Qualification concept for optical multi-scale multi-sensor systems

This article describes a new qualification concept for dimensional measurements on optical measuring systems. Using the example of a prototypical multi-scale multi-sensor fringe projection system for production-related inspections of sheet-bulk metal-formed parts, current measuring procedures of the optical system are introduced. Out of the shown procedures’ deficiencies, a new concept is developed for determining the orientations and positions of the sensors’ measuring ranges in a common coordinate system. The principle element of the concept is a newly developed flexible reference artefact, adapted to the measuring task of the fringe projection system. Due to its dull surface, the artefact is optimized for optical measuring systems, like the used fringe projection sensors. By measuring the reference artefact with each fringe projection sensor and aligning the resulting data sets on a digital reference model of the artefact, sensor-specific transformation matrices can be calculated which allow transformation of the sensors’ data sets into a common coordinate system, without the need for any overlapping areas. This approach is concluded in an automated measuring procedure, using alignment algorithms from commercial available software where necessary. With the automated measuring procedure, geometrical relations between individual measured features can be determined and dimensional measuring beyond the measuring range of a sensor became possible. Due to a series of experiments, the advantages of the new qualification concept in comparison with the current measuring procedures are finally revealed.