A Novel Surface Profile Measurement System

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1 A Novel Surface Profile Measurement System Nashtara Islam, Robert Parkin, Mike Jackson, Peter Mueller Mechatronics Research Center, Loughborough University Leicestershire, United Kingdom Abstract Surface profile measurement systems have been an integral part of metal working industry to determine the finish quality of machined surfaces. Mechanical stylus-based profilometers are in widespread use for this purpose due to its well-established standards, cost-effectiveness and ease of use. However, it has some serious drawbacks relating to issues concerning stylus loading, measurement speed and so on. It is well documented in recent research findings that, in softer materials, this technique falls well short of fulfilling the measurement requirements and can be destructive to the surface under test. This paper proposes a non-contact method of surface profiling with the help of a commercially available optical DVD reader. The proposed system is costeffective, non-destructive and has a small footprint for seamless integration into a given process line. Some preliminary test results and discussions have been put in place to indicate the suitability of the system in high-speed wood machining environment. Keywords: Profilometer, mechanical stylus, non-contact profile measurement, optical DVD reader, linear encoder, wood machining. 1. Introduction The most commonly employed technique until now to evaluate machined surfaces is human inspection (Sandak and Tanaka 2003). Not only is it a highly subjective way of looking into finish quality, it is also prone to errors due to human fatigue and judgment. Hence, instrumentations to accurately analyze the finish quality had become a necessity. Thus, mechanical stylus based instruments have been widely employed in various process and manufacturing industries in the past few decades. Despite well-established standards and cost-effectiveness, this technique is becoming unsuitable for some applications. Most notably, mechanical stylus based instruments can only be used in high-speed woodworking with limited success (Parkin and Jackson 1996). The method is destructive to timber surface due to the loading of stylus tip as well as slow and yielding parameters of little importance to indicate the surface form defects due to timber machining. Therefore, non-contact methods are proving to be the more suitable instrument in the wood machining scenario (Cutri et al. 1991). 2. Background Various non-contact methods for surface profile measurement have been developed and tested. However, most of the methods have been used to obtain surface texture information of metal or similar products (Parkin and Jackson 1996). Very little or almost no research has been carried out to successfully determine the finish quality of timber. Among these few researchers, Yang et al. (2005), Jackson et al. (2002), Sandak et al. (2003, 2004, 2005) have successfully explored non-contact methods for surface profile measurement of timber. As just stated before, various non-contact measurement methods are being developed and investigated around the globe. Ultrasonic and optical probes have become the most suitable candidates for many present day non-contact measurements. In this section of the paper, some of these non-contact techniques will be discussed in certain detail. 203

