points and
surfaces that are to be measured and recording these into the control memory, This is similar to the robot
programming technique of the same name. During regular operation, the CMM controller plays back the
program to execute the inspection procedure.
67. • Off-line programming is accomplished in the manner of computer-assisted NC part programming. The program is
prepared off-line based on the pan drawing and then downloaded to the CMM controller for execution. The
programming statements for a computer-controlled CMM include motion commands, measurement commands, and
report formatting commands. The motion commands are used to direct the probe to a desired inspection location, in
the same way that a cutting tool is directed in a machining operation. The measurement statements are used to
control the measuring and inspection functions of the machine, calling the various data processing and calculation
routines into play. Finally, the formatting statements permit the specification of the output reports to document the
inspection.
• An enhancement of off-line programming is CAD programming, in which the measurement cycle is generated
from CAD (Computer-Aided Design) geometric data representing the part rather than from a hard copy part
drawing. Off-line programming on a CAD system is facilitated by the Dimensional Measuring Interface
Standard(DMlS). DMTS is a protocol that permits two-way communication between CAD systems and CMMs.
Use of the DMIS protocol has the following advantages: (1) It allows any CAD system to communicate with any
CMM; (2) it reduces software development costs for CMM and CAD companies because only one translator is
required to communicate with the DMIS; (3) users have greater choice in selecting among CMM suppliers; and (4)
user training requirements are reduced.
68. CMM SOFTWARE
• CMM software is the set of programs and procedures (with supporting documentation) used to operate the
CMM and its associated equipment.
• In addition to part programming software used for programming DCC machines, discussed above, other
software is also required to achieve full functionality of a CMM.
• Indeed, it is software that has enabled the CMM to become the workhorse inspection machine that it is.
• Additional software can be divided into the following categories (1) core software other than DCC
programming, (2) post-inspection software, and (3) reverse engineering and application-specific software.
69. • Core Software other than DCC Programming: Core software consists of the minimum basic programs
required for the CMM to function, excluding part programming software, which applies only to DCC
machines. This software is generally applied either before or during the inspection procedure. Core
programs normally include the following:
• Probe calibration: This function is required to define the parameters of the probe (such as tip radius, tip
positions for a multi-tip probe, and elastic bending coefficients of the probe) so that coordinate
measurements can be automatically compensated for the probe dimensions when the tip contacts the part
surface, avoiding the necessity to perform probe tip calculations. Calibration is usually accomplished by
causing the probe to contact a cube or sphere of known dimensions.
• Part coordinate system definition: This software permits measurements of the part to be made without
requiring a time-consuming part alignment procedure on the CMM worktable. Instead of physically
aligning the part to the CMM axes, the measurement axes are mathematically aligned relative to the part.
70. • Geometric feature construction: This software addresses the problems associated with geometric features whose evaluation
requires more than one point measurement. These features include flatness, squareness, determining the centre of a hole or the
axis of a cylinder, and so on. The software integrates the multiple measurements so that a given geometric feature can be
evaluated.
• Tolerance analysis: This software allows measurements taken on the part to be compared to the dimensions and tolerances
specified on the engineering drawing.
• Post-Inspection Software. Post-inspection software is composed of the set of programs that are applied after the inspection
procedure. Such software often adds significant utility and value to the inspection function. Among the programs included in this
group are the following
• Statistical analysis: This software is used to carry out any of various statistical analyses on the data collected by the CMM. For
example. part dimension data can be used to assess process capability of the associated manufacturing process or for statistical
process control. Two alternative approaches have been adopted by CMM makers in this area. The first approach is to provide
software that creates a database of the measurements taken and facilitates exporting of the database to other software packages.
What makes this feasible is that the data collected by a CMM are already coded in digital fonn. This approach permits the user to
select among many statistical analysis packages that are commercially available. The second approach is to include a statistical
analysis program among the software supplied by the CMM builder. This approach is generally quicker and easier, but the range
of analyses available is not as great .
