Search Results (68)

This article presents research and a discussion on the proper use of filtration in optical measurements. Measurements were taken using a Werth multisensory machine using a Werth Zoom optical sensor. During optical measurements, the filtration option can be used. The manufacturer defines filters as “Dust”. They allow the machine operator to define the appropriate size depending on the type of inclusions or artifacts created in the production process. They can occur in processes such as punching on presses or production in the injection molding process of plastics. The presented research results and statistical analyses confirm the assumptions regarding the validity of using filters and their values. The use of filters with a higher value significantly affects the obtained results and forces the machine user to make a reasonable choice. Full article

As additive manufacturing technologies continue to gain ground in industrial applications, the need for the accurate metrological evaluation of parts produced with advanced materials becomes increasingly critical. In this context, non-contact metrology plays a key role. This research investigates the performance of conoscopic holography as an optical metrology technique for the inspection of ceramic parts manufactured by stereolithography. However, its reliability needs to be validated, especially as factors such as material properties, surface finish, and color can significantly affect measurement accuracy. Spherical artifacts in alumina were chosen as mathematically well-defined reference elements, and a representative series was produced with the best values for the printing, debinding, and sintering parameters. These spheres were first measured via contact with a coordinate measuring machine (CMM) to establish dimensional (diameter) and geometrical (form error) reference values. These parameters were then compared with measurements obtained via conoscopic holography and optimized by means of Gaussian filters. The results indicated significant dimensional (up to 60 µm) and geometrical (up to 280 µm) deviations from the CMM reference data. The investigation shows that conoscopic holography does not ensure an accurate measurement method for this additive process and ceramic material, making it impossible to achieve power and frequency settings that would allow signal-to-noise ratios above 50%. Full article

Optical window freeform surfaces have emerged as a critical research focus in advanced optical engineering owing to their extensive surface degrees of freedom. These surfaces enable the simultaneous correction of on-axis and off-axis aberrations while satisfying stringent requirements for high-performance, lightweight, and compact optical systems. In the initial metrological characterization of these surfaces, coordinate measuring machines (CMMs) are conventionally employed for target point cloud acquisition. However, the achievable measurement accuracy (>2 μm) inherently constrained by CMM precision imposes fundamental limitations for subsequent optical inspections requiring sub-micron to nanometer-level resolution. Meanwhile, although optical measurement methods can result in higher measurement accuracy, they also lead to an increase in costs and testing difficulties. To overcome these limitations, we propose an accelerated point cloud registration methodology based on point-to-triangulation distance estimation. In simulation, using optimal coordinate transformation enabled good capabilities for exceptional surface characterization: peak-to-valley (PV) surface error of 10⁻⁶ nm, residual error of 5 nm, and registration accuracy of log₁₀ (mm/°). Further, in the experiment, the PV surface error was reduced from 27.3 μm to 6.9 μm, equivalent to a reduction of 3.95 times. These results confirm that the point-to-triangulation distance approximation maintains sufficient fidelity to the nominal point-to-surface distance, thereby empirically validating the efficacy of our proposed methodology. Notably, compared with conventional 3D alignment methods, our novel 2D estimation registration approach with point-to-triangulation surface normal vectors demonstrates significant advantages in computational complexity, which achieved a 78% reduction from O(n³) to O(n) while maintaining sub-millisecond alignment times. We believe that the method has potential for use as a low-cost optical precision measurement in manufacturing technology. Full article

Wrist kinematics can provide insight into the development of repetitive strain injuries, which is important particularly in workplace environments. The emergence of markerless motion capture is beginning to revolutionize kinematic assessment such that it can be conducted outside of the laboratory. The purpose of this work was to apply open-source software (OSS) and machine learning (ML) by using DeepLabCut (OSS) to determine anatomical landmark locations and a variety of regression algorithms and neural networks to predict wrist angles. Sixteen participants completed a series of flexion–extension (FE) and radial–ulnar (RUD) range-of-motion (ROM) trials that were captured using a 13-camera VICON optical motion capture system (i.e., the gold standard), as well as 4 GoPro video cameras. DeepLabCut (version 2.3.3) was used to generate a 2D dataset of anatomical landmark coordinates from video obtained from one obliquely oriented GoPro video camera. Anipose (version 1.0.1) was used to generate a 3D dataset from video obtained from four GoPro cameras. Anipose and various ML algorithms were used to determine RUD and FE wrist angles. The algorithms were trained and tested using a 75%:25% data split with four folds for the 2D and 3D datasets. Of the seven ML techniques applied, deep neural networks resulted in the highest prediction accuracy (5.5) for both the 2D and 3D datasets. This was substantially higher than the wrist angle prediction accuracy provided by Anipose ($FE-99$; $RUD-25.2$). We found that, excluding cubic regression, all other studied algorithms exhibited reasonable performance that was similar to that reported by previous authors, showing that it is indeed possible to predict wrist kinematics using a low-cost motion capture system. In agreement with past research, the increased MAE for FE is thought to be due to a larger ROM. Full article