2 2.1 Ultrasonic Method Ultrasonic technique mainly includes the pulse echo and standing wave resonance methods. In principle, ultrasonics may still be regarded as a contact method as good acoustic coupling is essential for the electromagnetic waves to travel from one medium to the other (Blessing et al. 1993). Thus, the surface being measured must be immersed in an oil bath along with the transducer. Water jets are also used as a coupling medium. In some cases, air has been used as the coupling medium, paving the way for noncontact measurements of surfaces using ultrasonic sensors (Jolic et al. 1994). The drawbacks of this method are high power transmitter requirement, low sensitivity and, above all, the restriction of being able to measure only some certain materials (e.g., metals). Therefore, it is clear that, ultrasonic sensors cannot be used to measure most surfaces apart from metals. As a result, it is not suitable for measuring surface profile of timber. 2.2 Optical Methods Optical methods include optical profilometers (mostly laser based), microscopes, image analyzers, imaging spectrographs, interferometers, fiber-optic transducers, white-light speckles, laser scattering, optical light sectioning systems, etc. Some of the techniques e.g., microscopes, suffer from the fact that measurement speed is rather slow and thus they are not suitable for in-process measurements (Lee et al. 2002). Also, the cost is prohibitive notwithstanding the great accuracy and ultra-fine resolution of these probes. Image analyzers, spectrographs etc. are highly costly approach and only suitable for certain measurement tasks and environments. Interferometers offer excellent accuracy but require a complex arrangement of optical components as well as complicated control and image processing algorithms (Zhang and Cai 1997). The high cost of associated hardware is also an issue in this case. In the case of optical light sectioning as well as the white-light speckle method, very accurate optical alignment is an absolute necessity (Cutri et al. 1991). This limits the overall flexibility and robustness of the system. Another common precision method used for surface measurement is the fiber-optic transducer (Persson 1999). Very fine measurements can be carried out using this method with a high resolution. The drawbacks seem to be use of complex hardware as well as complicated signal processing algorithms. The fiber is very delicate in nature and thus must be shielded very carefully in the measurement setup. Extensive literature review reveals that, most of the techniques currently being used or investigated require complex hardware, high capacity image/signal processing, and complicated arrangement leading to high cost and low flexibility. Therefore, scope remains to develop low-cost, easy-to-use and flexible system for non-contact surface profile measurement. 3. The Proposed Method An alternative to the aforementioned non-contact methods has been investigated within the Mechatronics Research Group at Loughborough University and reported in this paper. The sensor used for this measurement purpose is the optical pick-up head of a Compact Disc (CD) / Digital Versatile Disc (DVD) player. Figure 1 shows the HOP-1000 pick-up head from Hitachi, which is being used for current research. It must be mentioned that, surface profiling with the DVD pickup as a sensor is not exactly a novel approach and a number of similar research has been carried out in the past by Chu et al. (2004), Fan et al. (2000, 2001, 2003), Zhang and Cai (1997) and so on. However, the profiles measured were ideal surfaces such as CD, mirror, Silicon substrate etc. 204

3 the measurement setup along with the working principle of the system has been discussed in the following sections. 4. Working Principle Figure 1 HOP-1000 DVD Pickup head The research work presented in this paper mainly focuses into the possibility of measuring materials having lesser reflectivity and integrate such measurement technique into a woodworking machine currently under development within the research group. Also, all the previous research have used micro-precision stage to position the optical head over the specimen, thus obtaining accurate positioning information. This approach is effective for laboratory based nano or micro metrology but would be prohibitively costly for viable industrial application. To overcome this drawback, a low-cost optical mouse sensor based linear encoder has been developed. This would eliminate the need for an expensive stage and the scanning motion can be provided through any motor driven linear stage. In this section, working principle of the optical DVD head and the mouse sensor has been discussed in some detail. 4.1 DVD Optical Pickup Head The optical pickup head mainly consists of a laser diode, grating, polarized beam splitter, a quarter-wave plate, a cylindrical and an objective lens (Figure 3). The laser diode emitted light (wavelength of 635 ~ 665 nm) is projected on to the object surface after passing through the grating, ¼ wave plate and the objective lens. This beam reflects back from the surface along the original path and after passing through a cylindrical lens projects on to the four-quadrant photodiode. f (x) Vertical displacement or profile captured through the DVD head 0 a Horizontal displacement information obtained via mouse sensor Figure 2 Schematic idea for surface profile measurement using DVD pickup and optical mouse sensor The measurement idea has been depicted in figure 2. The optical pickup is being used to measure the profile information, while the optical mouse based encoder provides the positional information of the sensor over the work-piece under test. Detailed explanation of Figure 3 Construction of the DVD pick-up head (Fan et al. 2001) This arrangement of four-quadrant photodiode produces a focus error signal (FES) output according to the main beam spot position in each quadrant. The produced FES is then used to drive the Voice Coil Motor (VCM), which shifts the objective lens until the focal point is back to the object surface. The amount of VCM movement is equivalent to the profile change of the surface the beam is focused on. The probe can be used to detect surface profile in two modes. The head can be used as 205

