Metrology

The growing demand for automated production systems is driving continuous innovation in smart and data-driven manufacturing technologies. In the field of production metrology, the trend is shifting from using measurement laboratories to integrating measurement systems directly into production processes. This has led the Institute of Manufacturing Technology at TU Vienna together with its partners to develop a roughness measurement device that can be directly integrated into machine tools. Building on this foundation, this study tries to find applications beyond mere surface roughness assessment and demonstrates how the device could be applied in broader contexts of manufacturing process monitoring. By linking surface measurements with tool wear monitoring, the study establishes a correlation between surface roughness and wear progression of indexable inserts in milling. It demonstrates how in situ data can support predictive maintenance and the real-time adjustment of cutting parameters. This represents a first step toward integrating in situ metrology into closed-loop control in machining. The experimental setup followed ISO 8688-1 guidelines for tool life testing. Indexable inserts were operated throughout their entire service life while surface roughness was continuously recorded. In parallel, cutting edge conditions were documented at defined intervals using focus variation microscopy. The results show a consistent three-phase pattern: initially stable roughness, followed by a steady increase due to flank wear, and an abrupt decrease in roughness linked to edge chipping. These findings confirm the potential of integrated roughness measurement for condition-based monitoring and the development of adaptive machining strategies. Full article

Lighting measurements and calculation is an old and widespread process, evolving with the variety of technologies that use light or operate efficiently depending on the natural or artificial light conditions in the ambient environment. The complexity of human activities gives rise to different techniques and approaches to lighting effect analysis, and this paper aims to clarify which type of units, photometric or radiometric, are appropriate, and which light measurement and calculation techniques are optimal for evaluating the environmental microclimate intended for an activity. Quantitative lighting analysis is common and accessible through the measuring devices, calculation formulas, and simulation software available. In contrast, qualitative analysis remains less prevalent, partly due to its complexity and the need to consider human perception as a central component in assessing lighting impact, as emphasized by the human-centric lighting paradigm. Current evaluation frameworks distinguish between the quantitative and qualitative approaches, with actinic calculations addressing biologically relevant aspects of lighting in specific environmental contexts. Full article

In this study, we propose a simple and effective method for gas analysis by establishing a correlation between residual gas analyzer (RGA) intensity and gas concentration. To achieve this, we focused on CF₄ and NF₃, two high-global warming potential (GWP) gases commonly used in industrial applications. The experiment was conducted in four key steps: identifying gas species using optical emission spectroscopy (OES), calibrating RGA with a quadrupole mass spectrometer (QMS), constructing a five-point calibration graph to correlate RGA and Fourier-transform infrared spectroscopy (FT-IR) data, and estimating the concentration of unknown samples using the calibration graph. The results under plasma-on conditions demonstrated correlation and accuracy, confirming the reliability of our approach. In other words, the method effectively captured the relationship between RGA intensity and gas concentration, providing valuable insights into concentration trends. Thus, our approach serves as a useful tool for estimating gas concentrations and understanding the correlation between RGA intensity and gas composition. Full article

Virtual experiments (VE) can be used to assess the measurement uncertainty of complex measurements. The typical calculation procedure implemented in such a VE, called VE-DA in this paper, is based on a Monte Carlo method involving simulating possible measurement errors and possible measurement data based on extensive modeling of the measurement instrument, followed by applying a data analysis function (DA) to evaluate the measurement data. This procedure is similar to the propagation of distributions using a Monte Carlo method (PoD) procedure presented in the written standard JCGM-101, in which the Monte Carlo method is applied to an explicit mathematical model for the measurand involving simulating and applying possible corrections to the observed measurement data. However, in this paper, we show that the uncertainty provided by the VE-DA procedure can be both larger and smaller than the uncertainty evaluated based on applying the PoD to the correct measurement model, when available. This is important to realize by users of the VE-DA procedure when claiming conformity of an uncertainty evaluation with JCGM-101. Full article

Some laser scanners utilize stepper motor-driven optomechanical assemblies to position the laser beam precisely during triangulation. In laser scanners such as the presented Technical Vision System (TVS), to enhance motion resolution, gear transmissions are implemented between the motor and the optical assembly. However, due to the customized nature of the mechanical design, errors in manufacturing or insufficient mechanical characterization can introduce deviations in the computed 3D coordinates. In this work, we present a novel method for estimating the degrees-per-step ratio at the output of the laser positioner’s transmission mechanism using a stereovision system. Experimental results demonstrate the effectiveness of the proposed method, which reduces the need for manual metrological instruments and simplifies the calibration procedure through vision-assisted measurements. The method yielded estimated angular resolutions of approximately 0.06° and 0.07° per motor step in the horizontal and vertical axes, respectively, key parameters that define the minimal resolvable displacement of the projected beam in dynamic triangulation. Full article