• Graphical data representation: The purpose of this software is to display the data collected during the CMM procedure in a
graphical or pictorial way, thus permitting easier visualization of form errors and other data by the user.
71. • Reverse Engineering and Application-Specific Software: Reverse engineering software is designed to
take an existing physical part and construct a computer model of the part geometry based on a large number
of measurements of its surface by a CMM. This is currently a developing area in CMM and CAD software.
The simplest approach is to use the CMM in the manual mode of operation. in which the operator moves the
probe by hand and scans the physical part to create a digitized three-dimensional (3-D) surface model.
Manual digitization can be quite lime-consuming for complex pan geometries. More automated methods are
being developed, in which the CMM explores the part surfaces with little or no human intervention to
construct the 3-D model. The challenge here is to minimize the exploration time of the CMM, yet capture the
details of a complex surface contour and avoid collisions that would damage the probe. In this context. it
should be mentioned that significant potential exists for using non contacting probes (such as lasers) in
reverse engineering applications.
• Application-specific software: refers to programs written for certain types of parts and/or products and
whose applications are generally limited to specific industries. Several important examples are:
72. 1. Gear checking. These programs are used on a CMM to measure the geometric features of a gear, such as
tooth profile, tooth thickness, pitch, and helix angle.
2. Thread checking: These arc used for inspection of cylindrical and conical threads.
3. Cam checking: This specialized software is used to evaluate the accuracy of physical cams relative to
design specifications.
4. Automobile body checking: This software is designed for CMMs used to measure sheet metal panels,
subassemblies, and complete car bodies in the automotive industry. Unique measurement issues arise in
this application that distinguish it from the measurement of machined parts, These issues include: (1) large
sheet metal panels lack rigidity, (2) compound curved surfaces are common, (3) surface definition cannot
be determined without a great number of measured points.
73. CMM APPLICATIONS AND BENEFITS
• Coordinate measuring machines are most appropriate for applications possessing the following characteristics:
1. Many inspectors performing repetitive manual inspection operations. If the inspection function
represents a significant labour cost to the plant, then automating the inspection procedures will reduce labour
cost and increase throughput.
2. Post-process inspection. CMMs are applicable only to inspection operations performed after the
manufacturing process.
3. Measurement of geometric features requiring multiple contact points. These kinds of features are
identified and available CMM software facilitates evaluation of these features.
4. Multiple inspection setups are required if parts are manually inspected. Manual inspections are generally
performed on surface plates using gage blocks, height gages, and similar devices, and a different setup is
often required for each measurement. The same group of measurements on the part can usually be
accomplished in one setup on a CMM.
74. 5. Complex part geometry. If many measurements are to be made on a complex part, and many contact locations arc required, then the
cycle time of a DCC CMM will be significantly less than the corresponding time for a manual procedure.
6. High variety of parts to be inspected. A DCC CMM is a programmable machine, capable of dealing with high parts variety.
7. Repeat orders. Using a DCC CMM, once the part program has been prepared for the first part, subsequent parts from repeat orders can
be inspected using the same program.
• When applied in the appropriate parts quantity-parts variety range, the advantages of using CMMs over manual inspection methods are
• Reduced inspection cycle time. Because of the automated techniques included in the operation of a CMM, inspection procedures are
speeded and labour productivity is improved. A DCC CMM is capable of accomplishing many of the measurement tasks listed in Table
23.4 in one-tenth the time or less, compared with manual techniques. Reduced inspection cycle time translates into higher throughput.
• Flexibility. A CMM is a general-purpose machine that can be used to inspect a variety of different part configurations with minimal
changeover time. In the case of the DCC machine, where programming is performed off-line, changeover time on the CMM involves only
the physical setup.
• Reduced operator errors. Automating the inspection procedure has the obvious effect of reducing human errors in measurements and
setups.