4 a focusing probe by keeping the VCM glued to the pickup head (Fan et al. 2000). The measurement range was limited to 10 µm and the resolution was observed to be 34 nm. However, a later research has shown that, in an auto-focusing configuration (i.e., allowing the VCM to move freely), a measurement range of 200 µm could be obtained with a 0.1 µm resolution (Fan et al. 2001). The first method is more suitable for surface profile measurement of micro and nano materials, while the second method can yield a measurement system for common machined surfaces, such as, timber. Therefore, current investigation has concentrated on developing a surface profile measurement system by acquiring data from the sensor in the auto-focusing configuration. 4.2 The Optical Mouse Sensor The optical mouse consists of Light Emitting Diode (LED), plastic lenses and the optical sensor. For this particular research, the optical sensor, which is an Integrated Circuit (IC) termed ADNS-2051 from Agilent Technologies, has been used. This IC is essentially a high-speed video camera and image processor packaged together. Approximately, the capture rate of the camera is in the region of 1500 frames per second, fast enough to ensure sequential picture overlap (Agilent 2001). The captured images are then sent to the navigation engine for further image processing. With the help of Agilent patented imageprocessing algorithm, the engine determines the common features between the two successive images and calculates the distance between them. This information is then translated into X-Y coordinate information. This coordinate information has been extracted from the mouse sensor IC and after further numerical manipulation, converted into linear distance. Thus, a non-contact linear encoder was obtained with a resolution of 30 µm (Mattoli 2004). 5. Experimental Setup The preliminary surface profile measurement setup involving the DVD pickup head and the optical mouse sensor has been shown in figure 5. Figure 5 Schematic idea of the measurement setup Figure 4 Working principle of the optical mouse (Agilent 2001) As shown in figure 4, light emitted by the red LED is used to illuminate the surface and a picture of the surface is then captured by the on-board camera of the sensor IC. The image formed at the camera is black and white in nature and the images are taken successively as the mouse moves. The measurement setup mainly consists of the sensor assembly, signal conditioning and power control circuitry, linear motor driven stage to provide the required scanning motion, data acquisition system and a personal computer (PC) for storing and analyzing measured data. Previous research has shown that, measurements carried out with the help of the pickup head have been affected by the ambient temperature (Fan et al. 2000). Thus, the output 206

5 power of the laser has to be regulated at all time to avoid errors being introduced in measurement results. The Automatic Power Control Circuit (APC) has been integrated into the setup for this purpose. 6. Results and Discussion Preliminary tests carried out with surface profile measurement system using a DVD pickup head shows good promise. A typical calibration curve of the DVD optical pickup head is shown in figure 6. It can be observed from the curve that, there is a linear region from approximately from 1.71 mm to 1.74 mm. Thus, within this 30 μm, the output FES voltage has a linear correspondence to the change in focal distance of the sensor. Calibration Test Result 1.00E+01 FES Output voltage (V) 5.00E E E E+01 Forward-pr1 Backward-pr1-1.50E+01 Distance from mirror (mm) Fig. 6. Calibration test result of the DVD pickup head This linear region can be used to successfully determine surface profile of a machined surface with good accuracy. Some testing has also been conducted to establish the suitability of optical mouse sensor based linear encoder in the case of timber. Repeatability error of this linear encoder has been reported in figure 7. % error Repeatability Error@25mm/s No. of iterations 207 Figure 7 Repeatability error of the linear encoder at 25 mm/s An industrial wood machining environment was simulated in the lab, by mounting a light colored timber on to a linear stage and passing it through the sensor assembly at 25 mm/s. From figure 7 it is evident that, in almost 80% of the cases, the measurement error was

