EdgeInspect

for high-precision 3D metrology of edge breaks/edge radiuses

EdgeInspect is a modular, non-contact 3D metrology system that:

  • Measures, down to the micron, any type of edge: cutting edges, inside or outside edges, edges on round holes, straight edges, etc.
  • Enables fully configurable automated digital inspection
  • Supports user-defined specifications for geometric dimensioning and testing (GD&T), edge break requirements, angle measurements, roughness, etc.
  • Detects micron-size surface defects such as burrs, scratches, porosities, etc.
  • Can measure thickness of semi-transparent coatings.

EdgeInspect measuring a high-precision cutting tool.

EdgeInspect measuring a high-precision cutting tool

 

Video

EdgeInspect in action


In this video, a drill bit is rotated on a chuck base while the EdgeInspect galvo scanner inspects the tool from top to bottom following a user-defined scanning sequence.

Overview

Measurements

  • Optical, non-contact, non-destructive
  • 2D and 3D edge geometry of cutting edges, leading and trailing edges, blade edge radiuses, chamfers, bevels, notches, fillets, thread mills, etc.
  • Fillet joints inside high-aspect-ratio features such as honeycomb structures
  • Micron-precision axial resolution and excellent sensitivity and measurement repeatability

Imaging options

  • Line profiles of edge radiuses
  • 3D images of workpiece surfaces
  • Height and intensity images
  • Cross-sections of semi-transparent materials
  • Deviation maps
Defect detection on chamfered aerospace disk edges

Defect detection on chamfered aerospace disk edges

 

 

Benefits

  • Easily integrated in lab, shop, or fully-automated industrial inspection setups 
  • Reduces inspection cycle time: the non-contact optical scanner (or probe, depending on the setup) obtains up to 30,000 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 set of user-defined GD&T callouts ( 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 industry-standard formats
  • Adaptable to harsh environments
  • No consumables are needed: The optical galvo scanner does not come in contact with the measured workpiece, and therefore does not wear out like contact probes.

 

Applications

3D metrology and imaging of edges 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 on edges

  • Full geometry, diameter, edge radius (sharpness), taper, runout, etc.
  • Deviation from CAD model
  • High-aspect-ratio features: teeth, undercuts, steps, grooves, threads, channels, sharp edges
  • Volume loss: surface wear or other damage
  • Defects detection and characterization: corrosion, pitting, cracking, denting, scratching, porosity
  • Surface roughness: linear or area roughness
  • Thickness of semi-transparent coating on edge surfaces: single-layer or multilayer films

Examples of edge inspection applications

Measurement, visualization, and GD&T inspection of edges on:

  • Parts made by machining (drilling, milling, grinding, honing, etc.), casting, injection molding, 3D printing, additive manufacturing, welding, brazing, soldering
  • Cutting tools before and after treatments
  • Cutting tool maintenance, sharp edge testing, burr detection
  • Scalpels, syringes, needles, razor blades, spindles
  • Automotive industry parts, aerospace industry parts
  • Hydraulic systems, bearings, tubes
  • Sheet metal parts
  • Chamfered edges, bevel edges, filleted edges, miter edges
  • Wafer edges

Gallery

Gallery (click images for close-up)

Razor blade edge measurement

Point cloud generated for a razor blade edge with edge radius of less than 6 µm (222 µin.). A cylinder fitted within the points gives the breaking edge diameter measurement down to the micron.

Point cloud generated for a razor blade edge with edge radius of less than 6 µm (222 µin.). A cylinder fitted within the points gives the breaking edge diameter measurement down to the micron.

Cutting tool measurement

Users can zoom from an on-screen rendering of the acquired drill bit (top left) into the edge area selected for analysis. The enlarged edge segment (bottom left) shows a colour-coded deviation map of the edge sharpness. Users may choose to view edge radii measurements at various points of analysis (right).

Users can zoom from an on-screen rendering of the acquired drill bit (top left) into the edge area selected for analysis. The enlarged edge segment (bottom left) shows a colour-coded deviation map of the edge sharpness. Users may choose to view edge radii measurements at various points of analysis (right).

Aerospace fir-tree base edge measurement

Edge radius measurement is carried out on a fir-tree base of a jet engine turbine (left). A chamfer defect is detected (top right) and measured (bottom right). Given the versatility and modularity of the EdgeInspect system, inspection of fir-tree edges on the entire jet engine turbine can be automated.