• Greater inherent accuracy and precision. A CMM is inherently more accurate and precise than the manual surface plate methods that
are traditionally used for inspection.
• Avoidance of multiple setups. Traditional inspection techniques often require multiple setups to measure multiple part features and
dimensions. In general, all measurements can be made in a single setup on a CMM, thereby increasing throughput and measurement
accuracy.
75. MACHINE VISION SYSTEM
• Machine vision can be defined as the acquisition of image data, followed by the processing and interpretation of
these data by computer for some useful application.
• Machine vision (also called Computer Vision, since a digital computer is required to process the image data) is a
rapidly growing technology, with its principal applications in industrial inspection.
• In this section, we examine how machine vision works and its applications in QC inspection and other areas.
• Vision systems are classified as being either 2-D or 3-D. Two-dimensional systems view the scene as a 2-D
image.
• This is quite adequate for most industrial applications, since many situations involve a 2-D scene, Examples
include dimensional measuring and gaging, verifying the presence of components. and checking for features on
a flat (or semi flat) surface.
• Other applications require 3-D analysis of the scene, and 3-D vision systems are required for this purpose. Sales
of 2-D vision systems outnumber those of 3-D systems by more than ten to one. Our discussion will emphasize
the simpler 2-D systems, although many of the techniques used fur 2-D are also applicable in 3-D vision work.
76. • 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. These functions and their
relationships are illustrated schematically in the following figure:
77. 1. IMAGE ACQUISITION AND DIGITIZATION
• Image acquisition and digitization is accomplished using a video camera and a digitizing system to store the
image data for subsequent analysis.
• The camera is focused on the subject of interest and an Image is obtained by dividing the viewing area into a
matrix of discrete picture elements (called pixels) in which each element has a value that is proportional to the
light intensity of that portion of the scene.
• The intensity value for each pixel is converted into its equivalent digital value by an ADC.
• The operation of viewing a scene consisting of a simple object that contrasts substantially with its background,
and dividing the scene into a corresponding matrix of picture elements is depicted in figure.
78.
79. • The figure illustrates the likely Image obtained from the simplest type of vision system called a binary- vision
system.
• In binary vision the light intensity of each pixel, is ultimately reduced to either of two values. white or black.
depending on whether the light intensity exceeds a given threshold level.
• A more sophisticated vision system is capable of distinguishing and storing different shades of gray in the
image. This is called a gray-scale system.
• This type of system can determine not only an object's outline and area characteristics, but also its surface
characteristics such as texture and colour.
• Gray-scale vision systems typically use 4, 6 or 8 bits of memory. Eight bits corresponds to 28 = 256 intensity
levels, which is generally more levels than the video camera can really distinguish and certainly more than the
human eye can discern.
• Each set of digitized pixel values is referred to as a frame. Each frame is stored in a computer memory device
called a frame buffer. The process of reading all the pixel values in a frame is performed with a frequency of
30 times per second.
80. • Types of Cameras. Two types of cameras are used in machine vision applications:
• Vidicon cameras (the type used for television) and solid-state cameras. Vidicon cameras operate by
focusing the image onto a photoconductive surface and scanning the surface with an electron beam to obtain
the relative pixel values.
• Different areas on the photoconductive surface have different voltage levels corresponding to the light
intensities striking the areas.
• The electron beam follows a well-defined scanning pattern, in effect dividing the surface into a large number
of horizontal lines, and reading the lines from top-to-bottom.
• Each line is in turn divided into a series of points. The number of points on each line, multiplied by the number
of lines, gives the dimensions of the pixel matrix shown in the above Figure 23.11.
• During the scanning process, the electron beam reads the voltage level of each pixel.
• Solid-state cameras operate by focusing the image onto a 2-D array of very small, finely spaced
photosensitive elements. The photosensitive elements form the matrix of pixels shown in Figure 23.11.
• An electrical charge is generated by each element according to the intensity of light striking the element.