6 lower than 1%. However, many more iterations will have to be carried out to determine the actual average repeatability error of the encoder. Future tests will involve specimen to move at a much faster rate and measurement errors will then be determined to evaluate the system s performance in high speed woodworking scenario. Some preliminary results have been reported in the paper, showing a good potential of the system being able to meet the measurement requirements in wood machining industry. 8. Acknowledgement The first author would like to gratefully acknowledge the research funding provided by Loughborough University through its Innovative Manufacturing and Construction Research Center (IMCRC). Fig. 8. Measured profile of a CD (Fan et al. 2001) Result obtained from a previous research has been shown in figure 8 (Fan et al. 2001). The profile of a CD has been measured with the system. The track distance was measured to be in the range of 1.4 to 1.7 µm, which compares well with the nominal distance of 1.5 µm. Also, the average height was found to be 0.15 µm, which is slightly less than the manufacturer s value of 0.20 µm. It is acknowledged that, the measurement results will be significantly different in the case of obtaining surface profile of wood or similar material as opposed to a CD. Construction of the test rig for such measurement purpose is currently underway and test results on timber will be presented in future publications. 7. Conclusions A research carried out on the possibility of using DVD pickup head as a surface profile measurement sensor has been presented in this paper. Also, a novel linear encoder to obtain measurement position on the specimen has been discussed. Great potential lies with such a system combining the two sensing system in terms of cost-effectiveness, smaller footprint and seamless integration into existing process machineries. 9. References Agilent Adns-2051 Optical Mouse Sensor Datasheet. Retrieved 25th February 2006, from Blessing, G.V.; Slotwinski, J.A.; Eitzen, D.G. and Ryan, H.M Ultrasonic measurements of surface roughness. Applied Optics 32(19): Chu, C.L.; Fan, K.C.; and Chen, Y.J A Compensation method for the hysteresis error of Dvd Vcm. Measurem. Sci. Tech. 15(4): Cutri, F.; Maycock, K.; and Parkin, R Surface measurement of planed and moulded timber products. Sensors and Actuators, A: Physical 26(1-3): Fan, K.C.; Chu, C.L.; and Mou, J.I Development of a low-cost autofocusing probe for profile measurement. Measurem. Sci. Tech. 12(12): Fan, K.C.; Lin, C.Y.; and Shyu, L.H Development of a low-cost focusing probe for profile measurement. Measurem. Sci. Tech. 11(1): 1-7. Fan, K.C.; Chu, C.L.; Liao, J.L.; and Mou, J.I Development of a high-precision straightness measuring system with Dvd Pick-up head. Measurem. Sci. Tech.14(1): Jackson, M.R.; Parkin, R.M.; and Brown, N Waves on Wood. Proc. Inst. Mech. 208

7 Engin. Part B: J. Engin. Manufacture 216(4): Jolic, K.I.; Nagarajah, C.R.; and Thompson, W. ;1994. Non-contact, optically based measurement of surface roughness of ceramics. Measurem. Sci. Tech. 5(6): Lee, S.; Miyoshi, T.; Takaya, Y.; and Takahashi, S Non-contact 3d Edge profile measurement for die and mould model Surface. J. Mater. Process. Tech. 127(2): Mattoli, V Optical Displacement Sensor Retrieved 10th April 2006, from n/opticaldisplacementsensor. Parkin, R.M.; and Jackson, M.R A mechatronic approach for analysing timber surfaces. Math. Comput. in Simul. 41(5-6): Persson, U Fibre-optic surfaceroughness sensor. J. Mater. Process. Tech. 95(1-3): Sandak, J.; and Tanaka, C. ;2003;. Evaluation of Surface Smoothness by Laser Displacement Sensor 1: Effect of Wood Species. J. Wood Sci. 49(4): Sandak, J.; and Tanaka, C Evaluation of surface smoothness using a light-sectioning shadow scanner. J. Wood Sci. 51(3): Sandak, J.; Tanaka, C.; and Ohtani, T Evaluation of surface smoothness by a laser displacement sensor Ii: Comparison of lateral effect photodiode and multielement Array. J. Wood Sci. 50(1): Yang, D.; Jackson, M.; and Parkin, R Measuring cutter marks on wood surfaces with machine vision techniques. 17th Int. Wood Machin. Seminar, September 2005 Rosenheim, Germany. Zhang, D.; Chang, C.; Ono, T.; and Esashi, M. (2003). A Piezodriven Xy-Microstage for multiprobe nanorecording. Sensors and Actuators A: Physical 108(1-3): Zhang, J.H. and Cai, L Autofocusing measurement system with a Piezoelectric Translator. IEEE/ASME Trans. Mechatronics 2(3): Zhang, J.H.; and Cai, L Profilometry Using an Optical Stylus with Interferometric Readout. Measurement Sci. & Tech. 8(5):

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