for 3D metrology of bores and other hard-to-reach spaces
Overview of features and benefits
- Easily integrated in lab, shop, or fully-automated industrial inspection setups
- Reduces inspection cycle time: the rotational scanner spins the probe at up to 30 rotations per second, and obtains up to 100,000 measurements per second. Each measurement represents a 3D topographic point.
- Flexible options for evaluating inspected parts: measured features can be compared to CAD drawings or to a user-defined set of locations, nominals, and tolerances
- Simple scan definition and execution: The scanning sequence is defined once by teaching the system with a joystick. The scanning sequence can later be executed with the push of a button.
- Time-saving automated reporting: Following a scan, go-no-go reports can be produced and results logged in a manner compatible with industry-standard mechanisms.
- Adaptable to harsh environments
- No consumables are needed: Optical probes do not come in contact with the measured samples, and therefore do not wear out like contact probes. Accidental damage is rare-probes are designed to be rugged.
3D metrology and imaging of bores for industry and R&D
- Quality control
- Automated 3D production inspection, geometric dimensioning and tolerancing (GD&T)
- Statistical process control (SPC)
- Research and development (R&D) inspection
- Reverse engineering and part-to-CAD
- Maintenance, repair and operations (MRO)
- Profilometry in harsh environments
Typical measurements inside bores
- Full geometry, diameter, circularity, cylindricity, taper, runout, etc.
- Deviation from CAD model
- High-aspect-ratio features: undercuts, steps, O-ring grooves, threads, channels, sharp edges, steep slopes, and cross-holes
- Volume loss: surface wear or other damage
- Defects: corrosion, pitting, cracking, denting, scratching, porosity
- Surface roughness: linear or area roughness
- Thickness of semi-transparent coating: single-layer or multilayer films
Examples of bore inspection applications
Measurement, visualization, and GD&T inspection of ID surfaces in:
- Parts made by casting, high-precision drilling, deep gun drilling, injection molding, 3D printing, additive manufacturing
- Extrusion dies, feed-through holes, blind holes
- Automotive industry engine components: valve bodies, valve seats, cylinder blocks, cylinder heads, camshafts, crankshafts, drive shafts, combustion chambers, any die cast parts, and more
- Aerospace industry: valves, cylinders, manifolds, and other engine components featuring bores or slots; drilled rivet holes at aircraft fuselage assembly
- Aerospace and industrial gas turbine engines: compressor and turbine airfoils and vanes, vane rings, duct or nozzle throats, shafts
- High-precision machining: bores and slots in parts for defense, industrial, medical equipment, nuclear, oil and gas, power generation, transportation (train and marine as well as aerospace and automotive) sectors
The BoreInspect system comes with Novacam high-performance data acquisition software, which is
- PC, Windows®-based
- User-friendly for scan programming and visualization
An application programming interface (API) is available for system integrators and OEMs. With the API, a wide variety of online and offline applications can be accommodated.
Data analysis and 3D imaging
The following options are available for data analysis and 3D imaging:
- Data output options: 3D point cloud, height image, intensity image, roughness, diameter, STL file format
- Integrated turnkey solution with PolyWorks Inspector
- Output is exportable to turnkey integrated 3rd party CAD packages selected by the client:
- CAD/CAM software: PolyWorks, Geomagic, SolidWorks, Creo Elements/Pro (Pro/ENGINEER), etc.
- Imaging, visualization and numerical analysis software: ImageJ, Octave, MatLab, Mathematica, IDL, IGOR Pro
- Surface and roughness analysis software
- Exported data can be integrated with data loggers and SPC software
2) Rotational scanner
The rotational scanner spins the optical probe at up to 30 times per second. It is fiber-based, meaning it is connected to the interferometer with a fiber-optic cable that can be hundreds of meters long. More than one scanner may be connected to one interferometer.
Rotational scanner models
3) Microcam interferometer
Microcam interferometer models
|Light wavelength||1310 nm, infrared|
|Interferometer enclosure||4U rackable enclosure|
445 (W) x 445 (D) x 178 (H) mm
|Depth of field||depends on selected probe parameters, |
see table "Standard probe characteristics" above
|Scanning depth range options *||3.5 mm||7 mm||5 mm|
|Acquisition (A-scan) rate||2.10 kHz||1.05 kHz||100 kHz|
|Axial (Z-axis) resolution||< 0.5 µm|
|Light spot size (Lateral [XY-axis] resolution)||4.1 - 146 µm, depends on selected probe parameters, |
see table "Standard probe characteristics" above
|Standoff distance||1 - 100 mm for standard probes|
up to 1 m for non-standard probes
|Repeatability||< 1 µm|
|Thickness measurement range (in Air, IR = 1.0)||10 µm - 3.5 mm||10 µm - 7 mm||20 µm - 5 mm|
|Typical materials for thickness measurements||glass, polymers, multi-layer films, coatings, plastics, silicone, liquids, specular or non-specular|
|Sample reflectivity||0.1 - 100%|
|*To further increase maximum scanning depth, a mechanical displacement axis is available.|
4) Inspection station
Inspection station configurations are application-dependent and can be supplied by Novacam.
Types of inspection stations
|Lab and shop floors||Automated and inline metrology|
|BoreInspect setups in labs and shops typically include an inspection station with scanner displacement in 2, 3 or 4 axes. |
- Motion controllers are included
- Fixturing for the part is not included
- Granite tables are optionally available and recommended for some applications
|BoreInspect rotational scanners may be integrated with:|
- third-party CMMs (coordinate-measuring machines)
- CNC (computer numerical control) machines, or
- any robots (as a robot end-effector) to support high-volume continuous flow manufacturing.
5) PC, monitor and joystick
The BoreInspect system comes with a PC (with Novacam acquisition software), a monitor, mouse, and joystick.
Polyworks InspectorTM metrology software for full GD&T inspection of the parts can be purchased with the system. Custom data processing, reporting and defect detection programs can also be written based on client requirements.See “software” tab for more detail.
6) Hardware for multiplexing support (optional)
Optical switches are available for multiplexing up to 8 probes to a single Microcam interferometer.
Frequently asked questions
How long does it take to scan a bore?
- Scan time depends on the bore size, bore length, and what aspects of the bore you need to measure. The scanner rotates at 1,800 rotations per minute (or 30 rotations/second) and the BoreInspect (with Microcam-4D) acquires up to 100,000 measurements per second, or roughly 1 million 3D topography points in 33 seconds. The user selects the rotation and acquisition speeds and the pitch of the spiral, which together determine the number of points that will be acquired and the time the scan will take. In general, dimensional measurement (for GD&T) require the least amount of points and can be achieved the fastest. Roughness callouts may take 3 to 4 seconds each. Defect detection requires the most amount of points, of course depending on the size of defect you are looking for. For help on estimating the time required to scan your sample, please contact us.
Is the system easy to use?
- Yes. The scanning sequence (recipe) can be programmed with a joystick and can be recalled at later times with the push of a button. See our how-to video on how to measure bore ID dimensions.
Is the system able to work right on production floor?
- Yes. Both inline and robot setups are possible.
Can BoreInspect give us automated measurements and reports?
I noticed the probe spins. Is runout an issue and does it affect the scan data?
- No, runout is not an issue. Gauge rings are used to calibrate the probe and validate the results. The system provides micron-level diameter measurement repeatability.
Does the BoreInspect rotational scanner (RS) probe have to be on the centerline of the bore?
- The BoreInspect RS probe should be positioned close to the centerline of the bore (within a mm) to capture the entirety of the features. For irregularly-shaped objects or slots or crevices, the RS probe can acquire the entire surface by scanning from several positions.