81. • The charge is accumulated in a storage device consisting of an array of storage elements corresponding one-to-
one with the photosensitive picture elements.
• These charge values are read sequentially in the data processing and analysis function of the machine vision.
• Illumination. Another important aspect of machine vision is illumination. The scene viewed by the vision
camera must be well illuminated, and the illumination must be constant over time. This almost always requires
that special lighting be installed for a machine vision application rather than rely on ambient lighting in the
facility.
• Five categories of lighting can he distinguished for machine vision application." as depicted in Figure 23.12:
(a) front lighting, (h) back lighting, (c) side lighting, (d) structured lighting, and (e) strobe lighting.
• These categories represent differences in the positions of the light source relative to the camera as much as
they do differences in lighting technologies.
• The lighting technologies include incandescent lamps, fluorescent lamps, sodium vapour lamps, and
lasers.
82.
83. • In front lighting, the light source is located on the same side of the object as the camera. This produces a reflected light from the
object that allows inspection of surface features such as printing on a label and surface patterns such as solder lines on a printed
circuit board.
• In back lighting, the light source is placed behind the object being viewed by the camera. This creates a dark silhouette of the
object that contrasts sharply with the light background. This type of lighting can be used for binary vision systems to inspect for
part dimensions, and to distinguish between different part outlines.
• Side lighting causes irregularities in an otherwise plane smooth surface to cast shadows that can be identified by the vision
system. This can be used to inspect for defects and flaws in the surface of an object.
• Structured lighting involves the projection of a special light pattern onto the object to enhance certain geometric features.
Probably the most common structured light pattern is a planar sheet of highly focused light directed against the surface of the
object at a certain known angle, as in Figure 23.12(d). The sheet of light forms a bright line where the beam intersects the surface.
In our sketch, the vision camera is positioned with its line of sight perpendicular to the surface of the object, so that any variations
from the general plane of the part appear as deviations from a straight line. The distance of the deviation can be determined by
optical measurement, and the corresponding elevation differences can be calculated using trigonometry.
• In strobe lighting, the scene is illuminated by a short pulse of high-intensity light, which causes a moving object to appear
stationary. The moving object might be a part moving past the vision camera on a conveyor. The pulse of light can last 5-500
microseconds. This is sufficient time for the camera to capture the scene, although the camera actuation must be synchronized
with that of the strobe light.
84. 2. IMAGE PROCESSING AND ANALYSIS
• The second function in the operation of a machine vision system is, image processing and analysis.
• As indicated, the amount of data that must be processed is significant. The data for each frame must be analyzed within the time
required to complete one scan (1/30 sec).
• A number of techniques have been developed for analyzing the image data in a machine vision system.
• One category of techniques in image processing and analysis is called segmentation. Segmentation techniques are intended to
define and separate regions of interest within the image.
• Two of the common segmentation techniques are thresholding and edge detection.
• Thresholding involves the conversion of each pixel intensity level into a binary value, representing either white or black. This is
done by comparing the intensity value at each pixel with a defined threshold value. If the pixel value is greater than the threshold, it
is given the binary bit value of white, say 1; if less than the defined threshold, then it is given the bit value of black, say 0. Reducing
the image to binary form by means of thresholding usually simplifies the subsequent problem of defining and identifying objects in
the image.
• Edge detection is concerned with determining the location of boundaries between an object and its surroundings in an image. This
is accomplished by identifying the contrast in light intensity that exists between adjacent pixels at the borders of the object. A
number of software algorithms have been developed for following the border around the object
85. • Another set of techniques in image processing and analysis that normally follows segmentation is feature
extraction.
• Most machine vision systems characterize an object in the Image by means of the object's features.
• Some of the features of an Object include the object's area, length, width, diameter, perimeter, center of
gravity, and aspect ratio.
• Feature extraction methods are designed to determine these features based on the area and boundaries of the
object (using thresholding, edge detection, and other segmentation techniques).