Most flow metering methods used in industrial applications produce results sensitive to the local velocity profile. In response, manufacturers often implement correction algorithms; however, these are rarely supported by rigorous uncertainty evaluations. This paper presents a Reynolds number-dependent velocity profile correction, applicable under fully developed flow conditions and for the Reynolds-dependent part of the correction in disturbed flows, demonstrated on the example of an ultrasonic clamp-on flow meter. Measurement uncertainties are evaluated and propagated through a regression model using Monte Carlo simulation, in compliance with the Guide to the Expression of Uncertainty in Measurement (GUM). Special care is taken to assess the validity range and impact of assuming fully developed flow conditions at the test rig. A validation case demonstrates the reliability of the correction algorithm and its associated uncertainty within the tested conditions. The proposed approach is applicable to other meter types and can be extended to corrections for specific flow disturbances. Full article

Droplet-based microlens fabrication using Ultra Violet (UV) curable polymers demands the precise measurement of three-dimensional geometries, especially for non-axisymmetric shapes influenced by electric field deformation. In this work, we present a polar coordinate-based contour fitting method combined with Hermite interpolation to reconstruct 3D droplet geometries from two orthogonal shadowgraphy images. The image segmentation process integrates superpixel clustering with active contours to extract the droplet boundary, which is then approximated using a spline-based polar fitting approach. The two resulting contours are merged using a polar Hermite interpolation algorithm, enabling the reconstruction of freeform droplet shapes. We validate the method against both synthetic Computer-Aided Design (CAD) data and precision-machined reference objects, achieving volume deviations below 1% for axisymmetric shapes and approximately 3.5% for non-axisymmetric cases. The influence of focus, calibration, and alignment errors is quantitatively assessed through Monte Carlo simulations and empirical tests. Finally, the method is applied to real electrically deformed droplets, with volume deviations remaining within the experimental uncertainty range. This demonstrates the method’s robustness and suitability for metrology tasks involving complex droplet geometries. Full article

Integrating optical metrology into steelmaking and metalworking processes faces challenges not only from harsh conditions but also from a limited understanding of metrology concepts. The literature often overlooks distinctions between different uncertainty sources. This paper proposes a model for the quantification of uncertainty in dimensional measurements of open-die forged components, addressing the different uncertainty sources related to the measurand variability, to the instrumental uncertainty and to the definitional uncertainty. Guidelines for their evaluation are provided, and two case-studies related to measurement of forged shafts are presented and discussed. Full article

In the course of digitalization, the importance of modeling and simulating real-world processes in a computer is rapidly increasing. Simulations are now in everyday use in many areas. For example, simulations are used to gain a better understanding of the real experiment, to plan new experiments, or to analyze existing experiments. Simulations are now also increasingly being used as an essential component of a real measurement, usually as part of an inverse problem. To ensure confidence in the results of such virtual measurements, traceability and methods for evaluating uncertainty are needed. In this paper, the challenges and benefits inherent to virtual metrology techniques are shown using three examples from different metrological fields: the virtual coordinate measuring machine, the tilted-wave interferometer, and the virtual flow meter. Full article

Particle accelerator laboratories, which enable world-class research across many scientific fields, depend on the magnets used to manipulate their particle beams for successful operation. The community employs various techniques, typically based on Hall probes and induction sensors/coils, to verify the performance of these accelerator magnets. When the transverse access around a magnet is restricted, conventional Hall probe systems cannot be deployed or require significant modification, while moving wire/coil systems tend to provide information only on the magnetic field’s integral. This research builds upon a vibrating wire setup first commissioned to locate the magnetic center of quadrupole magnets. Scans up to the n = 200 wire harmonic (∼10 kHz drive frequency) were measured to reconstruct the magnetic field across a wire strung through a test magnet. New software was developed to systematically process the many frequency response scans needed for a detailed field reconstruction. This research investigated the speed and precision of the measurement, identifying limitations due to both instrumentation and nonlinear wire behavior. The vibrating wire data agreed with a reference Hall probe scan on the order of 6%; roughly 0.7% RMS error persisted after calibrating the vibrating wire data to the reference scan via scaling factor. Full article