Surveys of fragmentations, especially in the early stages of the given event, are fundamental for determining the number of fragments, identifying and cataloging them, and monitoring their future evolution. The development of a ground-based optical survey strategy, i.e., a suitable observation and detection method for the fragments generated by these events, is an important contribution to acquiring data and monitoring these catastrophic phenomena. An optical survey offers an interesting and cost-effective method that supports radar operations in the Low Earth Orbit regime and can monitor higher orbits where radar cannot be used. This paper presents a developed optical survey strategy for multi-observatory observations. The strategy was tested on the fragmentation event of FREGAT R/B CLUSTER 2, a rocket body with a “dummy” payload, fragmented on 8 April 2024 on a Highly Elliptical Orbit. The observational campaign involved different observatory systems, and it represented a key collaboration within the Inter-Agency Space Debris Coordination Committee. The survey started from a simulation of the cloud of fragments and was implemented by the planification and coordination of different observatory systems with different schemes and methods to scan the sky vault. The acquired survey data were analyzed using machine learning methods to identify the unknown objects, i.e., the fragments. The data acquired were compared with the simulated cloud used for the survey, and a correlation of measurements belonging to the same object was performed. Also, the parent body was characterized in its tumbling motion by the light curve acquisition. Full article

Direct verification of the geometric accuracy of machined parts cannot be performed simultaneously with active machining operations, as it usually requires subsequent inspection with measuring devices such as coordinate measuring machines (CMMs) or optical 3D scanners. This sequential approach increases production time and costs. In this study, we propose a novel indirect measurement method that utilizes motor current data from the controller of a Computer Numerical Control (CNC) machine in combination with machine learning algorithms to predict the geometric accuracy of machined parts in real-time. Different machine learning algorithms, such as Random Forest (RF), k-nearest neighbors (k-NN), and Decision Trees (DT), were used for predictive modeling. Feature extraction was performed using Tsfresh and ROCKET, which allowed us to capture the patterns in the motor current data corresponding to the geometric features of the machined parts. Our predictive models were trained and validated on a dataset that included motor current readings and corresponding geometric measurements of a mounting rail later used in an engine block. The results showed that the proposed approach enabled the prediction of three geometric features of the mounting rail with an accuracy (MAPE) below 0.61% during the learning phase and 0.64% during the testing phase. These results suggest that our method could reduce the need for post-machining inspections and measurements, thereby reducing production time and costs while maintaining required quality standards. Full article

A compact and miniaturized laser collimation system was proposed to measure the four-degrees-of-freedom of an optical payload in high-altitude space. Compared with other systems, this system has a simple structure and low cost, high measurement accuracy, and a large measurement range. The optical structure of the system was designed, the measurement principle of the four-degree-of-freedom was described in detail, the interference between the distance measurement and the angle measurement in the optical path was analyzed, and the installation error was analyzed. The error was minimized under different temperature conditions to improve the robustness of the system. An engineering prototype was built based on the system design scheme and an experiment was conducted to measure a target with a measured distance of 500 mm. The current indicators reached the requirements for the ground testing of optical payloads. The application of the system can be used to measure six degrees of freedom simultaneously by installing two systems in different coordinate systems. The system can also be used in industry; for example, by measuring the machine tool error in real time and compensating for it, the system can improve the positioning and motion accuracy. It can also be used for feedback control of the robot’s motion by measuring and controlling it. Full article

