Automotive & Aerospace

In the sector of automotive & aerospace, the demands on products are particularly high and subject to strict standardisation systems. Surface characteristics determine not only functionality, but also have a crucial part to play concerning wear. The behaviour of emissions and acoustics are also dependent on consistent surface quality in the sub-µ range. In order to evaluate contours and micro-structures in a meaningful way, automobile suppliers use touchless optical measuring technology from Confovis. 

Fast surface scanning provides extensive 3D data

For many surfaces, the roughness properties are not isotropic on the surface, rather the profile forms are strongly influenced by their location on the surface. This is why profile-based roughness values often have only limited significance regarding the functional properties of the entire surface. The surface-related assessment facilitates deeper insights than profile-based measurements as not only a profile but the entire surface is captured, which can vary greatly depending on the position within the surface.

For many surfaces, the roughness properties are not isotropic on the surface, rather the profile forms are strongly influenced by their location on the surface. This is why profile-based roughness values often have only limited significance regarding the functional properties of the entire surface. The surface-related assessment facilitates deeper insights than profile-based measurements as not only a profile but the entire surface is captured, which can vary greatly depending on the position within the surface.

Confovis measures both measurement areas with high data density, e.g. for roughness, as well as measurement areas with low data density, e.g. for shape or contour measurements.The identified 3D point cloud is transferred to the analysis software.

Contour and roughness measurements, target/actual comparison, wear analysis

No matter whether the task is a focus variation or a confocal measurement, the combination of Confovis's own measurement software, ConfoViz®, and assessment software that has been established on the market such as MountainsMap® or PolyWorks®, provides a high degree of user friendliness. With MountainsMap®, parameters such as contours, angles, radii, volumes, oil reserve volumes, texture and roughness can be investigated. For progressive geometry analyses, Confovis uses PolyWorks® software. It can be used to create target/actual comparisons and generate feature-based reports.

Applications

Piston ring
Crankshaft
ball bearing
Common rail injector needle

Optical measurement technology for non-destructive measurements

With the combined measuring techniques of Focus variation and confocal measurement technology, these measurement tasks can be completed without any trouble. With the focus variation method, contours with wide angles can be captured. Roughness can be assessed with nanometre precision with the patented procedure of structured lighting based on the confocal measuring technique. This way, both micro geometries and roughness on reflective surfaces can be measured with nanometre precision and in accordance with standards.

Variations on confocal measurement technology

The measuring methods of focus variation and the confocal measuring technique based on the working principle of Structured Illumination both have contrast analysis as a foundation and work without interferograms. In contrast to conventional confocal microscopy, no rotating pinhole disk or other moving mechanical components such as scanner mirrors are used in the scanning process. The required accurate depth selection is instead guaranteed by the depiction and following evaluation of a sequence of illuminations patterns in the focal plane. A special static mask which coordinates the rays of the quickly shifting light sources is responsible for this. The contrast value is determined by the CCD sensor both in the confocal mode and during focus variation measurement. The contrast difference evaluates the out-of-phase sequences confocally.

For both methods, the depth blurriness is exploited to determine the z coordinate and the probe is driven through the focal plane. Height information is determined from the known relative z position in connection with the contrast value. The generated stacks of images contain the height information. This is sufficient to determine stage heights, radii and angles and – consequently – also for determining roughness.

Roughness measurements on components – standardised and traceable

Roughness measurements with the traditional roughness parameters Ra, Rq and Rz in accordance with DIN EN ISO 4287/4288 as well as DIN EN ISO 13656 can be taken in a way that is traceable according to the roughness standards certified by the National Metrology Institute of Germany (PTB). Here, Confovis measurement devices achieve a high degree of precision and provide the user with excellent comparability to conventional systems. The measurement surface of the roughness standards consists of ground and precision turned irregular profiles. This way, the standard has a broad spectrum of surface variations that can be found in practice. The basis for the surface roughness values can be derived from the Rpk, Rvk and Rk values and a transition to DIN EN ISO 25178 can be formed as well.

Suitable 3-D measurement systems for component analysis

Compact measurement system for small components. Equipped either with ConfoCam® or FocusCam® ScanModul. Combined with precise XYZ positioning and diverse specimen mounts. More> 

Flexibly scalable measurement system for large and heavy components. It is equipped with the DUO Vario scan module for measurements either with Structured Illumination Microscopy (SIM) oder Focus Variation. Combined with motorised rotary/swivel table for 360° stitching of the entire component geometry. More>

If you need more than the standard measuring devices: our modular system technology and compatible individual components can be used to design and implement customised measurement systems to suit all customer requirements. Please ask us. More >