This paper proposes using provenance information to describe processes in metrology. The PROV data model is used as an example to showcase a conceptual analysis about how to improve quality, reliability, and overall interoperability within cross-domain applications that require communicating measurement data and traceability information. The analysis considers various metrological processes and outputs that support traceability. The conceptual analysis will be used as a foundation for further contributions to the topic of improving the documentation of metrological traceability with provenance data models. Several use cases illustrate how provenance information can provide context for traceability claims, especially when the measurement result is the focal object of interest. The PROV family of specifications provides machine-actionable metadata and semantic interoperability when communicating measurement information in traceability chains. PROV supports various perspectives that arise in the context of metrological traceability. Full article

This article investigates the acoustic properties of artificial discontinuities in reference specimens for the ultrasonic testing of welded joints in polyethylene pipes. An analysis is conducted on the reflectivity of various materials (air, sand, heat-resistant silicate-based sealant, and aluminum foil) and their correspondence to real defects occurring in weld seams. A theoretical analysis of reflection coefficients is performed, along with laboratory studies using digital radiography and ultrasonic testing. The results demonstrate that heat-resistant silicate sealant is the most suitable material for simulating defects, as its acoustic properties closely match those of real inclusions, and its geometric parameters remain stable during the welding process. The use of such specimens enhances the reliability of ultrasonic testing and reduces the likelihood of errors in defect classification. Full article

Accurate characterization of 3D surface topography is essential for assessing the quality of machined components. This study investigates the influence of measurement area selection on the evaluation of roughness parameters in high-feed tangential turning of 42CrMo4 alloy steel. Cylindrical surfaces were machined using different process parameters, and their surface topography was analyzed by varying the size of the areal measurement region. Key roughness parameters were examined to determine the impact on the reliability and consistency of surface characterization. The results highlight how different measurement areas influence roughness values and their variations. The findings contribute to improved metrological practices in tangential turning, and they are particularly relevant for precision machining applications where surface integrity plays a critical role. The area width of the measurement area was shown to play a critical role in data reliability. The results showed that S_a and S_k stabilized after 5.5–6.0 mm, while S_sk and S_ku stabilized earlier, at approximately 5.0 mm. S_pk and S_vk required the longest evaluation area widths, up to 6.0 mm, to achieve consistent values. Full article

Background: Velocity-based training (VBT) requires precise measurement devices to monitor neuromuscular performance. PowerTrack^TM is a novel optoelectronic device designed to assess movement velocity in resistance training. This study aimed to evaluate the validity and reliability of PowerTrack^TM during the Smith machine back squat. Methods: Twenty experienced-trained men performed three repetitions at three submaximal loads (20, 50, and 70 kg) across two sessions. Velocity metrics—mean velocity (MV), mean propulsive velocity (MPV), and maximum velocity (Vmax)—were simultaneously recorded by PowerTrack^TM and the criterion device (MuscleLab^TM). Validity was assessed via ordinary least products (OLP) regression, Lin’s concordance correlation coefficient (CCC), and Bland–Altman plots. Reliability was determined using intraclass correlation coefficients (ICCs), standard error of measurement (SEM), coefficient of variation (CV), and minimum detectable change (MDC). Results: PowerTrack showed high agreement with MuscleLab^TM for MPV and Vmax (slope ≈ 1.00; CCC = 0.95–0.97), while MV presented a proportional bias (slope = 0.83). ICCs ranged from 0.78 to 0.91 across loads, and SEM remained <0.09 m/s for all metrics, indicating excellent relative reliability and acceptable absolute precision. Conclusion: Despite a slight underestimation of MV at light loads, PowerTrack^TM proved to be a valid and reliable device for velocity monitoring in VBT contexts. Full article

Cone Penetration Tests with pore pressure measurements (CPTu) are widely used in geotechnical site investigations due to their high-resolution profiling capabilities. However, traditional interpretation methods—such as the Soil Behavior Type Index ($I_c$)—often fail to capture the internal heterogeneity typical of mining tailings deposits. This study presents a machine learning-based approach to enhance stratigraphic interpretation from CPTu data. Four unsupervised clustering algorithms—k-means, DBSCAN, MeanShift, and Affinity Propagation—were evaluated using a dataset of 12 CPTu soundings collected over a 19-year period from an iron tailings dam in Brazil. Clustering performance was assessed through visual inspection, stratigraphic consistency, and comparison with $I_c$-based profiles. k-means and MeanShift produced the most consistent stratigraphic segmentation, clearly delineating depositional layers, consolidated zones, and transitions linked to dam raising. In contrast, DBSCAN and Affinity Propagation either over-fragmented or failed to identify meaningful structures. The results demonstrate that clustering methods can reveal behavioral trends not detected by $I_c$ alone, offering a complementary perspective for understanding depositional and mechanical evolution in tailings. Integrating clustering outputs with conventional geotechnical indices improves the interpretability of CPTu profiles, supporting more informed geomechanical modeling, dam monitoring, and design. The approach provides a replicable methodology for data-rich environments with high spatial and temporal variability. Full article

