TOPIC 4

NONCONTACT
INSPECTION
TECHNOLOGIES

Noncontact Inspection methods

Utilize a sensor located at a certain
distance from the object
This sensor measure or gauge the
desired features
2 categories
1) Optical
2) Nonoptical

Optical Inspection Technologies

Use light to measure or gauge
Optical Inspection is specialized to
industries
Examples :
1. Toolmakers microscope
2. Machine Vision
3. Optical comparator
4. Autocollimators

Nonoptical Inspection Technologies

Utilize energy forms other than light
to measure or gauge
Energy includes electrical field,
radiation and ultrasonics
Specialized metrology method
Utilized in certain industry only

Noncontact Vs Contact
Avoidance of damage to the surface
Inherently faster Inspection cycle
time
No additional handling of the parts to
be measured
Noncontact is suitable for 100%
automated inspection

Faster Inspection Cycle Time

Contact inspection procedure requires
the contacting probe to be positioned
against the part, which takes time
Noncontact methods use a stationary
probe that does not need
repositioning for each part
100% inspection is thus more feasible
in automated inspection

Noncontact less handling

Often noncontact can be
accomplished on the production line
without the need for any additional
handling of the parts
Contact methods require special
handling and positioning of the parts
on the production line
100% inspection is thus more feasible
in automated inspection

Automated Inspection
Uses variety of sensor systems that
monitor the relevant parameters during
the manufacturing process (on-line
inspection) / immediately after they are
produced (in-process inspection)
Automated inspection is integrated in
manufacturing operations
Flexible and responsive to product
design changes

Sensors in automated inspection

Detect dimensional accuracy, surface
roughness, temperature, force,
power, vibration, tool wear, the
presence of external or internal
defects
2 types tactile or nontactile
Able to be linked to microprocessor
and computers for graphics data
display

1) Microscopes
Optical instruments used to view
and measure very fine details,
shapes and dimensions
Suitable to small and medium-sized
tools, dies and workpieces.
Different microscopes available for
specialized inspections
Typically equipped with electronics

Toolmakers microscope
Able to read up to 2.5 m
Most common and versatile in tool
rooms.

Toolmakers microscope

FEATURES
The eyepiece section of the optical
tube incorporates a vernier.
Angle measurement is performed
easily by turning the protractor to
align the cross-hair reticle with the
workpiece image.
Both the transmitted and reflected
illumination intensity can be adjusted
to obtain the optimal illumination
intensity for the workpiece.

2) Machine Vision
Machine vision systems typically used
for visual inspections that require highspeed, high-magnification, 24-hour
operation, and/or repeatability of
measurements.
Machine vision encompasses computer
science, optics, mechanical engineering,
and industrial automation.

Technologies in machine vision

Machine Vision - Uses

Range of applications ie.
gauging/measurement
identification
optical character recognition (OCR)
presence verification
print inspection
surface inspection
colour analysis
code reading

A typical machine vision system

components:
One or more digital or analogue
cameras
Input/Output hardware
A synchronizing sensor for part
detection
A program to process images and
detect relevant features.

Cameras
One or more digital or analogue
cameras (black-and-white or colour)
with suitable optics for acquiring
images,
Example are lenses to focus the
desired field of view onto the image
sensor and suitable, often very
specialized, light sources

Camera

Input/Output hardware
Example digital I/O) or
communication links
e.g. network connection or RS-232 to
report results

Input/Output

Sensor and software

A synchronizing sensor for part
detection (often an optical or
magnetic sensor) to trigger image
acquisition and processing and some
form of actuators to sort, route or
reject defective parts
A software program to process
images and detect relevant features.

Data process and output

Gauging/measurement
Can inspection in the food industry
Inspection must take place at high
speed; in this one at 20 parts per
second.
The requirement is to inspect a can for
ovality and the bottom of the can for
defects, and check for absence of dents,
edge rollovers and foreign objects.

Can inspection

Identification
Needle-stamped ID codes on
metal
Metal parts are often coded by needle
stamping characters.
This results in a very robust ID that
will easily survive subsequent
manufacturing process

Presence verification
Locating screws
Able to do 100% inspection solution
for checking the contents of flat
packed furniture prior to dispatch.

Print Inspection
Circular syringe barrel
Verifying the quality and position of
print on a tubular structure like a
syringe barrel requires a different
approach
Use a linescan camera rather than a
CCD camera and pre-processing to
orient the image for checking - and all
in 100 milliseconds.