• For example. the area of the object can be determined by counting the number of white (or black) pixels that
make up the object. Its length can be found by measuring the distance (in terms of pixels) between the two
extreme opposite edges of the part.
86. 3. INTERPRETATION
• For any given application, the image must be interpreted based on the extracted features.
• The interpretation function is usually concerned with recognizing the object, a task termed object recognition or
pattern recognition.
• The objective in these tasks is to identify the object in the image by comparing it with predefined models or standard
values.
• Two commonly used interpretation techniques are template matching and feature weighting.
• Template matching is the name given to various methods that attempt to compare one or more features of an image
with the corresponding features of a model or template stored in computer memory.
• The most basic template matching technique is one in which the image is compared, pixel by pixel, with a
corresponding computer model.
• Within certain statistical tolerances, the computer determines whether the image matches the template.
• One of the technical difficulties with this method is the problem of aligning the part in the same position and
orientation in front of the camera, to allow the comparison to be made without complications in image processing.
87. • Feature weighting is a technique in which several features (e.g., area, length, and perimeter) are combined
into a single measure by assigning a weight to each feature according to its relative importance in identifying
the object.
• The score of the object in the image is compared with the score of an ideal object residing in computer
memory to achieve proper identification.
• Machine Vision Applications
• The reason for interpreting the image is to accomplish some practical objective in an application.
• Machine vision applications in manufacturing divide into three categories: (1) inspection, (2) identification,
and (3) visual guidance and control.
1. Inspection. By far, quality control inspection is the biggest category. Estimates are that inspection
constitutes about 80% of machine vision applications. Machine vision installations in industry perform a
variety of automated inspection tasks, most of which are either on-line-in-process or on-line/post-process.
The applications are almost always in mass production where the time required to program and set up the
vision system can be spread over many thousands of units.
88. • Typical industrial inspection tasks include the following:
• Dimensional measurement. These applications involve determining the size of certain dimensional features of parts
or products usually moving at relatively high speeds on a moving conveyor. The machine vision system must
compare the features (dimensions) with the corresponding features of a computer-stored model and determine the
size value
• Dimensional gaging. This is similar to the preceding except that a gaging function rather than a measurement is
performed.
• Verification of the presence of components in an assembled product. Machine vision has proved to be an
important element in flexible automated assembly systems.
• Verification of hole location and number of holes in a part. Operationally, this task is similar to dimensional
measurement and verification of components.
• Defection of surface flaws and defects. Flaws and defects on the surface of a part or material often reveal
themselves as a change in reflected light. The vision system can identity the deviation from an ideal model of the
surface
• Detection of flaws in a printed label. The defect can be in the form of a poorly located label or poorly printed text,
numbering, or graphics on the label.
89. • All of the preceding inspection applications can be accomplished using 2-D vision systems. Certain
applications require 3-D vision, such as scanning the contour of a surface, inspecting cutting tools to check for
breakage and wear, and checking solder paste deposits on surface mount circuit boards. Three-dimensional
systems are being used increasingly in the automotive industry to inspect surface contours of parts such as
body panels and dashboards. Vision inspection can be accomplished at much higher speeds than the traditional
method of inspecting these components, which involves the use of CMMs.
2. Other Machine Vision Applications. Part identification applications are those in which the vision system is
used to recognize and perhaps distinguish parts or other objects so that some action can be taken. The
applications include part sorting, counting different types of parts flowing past along a conveyor, and
inventory monitoring. Part identification can usually be accomplished by 2-D vision systems. Reading of 2-
D bar codes and character recognition represent additional identification applications performed by 2-D
vision systems.
3. Visual guidance and control involves applications in which a vision system is teamed with a robot or
similar machine to control the movement of the machine. Examples of these applications include seam
tracking in continuous arc welding, part positioning and/or reorientation, bin picking, collision avoidance,
machining operations, and assembly tasks. Most of these applications require 3-D vision.
