CHAPTER THREE COMPUTER AIDED METROLOGY

Principles and interfacing

Computers can be effectively applied in the field of Engineering Metrology for tasks like processing
of acquired data, control of calibration equipment, and in CMM. Computers are capable of
automating and streamlining most of the fields of metrology.

Once proven computational methods employed to process measurement data and present the final
result in a way which is easily understood by the operator. With the use of computer systems, it
becomes possible to prevent making defective parts rather than rejecting them at the end of the
whole cycle.
The application of using a computer for processing the output of measuring instruments is unlimited.
Now a days micrometer. Screw gauge, vernier caliper, height gauges etc. are available so that they
can produce output in digitized form which can be fed into computers.
The output after analyzing can be presented as numerical tabulations, or in a variety of graphical
forms, or as three dimensional representations of complex profiles.

The fast developments taking place in electronics, particularly microprocessors, has dramatically
changed the nature and scope of metrology, too. The introduction of micro-processors, i.e. computer
on chip has brought about a great revolution. These are cheap, versatile, and fast and can be easily
interfaced with metrology equipment. In such measurement systems where lot of data has to be
gathered from several measuring instruments and data has to be processed, stored and displayed, the
use of such device (microprocessor) is highly desirable. Either general purpose or special purpose
software could be used depending on the application.

It is now not necessary to take parts to be inspected to measuring machine, but a robot arm having 4
degrees of freedom (3 rectangular linear motions plus wrist motion) is brought for inspection near
the equipment while being machined. It incorporates various attachments and accessories such as
electronic probes, automatic tool magazines, sensors and devices for parts recognition. The motion
of the robot arm is controlled by a microprocessor which performs simultaneous multi-axis control
of position, speed and acceleration and thus provides high dynamic performance of the arm.

The inspection data handling is organised at two levels;

One to perform the dimensional analysis of the part being inspected to discriminate good, bad and
reworkable parts and Second, the inspection data is reduced on real-time statistical basis to derive
trends, relationships and cumulative results from which potential dimensional problems can be
spotted for immediate corrective action.
Another use of computers in metrology is for on-line non-contact dimensional measurement in which
a television camera, using charge-coupled photodiode arrays, is focused on the workpiece and
interfaced to a computer which can analyse shapes and sizes of the image.

Laser illumination is commonly used for projecting shadows because the beam is well defined. The
image is processed using microprocessor-based system. Vision systems break down images into
sectors and segments and then recognise and measure their geometry.

A vast array of information about various geometrical features is stored, with which the digitized
information of the processed TV image is compared.

In the field of metrology computer can be used for

(i) Controlling the function of a piece of measuring equipment (for which the movements of the
measuring instrument/machine have to be motorized) and

(ii) Processing the output of the measurement process.

The software for computer may be either written by the user, which is usually a difficult task, or be
supplied by the manufacturer, or the computer be programmed to compile an operating program
from the procedure used when a sample component is being measured manually.

A hand held computer is connected to these devices to store and process the inputs it collects from
measuring instruments. It can also feed its contents into the large capacity central computer. The
central computer can thus be fed with large quantities of data from different inspection locations in
the plant and analyses them collectively. The output, after analysing, can be presented as numerical
tabulations or in a variety of graphical forms, or as three dimension representation of complex
profiles so that same surface is visible on CRT screen as would be viewed from all the corners.

Similarly slip gauge box with built in computer and printer has been developed. The computer
assists in selecting various combinations of gauges to develop any dimension. The required
dimension has to be fed to computer and it displays the combination of gauges required. Not only
this, it also illuminates the arrows above the actual block required to build the desired dimension.

It also keeps in memory all the deviations from the precise size of all the blocks, prints the total
deviation from the combination of blocks for a required size, stores and displays the information
regarding calibration requirements.

The roundness measuring machine fitted with computer exploits fully the ability of a computer to
carry out almost instantaneously, a large number of tedious calculations. Computer can easily define
the circle if three points on its circumference are completely defined.

Similarly in gear measuring machine, the use of computer is made to do all tedious calculations and
give final results in no time and very accurately.
Software in metrology

Use of computers and software support in management of gauges and measuring instruments
through management of information support can result in improvement of quality, efficiency and
effectiveness of entire measuring process. System for surveillance and control of gauges, measuring
instruments and other inspection equipment can be either in the form of acceptance inspection of
new items or the periodic calibration of gauges and instruments. The flow charts for both the types
of requirements need to be developed, clearly identifying where the support of software will be
needed.

The software used should be as user friendly as possible so that persons can use computers with
minimum training. Separate work stations have to be developed for calibration of gauges,
instruments and inspection equipment in various shops as per requirement. The entire information
shall be made available to a central monitoring and development station.

The software should be developed in the form of modules, each module being complete in itself and
interaction being possible between various modules as per requirements. Various modules could be:
master data maintenance module (incorporating new item code entry, retrieve item history, maintain
test specification, vendor master, etc.), purchase order and item receipt module (provision for
addition and updating of orders and receipts, inventory control etc.).

Scheduling module (for schedule generation and schedule adjustment) to meet work load, inspection
module (help and data entry, approval by supervisors etc.), analytical information module to generate
various reports menus etc, and system maintenance module for maintaining security.

 Steps in producing software for Engineering Metrology

 The precise and detailed definition of geometric form

 The specification of the measurement procedure

 The mathematical modeling of the measurement

 The design of the mathematical algorithm

 The implementation, validation and dissemination of the software