Optical bi-sensorial measurement system for production control of extruded profiles

Extruded profiles are semi-finished products (made out of steel, brass, aluminum, synthetics...) which are appointed for wide applications in manufacturing of technical products. As yet used optical sensors in process control working to the shading technology detect the object's shadow orthographically to the axis of illumination. As a consequence they record it unattached by the profiles coat in measurement range at any point of the measured profile with high precision. As a matter of fact, concave zones cannot be captured. Alternatively the measurement of concave zones can be arranged by light-section systems. These do not comply with the required accuracy, are comparatively slow and moreover affected by dislocations of the section of the profile. A measurement system including a light-section and a shading system combines the advantages of both optical systems. It is to serve with a reliable conception for the assembly of a bi-sensorial measurement system consisting of both systems as well as suitable methods of analysis for the in-line inspection of concave profiles. As a result it contains conclusions concerning requirements of the light source, the arrangement of this source and the cameras, obtainable precision and sampling rate as well as the essential synchronization of both systems. After designing an appropriate prototype, the selected light-section system and the shading system will be synchronized and aligned. Therefore, the metered geometrical data will be merged for the evaluation of form deviation. So, developed and adapted software supports and contains proposals to the uncertainty after successful tests. The system and a calibration method will be proved in production where robustness will be a most critical despite of heat, dust and vibrations. The target uncertainty of less than 0.1 mm at every section of the profiles coat has to be met.