A Non-Contact Measuring System for In-Situ Surface Characterization Based on Laser Confocal Microscopy

Area of Science:

• Metrology and Surface Engineering
• Advanced Manufacturing Technologies

Background:

• Traditional surface characterization relies on off-line, 2D methods.
• Integration of in-situ measurement systems is crucial for real-time manufacturing feedback.

Purpose of the Study:

• To develop and validate a non-contact, in-situ surface topography measurement system.
• To enable real-time surface roughness assessment within a robotic manufacturing process.

Main Methods:

• Utilized a laser confocal sensor in lateral and vertical scanning modes.
• Developed data processing software for roughness parameter calculation (ISO 4287).
• Calibrated the system and applied a linear correction factor to mitigate confocal microscopy limitations.

Main Results:

• Successfully integrated the system onto a robotic arm for dynamic measurements.
• Achieved accurate surface roughness measurement within the Ra range of 0.2–7 μm.
• Demonstrated a relative accuracy of 5% for the in-situ measurements.

Conclusions:

• The proposed non-contact system effectively measures in-situ surface topography on robotically finished components.
• The system provides a viable solution for real-time quality control in advanced manufacturing.