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Ultra-deep-hole high-precision visual inspection system
Optics Express
|May 4, 2026
Summary
A new optical inspection system offers high-precision measurement for small, deep holes. This system achieves sub-10μm resolution and accurate panoramic stitching for industrial applications.
Area of Science:
- Optical Engineering
- Metrology
- Industrial Inspection
Background:
- Accurate measurement of inner walls in small-diameter, ultra-deep holes is challenging.
- Existing methods often lack the required precision and resolution for critical industrial applications.
Purpose of the Study:
- To develop a high-precision optical inspection system for small-diameter ultra-deep-hole measurement.
- To introduce novel methods for quantitative optical design and distortion correction in such systems.
Main Methods:
- Developed an ultra-slim, long-working-length imaging system using reverse-tracing flux matching (RTFM) for optical design.
- Proposed a bidirectional ray-tracing calibration (BRTC) method for accurate panoramic unwrapping of non-planar surfaces.
- Fabricated a prototype endoscope (UHVE) and conducted experimental evaluations.
Main Results:
- The UHVE system achieved a practical spatial resolution better than 10μm for bore sizes of 4-8mm.
- Demonstrated high imaging quality, low tolerance sensitivity, and strong thermal robustness through optical simulations.
- Validated panoramic stitching accuracy with lateral and axial errors of 4.873μm and 10.190μm, respectively.
Conclusions:
- The developed UHVE system provides a compact and reliable solution for high-precision inner-wall inspection.
- The RTFM and BRTC methods enable accurate optical design and distortion correction for challenging geometries.
- This technology advances inspection capabilities in small-aperture ultra-deep-hole applications.