Optical fringe projection is an outstanding technology that significantly enhances three-dimensional (3D) metrology in numerous applications in science and engineering. Although the complexity of fringe projection systems may be overwhelming, current scientific advances bring improved models and methods that simplify the design and calibration of these systems, making 3D metrology less complicated. This paper provides an overview of the fundamentals of fringe projection profilometry, including imaging, stereo systems, phase demodulation, triangulation, and calibration. Some applications are described to highlight the usefulness and accuracy of modern optical fringe projection profilometers, impacting 3D metrology in different fields of science and engineering. Full article

Thermal management is an area of study in electronics focused on managing temperature to improve reliability and efficiency. When temperatures are too high, cooling systems are activated to prevent overheating, which can lead to reliability issues. To monitor the temperatures, sensors are often placed on-chip near hotspot locations. These sensors should be very small to allow them to be placed among compact, high-activity circuits. Often, they are connected to a central control circuit located far away from the hot spot locations where more area is available. This paper proposes sensing units for a novel temperature sensing architecture in the TSMC 180 nm process. This architecture functions by approximating the current through the sensing unit at a reference voltage, which is used to approximate the temperature in the digital back end using fitting functions. Sensing units are selected based on how well its temperature–current relationship can be modeled, sensing unit area, and power consumption. Many sensing units will be experimented with at different reference voltages. These temperature–current curves will be modeled with various fitting functions. The sensing unit selected is a diode-connected p-type MOSFET (Metal Oxide Semiconductor Field Effect Transistor) with a size of W = 400 nm, L = 180 nm. This sensing unit is exceptionally small compared to existing work because it does not rely on multiple devices at the sensing unit location to generate a PTAT or IPTAT signal like most work in this area. The temperature–current relationship of this device can also be modeled using a 2nd order polynomial, requiring a minimal number of trim temperatures. Its temperature error is small, and the power consumption is low. The range of currents for this sensing unit could be reasonably made on an IDAC. Full article

Articulated arm coordinate measuring machines are designed for in situ use directly in manufacturing environments, enabling efficient dimensional control outside of climate-controlled laboratories. This study investigates the influence of ambient temperature variation on the accuracy of length measurements performed with the Hexagon Absolute Arm 8312. The experiment was carried out in a laboratory setting simulating typical shop floor conditions through controlled temperature changes in the range of approximately 20–31 °C. A calibrated steel gauge block was used as a reference standard, allowing separation of the influence of the measuring system from that of the measured object. The results showed that the gauge block length changed in line with the expected thermal expansion, while the articulated arm coordinate measuring machine exhibited only a minor residual thermal drift and stable performance. The experiment also revealed a constant measurement offset of approximately 22 µm, likely due to calibration deviation. As part of the study, an uncertainty budget was developed, taking into account all relevant sources of influence and enabling a more realistic estimation of accuracy under operational conditions. The study confirms that modern carbon composite articulated arm coordinate measuring machines with integrated compensation can maintain stable measurement behavior even under fluctuating temperatures in controlled environments. Full article

Current temperature sensors require regular recalibration to maintain reliable temperature measurement. Photonic/quantum-based approaches have the potential to radically change the practice of thermometry through provision of in situ traceability, potentially through practical primary thermometry, without the need for sensor recalibration. This article gives an overview of the European Partnership in Metrology (EPM) project: Photonic and quantum sensors for practical integrated primary thermometry (PhoQuS-T), which aims to develop sensors based on photonic ring resonators and optomechanical resonators for robust, small-scale, integrated, and wide-range temperature measurement. The different phases of the project will be presented. The development of the integrated optical practical primary thermometer operating from 4 K to 500 K will be reached by a combination of different sensing techniques: with the optomechanical sensor, quantum thermometry below 10 K will provide a quantum reference for the optical noise thermometry (operating in the range 4 K to 300 K), whilst using the high-resolution photonic (ring resonator) sensor the temperature range to be extended from 80 K to 500 K. The important issues of robust fibre-to-chip coupling will be addressed, and application case studies of the developed sensors in ion-trap monitoring and quantum-based pressure standards will be discussed. Full article