3rd IEEE International Conference on Knowledge Innovation and Invention 2020

Fast and Cost-Effective Measurement of Contour of Large Cylinder Using Optical

Methods

Yu-Liang Chen, Anh-Tuan Dang, Quang-Cherng Hsu*

Department of Mechanical Engineering, National Kaohsiung University of Science and Technology

*
Corresponding Author: Email: [email protected]

Abstract al. [5] developed a rapid 3D shape measurement projection

mapping system. The projected image was deformed
During manufacturing, a crucial component of improving according to the 3D shape of the object. The z-direction value
2020 3rd IEEE International Conference on Knowledge Innovation and Invention (ICKII) | 978-1-7281-9333-5/20/$31.00 ©2020 IEEE | DOI: 10.1109/ICKII50300.2020.9318892

production capacity and yield is the selection of an appropriate was measured using two pitches of grating patterns that were
measurement method. Reducing inspection time improves projected onto the object. Ye et al. [6] developed a method of
production capacity and yield. Therefore, optical measurement determining the form quality of optical lenses during rough
systems are commonly used in real-time quality monitoring polishing. The authors proposed a phase decoupling algorithm
and rapid product inspection. This paper presents theoretical for superposing patterns with the upper and lower surfaces of
and experimental studies comparing two self-developed transparent optics. Double-sided reflective fringe patterns
optical measurement systems, namely an area scanning system could be retrieved and reconstructed on the upper surface of
and a line scanning system. The measured object was a the workpiece.
cylindrical workpiece with an outside diameter of Line scanning systems have extremely sensitive cameras
approximately 200 mm and irregular contours on both the with a rapid sampling rate. The captured images appear as
inner and outer side. thick lines. The shape of a measured sample is obtained when
these lines are individually linked together. Therefore, the
Keywords: precision measurement, contour, edge detection, control link speed is crucial in line scanning systems. The
optical measurement. automatic transport mechanism controls the sample movement
speed for image linking. Excessively high speeds cause image
Introduction data loss and result in longer image dimensions. By contrast,
sample movement speeds that are excessively slow result in
Non-contact measurement is common in inspection shorter image dimensions. Konaganti et al. [7] proposed the
technologies. In this study, two types of measurement systems KEYENCE LS-7030 optical measurement meter to measure
for a large cylindrical workpiece were developed. This study the extrudate swell of high-density polyethylenes in capillary
compared the benefits of both systems of area and line flow.
scanning. Area scanning systems use a camera or
charge-coupled device (CCD) to obtain an image. Captured Metrology Systems
images are analyzed to transform the dimensions of an object
in a world coordinate system. Because measurement must be cost effective and rapid, an
Rejc et al. [1] proposed an automated visual inspection area scanning camera with an image size of only 5 million
system for dimensional measurement in mechanical assembly. pixels was adopted. A line scanning system is used in this
The proposed system comprised a mechanical clamping study for rapid high-accuracy optical measurement, and its
system with a light shield and protector positioning system. accuracy was comparable to that of the coordinate measuring
The system could capture images, process images, and display machine.
measurement results in <1s and had a measurement accuracy Figure 1 presents the setup of the experimental area scanning
of ±0.02 mm. Moreover, the user could transform a specified system. The circular workpiece was placed on a circular
number of pixels into metric units flexibly. Ali et al. [2] rotating plate, and a circular calibration plate cover was placed
proposed a camera system with gear profile precision on the workpiece. Both the rotating plate and calibration plate
measurement to improve the safety and reliability. The system were made of acrylics. The moving workpiece and calibration
software adaptively controlled threshold values to identify the plate has the same center of rotation as that of the rotating plate.
gear profile. The calibration plate and rotating plate were made of acrylics,
A measurement system for quantifying tool wear based on the light source was placed directly below the components.
the overall worn area was proposed by Ref. [3]. This approach Because of the system without a telecentric lens, the
used automated image cropping and digital image processing calibration plate covered the workpiece, and the CCD position
tools to identify the affected area without manual intervention. was above the sample to reduce errors of perspective
An isometric mapping method based on adaptive machining distortion.
was developed by Bi et al. [4]. This system had a laser scanner Figure 2 depicts the line scanning system (KEYENCE
based on an on-machine measurement system and could obtain LS-7030) which includes a line scanning CCD with subpixel
the real geometry of a deformed surface. Moreover, the accuracy, a telecentric lens, laser lighting, and an LS-7030
toolpath could be adaptively adjusted to enhance the CCD micrometer (LS-7001 micrometer display). A rotating
machining accuracy of curved contours on large thin-walled table with another CCD camera (IDS 500 million
skins. The projection mapping of grating images is a popular CCD/UI-3580 CP-C-HQ_REV 2, 2/3” 8 mm f1.4 locking iris
method of measuring three-dimensional (3D) shapes. Suzuki et and M0814-MP2 focus lens) was fixed above the platform to

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 3rd IEEE International Conference on Knowledge Innovation and Invention 2020

confirm that the rotational center was located along the

measurement light band in accordance with Abba’s
measurement principle.
Two data transmission modes, namely RS-232 and
binary-coded decimal (BCD), were used. In the line scanning
system, the Butterworth filter was used for data processing to
filter noise from the ring gauge and achieve stability in the
measurement system. The median filter was used for data
processing to filter noise from the tooth workpiece.
The system components are listed in Table I.