Edge radius measurement is carried out on a fir-tree base of a jet engine turbine (left). A chamfer defect is detected (top right) and measured (bottom right). Given the versatility and modularity of the EdgeInspect system, inspection of fir-tree edges on the entire jet engine turbine can be automated.

Software

Metrology software

Data acquisition

The EdgeInspect 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.

Novacam data acquisition software

 

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

Point cloud generated for a razor blade edge with edge radius of less than 6 µm (222 µin.). A cylinder fitted within the points gives the breaking edge diameter measurement down to the micron.

Point cloud generated for a razor blade edge with edge radius of less than 6 µm (222 µin.).

Option: Novacam volume loss application

Novacam Volume Loss application processes the acquired surface dimensional data to determine volume loss from abrasion and wear:

  • with micron precision
  • on samples and components of various shapes and sizes

 

Novacam Volume Loss Calculation Application

Novacam Volume Loss Application – click for closeup

Novacam Volume Loss Application: scan control user interface

Novacam Volume Loss Application – click for closeup

System components

System components

The EdgeInspect is a modular system comprised of 1) a galvo (raster) scanner, 2) Microcam interferometer, 3) an inspection station, 4) a PC, and, optionally, 5) multiplexing hardware (not shown in diagram).

EdgeInspect system diagram
The inspection capabilities of the EdgeInspect are determined jointly by its components:

1) Galvo scanner

Novacam galvo scanners come in several standard sizes of field-of-view and can be custom built as well.

Diagram

Standard galvo scanner characteristics*

galvo scanner for edge break/ edge radius metrology
Field of view
(mm)
Standoff distance
(mm)
5 x 57.5
10 x 1025
15 x 1542
30 x 3087 or 95
54 x 54126
90 x 90215
*Only standard galvo scanner characteristics are listed in this table. Non-standard specifications are custom-built upon request.

2) Microcam interferometer

Microcam-3D profilometer (low-coherence interferometer) The Microcam interferometer provides the light source to the galvo scanner and processes the optical signal received from the scanner.
ModelMicrocam-3DMicrocam-4D
Technologylow-coherence interferometry
Light wavelength1310 nm, infrared
Non-contact measurements
Depth of fielddepends on selected scanner characteristics.
Scanning depth range options*3.5 mm7 mm5 mm
Acquisition (A-scan) rate2.10 kHz1.05 kHz30 kHz
Axial (Z-axis) resolution< 0.5 µm
Light spot size (Lateral [XY-axis] resolution)4.1 - 146 µm, depends on selected scanner characteristics.
Standoff distance1 - 100 mm for standard probes
up to 1 m for non-standard probes
Repeatability< 1 µm
Thickness measurements
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 measurementsglass, polymers, multi-layer films, coatings, plastics, silicone, liquids, specular or non-specular
Sample reflectivity0.1 - 100%

*To further increase maximum scanning depth, a mechanical displacement axis is available.

3) Inspection station

Inspection station configurations are application-dependent and can be supplied by Novacam. Fixturing for the part is not included.
Lab and shop floor inspection These inspection stations typically include scanner displacement in 2, 3 or 4 axes. Motion controllers are included.
Granite tables are optionally available and recommended for some applications.
Automation and inline industrial inspectionThe EdgeInspect galvo 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.

4) PC, monitor and joystick

The EdgeInspect 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.

5) Hardware for multiplexing support (optional)

Optical switches are available for multiplexing more than one scanner or probe to a single Microcam interferometer.

Additional info

Standard system configuration

A standard configuration of the EdgeInspect includes:

  • Galvo scanner with a 5x5mm field of view
  • Microcam-3D profilometer
  • 2-axis inspection station and 2-axis motion controller
  •  3-jaw chuck
  • PC with Novacam acquisition software
  • 1 year warranty

Instrument safety

  • Microcam systems feature an in-probe red laser pointer (650 nm wavelength) for alignment purposes.
  • Microcam systems are Class 1M Laser products, with < 20 mW of infrared and < 5 mW of in-probe laser pointer.
MicroCam non-contact profilometers are Class 1M laser products

EdgeInspect in the news

The EdgeInspect system was recently featured in Cutting Tool Engineering magazine.

  • For any questions or for assistance with configuring your optimal EdgeInspect system, please Contact us.