3D Profilometer

Properties

For recording surface roughness and for height measurements. The profilometer is used to measure roughness on surfaces with micrometer resolution. The testing device moves a camera upwards in the Z-plane and generates between 2 and 255 individual images at fixed positions along the measuring distance. These are superimposed in so-called pyramidal stacking (focus fusion) or (depth of field enhancement) so that the sharpest pixel groups describe the height from which they were taken.

Tribological friction track analysis

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With the detailed images of friction tracks and their height representation as a topographical surface, it is possible to evaluate the effect of which pin on the friction disk. The topographical profiles can also be used to determine the frequency with which vibrations build up in the friction track. In addition, other surfaces can also be displayed in their condition after a load. The resolution of the system can be scaled with even more powerful cameras. It is also possible to use a rotation table to inspect an entire ring disk at all positions. This is an extension as a 3D portal system that can capture entire surfaces up to 300x400 mm.

Compact design

Procedure description

The measurement repeatability is in the ~1 µm range, this is achieved by acquiring dozens of images via the Z-axis movement, from these real-time photos only the sharpest pixels are translated into a new 32-bit RGBA image via the so-called pyramidal matrix folding. This results in a new Z-plane for each pixel group of 5x5 pixels in which the respective height is described. The height of an object can be displayed continuously in the micrometer range between the individual planes created (base height/granularity). In addition, the method makes it possible to obtain information about the surface roughness and its procurement (friction marks).

Surfaces

Software operation

The DFS profilometer software is used to control the measurement process. There are only 8 buttons to control the entire measurement process. This makes it possible to create a height measurement or an area profile without any introduction or special knowledge. The results can be printed out as a PDF test report. The entire measurement process is stored in the control software as a test plan. Individual extensions/additions can be added here to operate the measuring device completely in an automated environment. The controller can receive or transmit additional TTL levels and communicate with the controlling system via Ethernet (TCP) /Serial (RS232) or via the Wago Modbus terminal, as well as via a PLC (plc). This makes it suitable for a wide range of applications under industrial conditions.

Software

Ergonomic design

Compact designSwing doors

The profilometer is supplied with hinged doors so that the sample table can be accessed from all sides. The profilometer is supplied with 2 screens and a powerful 3D computer with 10 core processors and a large memory. Alternatively, the software can also be operated on a laptop, with minor performance compromises. The entire control system is installed in a black box and only has an on/off switch. The connection to the PC is made via a USB3.0 camera connection cable, which is also used for motor control via RS232. This means that there is no large cable harness in the test field.

 

 

Technical specifications

Testing System: Camera as Depth of Field Extension in Deep Focus Stacking (DFS)
Camera Resolution: 1392 x 1040 [pixels] Color
Field of View (FOV): 2.5x2.0 [mm²]
Capture Frequency: 18 [Hz]
Image Stack Calculation Time: 58 [ms] / image
Camera Resolution Z: 1 [µm] Repeatability
Camera Resolution X: 1.7 [µm]
Camera Resolution Y: 1.9 [µm]
Axis Resolution Z: 5 [µm] (Base Height/Granularity)
Lighting: Flash LED (white) triggered by the camera. d=50 [mm]
Lift Table: Spindle axis with stepper motor resolution ~ 5 [µm]
Travel Distance: 100 [mm]
Measurement Path Length: 1.275 [mm] with 1 [µm] repeatability
Software: Operating System MS Windows 10,11 64 Bit
Software Control: DFS Profilometer V9.5 / 64 Bit
Operating Resources: Power 230 VAC 50/60 Hz
Dimensions (Testing Device) W x H x D: 370 x 330 x 530 mm
Weight (Testing Device): approx. 20 Kg