Fig. 2 Schematic of the automatic line scanning optical

measurement system.

Fig. 1 Structure of the area scanning optical measurement system.

A subregion measurement scheme and whole-region

calibration method were developed for the area scanning
system.
Figure 3 is a diagram of the workpiece with the calibration
plate. The principle of area scanning is the transformation of an
image coordinate system to a world coordinate system by the Fig. 3 Principle of the area scanning system.
calibration plate. The left and right boundary lines for one
sub-region were automatically determined, after which image Figure 4 presents the principle of the line scanning system. A
masking, calibration point detection, and object contour ring gauge was used to calibrate the Abbe error and calculate
detection were performed. the positions of data corresponding to End 1 and End 2. The
In the captured region of picture, there were 12 separating ring gauge was 192.68 mm in diameter. First, real and virtual
lines and 276 black points arranged in three concentric circles. conversion were performed. The End 1 and End 2
Each of the 12 sections are 30° wide. The system captured measurement data of the LS-7030 were translated to their
images of the 12 sections for a total of 12 images. The rotating corresponding world coordinates. Subsequently, filtering and
plate was rotated 30° after each image was captured. The size eccentric correction and calibration were performed. Finally,
of each captured image was 75 mm × 55 mm, and the camera outputs were obtained. No filtering was processed when the
resolution was 2560 × 1920. Therefore, the image resolution speed was 0.25 rpm, and the RS-232 interface was used
was approximately 0.03 mm / pixel. because hardly high-frequency noise was produced. Therefore,
First, the unused outside area was detected and marked using the results could be used directly.
the separating line. Second, calibration points and the object’s
profiles were detected using blob analysis. Subsequently, the
calibration coefficients were calculated, and the image
coordinates of the calibration points were matched with their
corresponding world coordinates. These coefficients enabled
the image coordinates of each pixel in the profile to be
transformed into world coordinates. Data from the 12 images
were merged into a point cloud, and the sample profile was
obtained using computer-aided design (CAD) software
because of contour complexity. The length and angle of the
two lines were determined using the Hough line transform.

Fig. 4 Principle of the line scanning system.

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 3rd IEEE International Conference on Knowledge Innovation and Invention 2020

TABLE I
EQUIPMENT COMPONENTS
Component Area scan system Line scan system
Camera/CCD Imaging Development Systems GmbH (IDS), Line scan CCD unit: LS-7030 CCD micrometer,
Germany, UI-3580CP-C-HQ Rev.2, USB 3.0, LS-7001 micrometer display.
1/2", CMOS, 2560 x 1920, 4.92 MPix, ON, USB Top CCD: IDS 500 million CCD / UI-3580
3.0 CP-C-HQ_REV 2.
Lens Myutron Inc., Japan, MV2514, focal length In the top CCD, Computar 2/3” 8 mm f1.4
25mm, Fno 1.4, working distance 0.5m〜∞, locking iris and focus lens (M0814-MP2).
FOV 28.5°×21.6°
Light Epoch Chemtronics Corp., Taiwan, LB-B239, N/A
white plane uniform lighting, area (Built-in)
580mm×80mm, 11.8W
CCD N/A A programmable logic controller (PLC)
Controller KV-7500.
Measurement Manual rotary table Automatic line scanning system.
Mechanism An XY linear micrometer manual stage (TSD
XY-TS100AR).
Rotary table components: a harmonic reducer
(GTC 1:80), a servo motor (SME-L04030SAB,
AC400W) and servo motor driver, and a control
box.
I/O unit N/A BCD: KV-SIR32XT for type of rapid
measurement system
Software Microsoft Visual Studio 2010, Emgu CV 3.2 Microsoft Visual Studio 2010, Emgu CV 3.2

Results and Discussion required substantial time.

