New Confovis DUO Vario measurement system for a high degree of measuring flexibility

For the first time at the AMB 2016, Confovis is presenting the variable measurement system Confovis DUO Vario which was specially developed for use in the automotive and tools sector. With it, demanding measurement tasks can be completed with a single measurement system.

Confovis is expanding its application range with the new DUO Vario integrated measurement system. Aligned to the needs of the industry, the measurement system offers two measuring principle: the confocal and focus variation. Where numerous measurement devices were previously needed for different measurement tasks, now only the DUO Vario is needed. With this product, Confovis offers a compact and high-precision measurement device for the comprehensive surface analysis of roughness – including on reflective samples, such as coated tools – as well as, for example, the contour measurements of cutting edges. This saves investment costs and the effort of user training.

One measurement device – two measuring principle
With the confocal procedure of structured illumination, strongly reflective surfaces can be easily and traceably measured for roughness standards which are manufacturer independent using proven methods. With the new device generation this is now also possible with a larger field of view and – thanks to the light wavelength of 415 nm (violet) – with a higher lateral resolution. In order to record and analyse steep sides, the DUO Vario also uses the focus variation principle in addition to high-resolution confocal measurement principle. This is mainly advantageous for the measurement of shapes and contours. The acceptance angle here is 85°. As both measurement procedures are used in a global coordinates system, a great variety of surfaces can be captured down to the nanometre.

Artefact-free measurements for reliable measurement results

If the measurement is confocal, the Confovis measurement system has the advantage that measurement artefacts hardly occur when compared to laser confocal measurement procedures, as virtually no unwanted interferences such as coherence and speckle effects occur. Confovis measures with structured illumination technology developed and patented in-house.  This measures extensively and robustly and belongs to the confocal microscopy procedure. In addition to the use of an efficient LED light source instead of a laser, the main difference lies in the fact that the Confovis measurement procedure gets by without a pinhole disc and is correspondingly more robust and subject to less wear and tear.

Scanning module with application-specific LED illumination  
The measurement module of the Confovis DUO Vario is optionally equipped with a violet (415 nm), green (535 nm) or red (658 nm) LED. In this way, depending on the field of application, the benefits of the respective light wavelength can be used. For the measurement of very fine microstructures, Confovis uses the violet LED illumination, which has a particularly fine lateral resolution with a light wavelength of 415 nm. For applications in the semiconductor industry and depending on the sensitivity of the photoresist, the measurement module can be equipped with a red, green or violet LED light source in order to avoid any damage from resists.

Tolerance check and target/actual comparison
For the measurement of micro tools, as well as taps or small mills, the user has the motorised workpiece pivot available to them together with the global coordinates system. Measurement data which has been recorded with the two measurement procedures can be put together in this. Data from the ConfoVIZ© measurement software with its global coordinates is exported from here to the Polyworks® analysis software and finely aligned automatically using an internal grid. Workpieces can be measured in five axes using the measurement system and target data can be made available. Recurring measurements can be greatly simplified thanks to the software-side user prompts.
Relevant surface features such as circles, cylinders, slots or planes can be inspected in terms of their position and dimensions. Furthermore, gaps and angles can be measured and compared to one another as well as to the CAD reference – including shape and position tolerance measurements. The measurement results can be presented in the form of a report based on an individual report template.
For a greater overview, the tolerance utilisation of test parts can be classified and illustrated using a traffic light system. It can therefore be seen at a glance whether parts are within the tolerances, within the control limits or whether they are beyond them. Reports such as control charts for static process checking are also standards in Polyworks®. An interface to the current ERP systems is also available. It is also possible to issue correction matrices between the target and actual values and to directly correct the machine data thereafter (closed loop manufacturing).
For industrial applications in which other analysis tools are to be used, the ConfoVIZ© software offers a variety of output formats, including G3D, STL or ASCII. This allows previously used and trained analysis tools to be used on the customer side.

Automatic measurement by preset measurement plan
The Confovis DUO Vario is robust, easy to set up and quick to convert. Use of the ConfoVIZ© software intuitive and allows both untrained and qualified machine users to achieve safe and reliable measurement results at any time. For recurring workpieces and microstructures, the user can start the measurement positions once and determine the measurement range then save this as a measurement plan. All measurement parameters such as lighting times etc. are automatically accepted by the system and saved under the product identity number. In the event of a recurring measurement, an untrained user can call up the measurement plan that is applied once and the measurements are automatically repeated.