Magnetorheological finishing (MRF) of aspherical optical elements usually requires the coordination between the translational axes and the oscillating axes of the machine tool to realize the processing. For aspheric optical elements whose steepness exceeds the machining stroke of the equipment, there is still no better method to achieve high-precision and high-efficiency error convergence. To solve this problem, an MRF method combining virtual-axis technology and a spiral scanning path is proposed in this paper. Firstly, the distribution law of the magnetic induction intensity inside the polishing wheel is analyzed by simulation, the stability of the removal efficiency of the removal function within the ±7^∘ angle of the normal angle of the polishing wheel is determined, and MRF is expanded from traditional single-point processing to circular arc segment processing. Secondly, the spiral scanning path is proposed for aspherical rotational symmetric optical elements, which can reduce the requirements of the number of machine tool axes and the dynamic performance of machine tools. Finally, an aspherical fused silica optical element with a curvature radius of 400 mm, K value of −1, and aperture of 100 mm is processed. The PV value of this optical element converges from 189.2 nm to 24.85 nm, and the RMS value converges from 24.85 nm to 5.74 nm. The experimental results show that the proposed combined process has the ability to modify curved optical elements and can be applied to ultra-precision machining of high-steepness optical elements. Full article

Additive Manufacturing (AM) is advancing technologically towards the production of components for high-demand mechanical applications with stringent dimensional accuracy, leveraging metallic and ceramic raw materials. The AM process for ceramic components, known as Ultraviolet Laser Stereolithography (SLA), enables the fabrication of unique parts or small batches without substantial investments in molds and dies, and avoids the problems associated with traditional manufacturing, which involves multiple stages and final machining for precision. This study addresses the need to produce reference elements or targets for metrological applications, including verification, adjustment, or calibration of 3D scanners and mid- to high-range optical sensors. Precision spheres are a primary geometry in this context due to their straightforward mathematical definition, facilitating rapid and accurate error detection in equipment. Our objective is to exploit this novel SLA process along with the advantageous optical properties of technical ceramics (such as being white, matte, lightweight, and corrosion-resistant) to materialize these reference objects. Specifically, this work involves the fabrication of alumina hemispheres using SLA. The manufacturing process incorporates four design variables (wall thickness, support shape, fill type, and orientation) and one manufacturing variable (the arrangement of spheres on the printing tray). To evaluate the impact of the design variables, dimensional and geometric parameters (GD&T), including diameters, form errors, and their distribution on the surface of the sphere, have been characterized. These measurements are conducted with high accuracy using a Coordinate Measuring Machine (CMM). The study also examines the influence of these variables in the dimensional and geometric accuracy of the spheres. Correlations between various parameters were identified, specifically highlighting critical factors affecting process precision, such as the position of the piece on the print tray and the wall thickness value. The smallest diameter errors were recorded at the outermost positions of the tray (rear and front), while the smallest shape errors were found at the central position, in both cases with errors in the range of tens of micrometers. In any case, the smallest deformations were observed with the highest wall thickness (2 mm). Full article

This article discusses a comparative analysis of the wear and quality of planer knife blades used in wood planers. The novelty in this work is the use of a simple coordinate measuring machine with a vision system to assess the wear of the cutting edges of planer knives. The primary objective of the research described in this paper was to verify whether the wear of the cutting edge of planer knives can be measured quickly and accurately using an optical coordinate measuring machine with a vision system. To date, contact profilometry methods have been used for this purpose, which require a specialist apparatus and qualified measuring equipment operators and are expensive and time-consuming. The research presented in this work was conducted on twelve planer knives. The condition and wear of the working surfaces of the tested knives were assessed using an optical digital microscope. The wear of the cutting edge of the knives was measured using two methods: the contact profilometry method and an optical coordinate measuring machine equipped with a vision system. The edge profiles and their parameters obtained by the optical method were compared to the results of measurements with a stylus profilometer. Based on the research and analyses conducted, it was found that the optical method used in this research significantly shortens the time of measuring the wear of the cutting edges of planer knives. In addition, this method has a wider measurement range, and the obtained measurement results are characterized by lower measurement uncertainty. Full article

Hydrostatic bearings are frequently used for moving large structures smoothly and precisely. In such applications, difficulties with manufacturing, transportation, and assembly arise. The safety and precision of the entire supported structure depend on the accuracy of the hydrostatic bearing alignment. There are several suitable methods for its alignment, yet it is not clear which method can achieve the highest bearing precision. This study provides a comparative experimental assessment of the three methods. The measurements were performed on a hydrostatic bearing test rig with independent positioning of the pads. Conventional measuring devices, a pressure distribution alignment method, and an optical method, OCMM (optical coordinate measuring machine), were compared. The accuracy of the selected methods and the difficulty of the aligning process were included in the comparison. The OCMM method was able to achieve an accuracy 1.6 times higher relative to the pressure method and 6 times higher compared to conventional measuring devices. This method is versatile and can be applied for a wide range of bearing sizes. Full article