Table II compares the measurement results of the two
A rapid optical line scanning measurement system was systems as well as those of ATOS. The area scanning system
developed that can reduce the inspection time from the 20min has favorable inspection performance in terms of tooth
required in ATOS scanners to 60s. ATOS is a 3D scanner for thickness because the data were transformed from captured
precision measurement which is made by GOM. images. The difference with ATOS is 0.005mm. However, the
The line scanning system had rotation speeds of 0.25 and line scanning system data were related to the sampling rate of
2.5rpm, and the measurement time were 5min and 30s (within LS-7030. Moreover, the rotational speed of the rotary plate and
1 min), respectively. The RS-232 and BCD data transmission the input/output unit influence the sampling rate. High speeds
modes were used for the rotation speeds of 0.25 and 2.5rpm, reduce the sampling rate. Because the contours of tooth
respectively. Because the measurements of the profiles (angle, thickness were formed from the collected sampling data, the
length, and diameter) were complex and the result of the final error was larger in the line scanning results than it was in the
contour was a two-dimensional point cloud, these points were captured images of the area scan.
connected as a line to create a smooth contour before The line scanning system is advantageous in tooth height
measurement. In this study, Geomatic Design and AutoCAD measurement. A difference of −0.007 with ATOS was
were used to generate the CAD solutions. obtained because the calibration and measurement method
Figure 5 presents the area scanning system result. The inside used a ring gauge to match world coordinates with the
and outside contours are clear and have no errors in shape. The diameter of the workpiece. Because 12 images were integrated
tooth height is Rt − Rr, and A is the inner diameter. Figure 6 to obtain workpiece data in the area scanning system, the
presents the results of the line scanning system, which yielded diameter of the workpiece was formed by 2 images, which
errors in the inner shape. The errors were formed by the rib of caused the double image errors for the radius. In the inner
the rotating table because the measurement light of sensor diameter inspection, the area scanning system obtained a
passed through the sample and the rotary table. perfect image because of the acrylics rotating plate without
In terms of measurement time, the area scanning system ribs. Five errors in the rib data of the line scanning system
completed inspection in approximately 15min. The line caused distortion in the measurement results.
scanning system conducted inspection at a high rotary plate Another benefit is the cost. ATOS scanner is approximately
speed (2.5rpm) and at a low rotary plate speed (0.25rpm). The US$50 000, whereas developed area scanning and line
inspection time for these two speeds was approximately 1 and scanning systems cost US$10 000 and US$20 000,
5min, respectively. The data import time required in ATOS respectively.
measurement is approximately 20min. Importing the point data
of a measured workpiece into GOM software for measurement

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 3rd IEEE International Conference on Knowledge Innovation and Invention 2020

thickness measurement with a difference of 0.005 mm

from ATOS, and the line scanning system achieved the
most accurate radial dimension measurement with a
difference of −0.007 mm from ATOS.
(4) Both developed systems are more cost efficient than
ATOS, which costs approximately US$50 000. The area
scanning system costed US$10 000, and the line scanning
system costed US$20 000.
(5) Before measurement, the line scanning system must
calibrate to identify the measurement origin. Moreover, it
requires a ring gauge for calibration. However, the area
scanning system required only the calibration points for
measurement calculation.

Fig. 5 Area scanning result. (W: outside tooth thickness; A: inner

References
diameter; Rt – Rr: tooth height.)
[1] J.Rejc et al., “The mechanical assembly dimensional
measurements with the automated visual inspection system,”
Expert Syst. Appl., vol. 38, no. 8, pp. 10665–10675, 2011.
[2] M. H.Ali, S.Kurokawa, andK.Uesugi, “Application of machine
vision in improving safety and reliability for gear profile
measurement,” Mach. Vis. Appl., vol. 25, no. 6, pp. 1549–1559,
2014.
[3] X.Yu, X.Lin, Y.Dai, andK.Zhu, “Image edge detection based
tool condition monitoring with morphological component
analysis,” ISA Trans., vol. 69, pp. 315–322, 2017.
[4] Q.Bi, N.Huang, S.Zhang, C.Shuai, andY.Wang, “Adaptive
machining for curved contour on deformed large skin based on
on-machine measurement and isometric mapping,” Int. J.
Mach. Tools Manuf., vol. 136, no. September 2018, pp. 34–44,
2019.
[5] S.Suzuki, Y.Akatsuka, W.Jiang, M.Fujigaki, andM.Otsu,
“Development of quick three-dimensional shape measurement
projection mapping system using a whole-space tabulation
Fig. 6 Line scanning result. method,” Appl. Sci., vol. 9, no. 20, 2019.
[6] J.Ye, Z.Niu, X.Zhang, W.Wang, andM.Xu, “In-situ
TABLE II deflectometic measurement of transparent optics in precision
COMPARISON OF THE TWO SYSTEMS robotic polishing,” Precis. Eng., vol. 64, no. January, pp. 63–
Dimension Measurement result Difference with 69, 2020.
ATOS [7] V. K.Konaganti, M.Ansari, E.Mitsoulis, andS. G.Hatzikiriakos,
ATOS Area line Area line “The effect of damping function on extrudate swell,” J.
scan scan scan scan Nonnewton. Fluid Mech., vol. 236, pp. 73–82, 2016.
Tooth 10.888 10.893 10.31 0.005 -0.572
Thickness 6
Tooth Height 3.057 3.089 3.049 0.032 -0.007
Inner Radius A 84.125 84.195 N/A 0.070 N/A

Conclusions

This study presents two rapid and cost-effective precision

contour optical measurement systems for large cylindrical
workpieces approximately 200mm in size.
The conclusions are summarized as follows.
(1) The area scanning system is an image resolution of
approximately 0.03 mm/pixel because the size of a
captured image was 75 mm × 55 mm and the camera
resolution is 2560 × 1920.
(2) The area and two speeds of line scanning systems
achieved measurement time of 15 min, 5 min and 1 min,
respectively. Both systems inspected the large cylindrical
workpiece more rapidly than ATOS.
(3) Relative to ATOS, each of the developed inspection
systems were advantageous for different dimensions. The
area scanning system achieved the most accurate tooth

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