A high-precision catadioptric telescope such as a space-borne telescope is usually tested with interferometer to check the optical quality in assembly. The coarse and fine alignment of the telescope are mainly based on the information from the coordinate measuring machine and the fringe pattern of the interferometer, respectively. In addition, further fine-tuning can be achieved according to the variation in wavefront error and Zernike data. The issue is that the vast majority of the catadioptric telescopes contain plural lens surfaces which could produce unwanted ghost fringes, disturbing the wavefront measurement. Technically, off-axis installation to shift away ghost fringes from central interferogram could be acceptable in some cases. Nevertheless, in this paper, the source of ghost fringe in interferometric measurement for catadioptric telescopes is investigated with light path simulation, and a solution of reducing the f-number of the diverger lens is proposed to eliminate the ghost fringe disturbance. Both simulation and experimental results verify the effectiveness of the proposed concept. Full article

We present the use of interconnected optical mesh networks for early earthquake detection and localization, exploiting the existing terrestrial fiber infrastructure. Employing a waveplate model, we integrate real ground displacement data from seven earthquakes with magnitudes ranging from four to six to simulate the strains within fiber cables and collect a large set of light polarization evolution data. These simulations help to enhance a machine learning model that is trained and validated to detect primary wave arrivals that precede earthquakes’ destructive surface waves. The validation results show that the model achieves over 95% accuracy. The machine learning model is then tested against an M4.3 earthquake, exploiting three interconnected mesh networks as a smart sensing grid. Each network is equipped with a sensing fiber placed to correspond with three distinct seismic stations. The objective is to confirm earthquake detection across the interconnected networks, localize the epicenter coordinates via a triangulation method and calculate the fiber-to-epicenter distance. This setup allows early warning generation for municipalities close to the epicenter location, progressing to those further away. The model testing shows a 98% accuracy in detecting primary waves and a one second detection time, affording nearby areas 21 s to take countermeasures, which extends to 57 s in more distant areas. Full article

The purpose of the experimental results evaluated in this paper is to verify the viability of using a prototype drag finishing machine for the modification of machined workpieces. The workpieces used in the experiments had a cylindrical shape and were manufactured by turning. Three different workpiece materials were tested, and three workpieces for each material were machined with different cutting parameters. Multiple aspects of the drag-finishing process influence were kept track of—surface roughness, dimensional accuracy, and edge burr shape change. The parameters of the drag finishing were kept constant for all workpieces, and the development of each aforementioned observed aspect was recorded. The workpieces were periodically removed from the process and measured using a coordinate measuring machine with a touch probe, a surface roughness measuring machine, and an optical microscope. Based on the gathered data, it can be concluded that the usage of a prototype drag finishing machine designed primarily for cemented carbide tool microgeometry modification is viable for workpiece finishing as well. The parameters of the drag-finishing process need to be adjusted depending on the workpiece material and initial surface roughness. Additionally, the medium used for the drag finishing should be considered with respect to the desired output quality of the workpiece. Experimental work shows that having one multi-purpose machine for precise modification of wide range of materials and shapes can be an effective approach from the standpoint of economy and productivity when it comes to small numbers of workpieces requiring surface finishing. Full article

The aerospace industry is imposing increasingly strict dimensional tolerances, which is forcing continuous development in component manufacturing. Ensuring tight dimensional tolerances is difficult for thin-walled structures due to their reduced stiffness, which are increasingly used in the aerospace industry, where titanium alloys and nickel alloys, among others, dominate. Developments in this area are causing a search for machining conditions that provide sufficient quality characteristics including dimensional and shape accuracy. We discuss, herewith, thin wall deformations in the horizontal orientation of Inconel 625 nickel alloy samples in cross-sections perpendicular and parallel to the direction of tool feed motion. We measured dimensional and shape accuracy using a 3D optical scanner and also using a coordinate measuring machine to correlate these results. We compared the results obtained by the two methods and obtained the maximum discrepancy of the results equal to around 8%. Samples made with adaptive cylindrical milling had similar values of thin wall deviations, with the smallest deviations observed for the sample made with the tool for high-performance machining using adaptive cylindrical milling. Full article