Design and application of thickness measurement calibration system based on laser displacement sensor

This study aims to improve the accuracy and safety of steel plate thickness calibration.A differential noncontact thickness measurement calibration system based on laser displacement sensors was designed to address the problems of low precision of traditional contact thickness gauges and radiation risks of radiation-based thickness gauges.First,the measurement method and measurement structure of the thickness calibration system were introduced.Then,the hardware circuit of the thickness system was established based on the STM32 core chip.Finally,the system software was designed to implement system control to filter algorithms and human-computer interaction.Experiments have proven the excellent performance of the differential noncontact thickness measurement calibration system based on laser displacement sensors,which not only considerably improves measurement accuracy but also effectively reduces safety risks during the measurement process.The system offers guiding significance and application value in the field of steel plate production and processing.

Measurement and Analysis of Vibration Effect of Free-falling Corner Cube Driving Mechanism in Free Fall Absolute Gravimeter

The vibration interference of the reference corner cube runs through the free flight process of the free-falling corner cube,which is superimposed on the whole laser interference fringes.Thus,it is necessary to solve the interference fringes with the entire fringe to analyze the quantitative influence of vibration on gravity measurements.

In-situ 3D contour measurement for laser powder bed fusion based on phase guidance

In-situ layerwise imaging measurement of laser powder bed fusion(LPBF)provides a wealth of forming and defect data which enables monitoring of components quality and powder bed homogeneity.Using high-resolution camera layerwise imaging and image processing algorithms to monitor fusion area and powder bed geometric defects has been studied by many researchers,which successfully monitored the contours of components and evaluated their accuracy.However,research for the methods of in-situ 3D contour measurement or component edge warping identification is rare.In this study,a 3D contour mea-surement method combining gray intensity and phase difference is proposed,and its accuracy is verified by designed experiments.The results show that the high-precision of the 3D contours can be achieved by the constructed energy minimization function.This method can detect the deviations of common ge-ometric features as well as warpage at LPBF component edges,and provides fundamental data for in-situ quality monitoring tools.

Establishment and Error Analysis of Model of Interference Fringe Contrast for Laser Tracing Measurement Optical System

A method was proposed to analyze the influences of the non-ideal spectroscopic performance of optical components and orientation errors of a laser tracing measurement optical system on the tracing measurement performance.A comprehensive model of the interference fringe contrast based on the laser tracing system s measurement principle was established in this study.Simulation results based on ZEMAX verified the model.According to the simulation results,the placement angle of the analyzer had a direct influence on the interference fringe contrast.When the angle of the polarized light to the analyzer’s transmission axis increased from 65°to 85°,each contrast of the four-way interference fringes decreased from 0.9996 to 0.3528,the interference fringe contrast is decreased by 65%.Under the split ratio of beam splitters in the interference part(BS 1)of 5∶5,when the splitting ratio of BS 2 changed from 2∶8 to 8∶2,the fringe contrast of the interference signals received by the photodetectors increased,but the injection light intensity onto the PSD reflected by BS 2 decreased.The significant influence of the tracing performance was verified by the experiments.When splitting ratio of BS 2 increased,the contrast of the interference fringes increased.Due to the weakening of the incident light intensity of the PSD caused by the change of BS 2 splitting ratio,the response time of the tracing system is increased by 23.7 ms.As a result,the tracing performance of the laser tracing measurement optical system was degraded.An important theoretical basis was provided to evaluate and improve the accuracy and reliability of laser tracing measurement systems.

Novel Method for Spatial Angle Measurement Based on Rotating Planar Laser Beams

Spatial angle measurement, especially the measurement of horizontal and vertical angle, is a basic method used for industrial large-scale coordinate measurement. As main equipments in use, both theodolites and laser trackers can provide very high accuracy for spatial angle measurement. However, their industrial applications are limited by low level of automation and poor parallelism. For the purpose of improving measurement efficiency, a lot of studies have been conducted and several alternative methods have been proposed. Unfortunately, all these means are either low precision or too expensive. In this paper, a novel method of spatial angle measurement based on two rotating planar laser beams is proposed and demonstrated. Photoelectric receivers placed on measured points are used to receive the rotating planner laser signals transmitted by laser transmitters. The scanning time intervals of laser planes were measured, and then measured point＇s horizontal/vertical angles can be calculated. Laser plane＇s angle parameters are utilized to establish the abstract geometric model of transmitter. Calculating formulas of receiver＇s horizontal/vertical angles have been derived. Measurement equations＇ solvability conditions and judgment method of imaginary solutions are also presented after analyzing. Proposed method for spatial angle measurement is experimentally verified through a platform consisting of one laser transmitter and one optical receiver. The transmitters used in new method are only responsible for providing rotating light plane signals carrying angle information. Receivers automatically measure scanning time of laser planes and upload data to the workstation to calculate horizontal angle and vertical angle. Simultaneous measurement of multiple receivers can be realized since there is no human intervention in measurement process .Spatial angle measurement result indicates that the repeatable accuracy of new method is better than 10＂. Proposed method can improve measurement＇s automation degree and speed while ensuring measurement accuracy.

Review of low timing jitter mode-locked fiber lasers and applications in dual-comb absolute distance measurement

Passively mode-locked fiber lasers emit femtosecond pulse trains with excellent short-term stability. The quantum-limited timing jitter of a free running femtosecond erbium-doped fiber laser working at room temperature is considerably below one femtosecond at high Fourier frequency. The ultrashort pulse train with ultralow timing jitter enables absolute time-of-flight measurements based on a dual-comb implementation, which is typically composed of a pair of optical frequency combs generated by femtosecond lasers. Dead-zone-free absolute distance measurement with sub-micrometer precision and kHz update rate has been routinely achieved with a dual-comb configuration, which is promising for a number of precision manufacturing applications, from large step-structure measurements prevalent in microelectronic profilometry to three coordinate measurements in large-scale aerospace manufacturing and shipbuilding. In this paper, we first review the sub-femtosecond precision timing jitter characterization methods and approaches for ultralow timing jitter mode-locked fiber laser design. Then, we provide an overview of the state-of-the-art dual-comb absolute ranging technology in terms of working principles, experimental implementations, and measurement precisions. Finally, we discuss the impact of quantum-limited timing jitter on the dual-comb ranging precision at a high update rate. The route to highprecision dual-comb range finder design based on ultralow jitter femtosecond fiber lasers is proposed.

Measurement of Cavity Loss and Quasi-Fermi-Level Separation for Fabry-Pérot Semiconductor Lasers

A fitting process is used to measure the cavity loss and the quasi Fermi level separation for Fabry Pérot semiconductor lasers.From the amplified spontaneous emission (ASE) spectrum,the gain spectrum and single pass ASE obtained by the Cassidy method are applied in the fitting process.For a 1550nm quantum well InGaAsP ridge waveguide laser,the cavity loss of about ～24cm -1 is obtained.

New Measurement Method for Spline Shaft Rolling Performance Evaluation using Laser Displacement Sensor

In order to control the quality of spline shaft in rolling process, an efficient measurement method for rolling performance evaluation is essential. Here, a newly developed on-machine non-contact measurement prototype based on laser displacement sensor and rotary encoder is proposed. The prototype is intended for the automated evaluation of the spline shaft rolling performance by measuring the dimensional change of tooth root, which is correlated with the surface residual stress and micro-hardness. Laser displacement sensor and rotary encoder are used to record the polar radius and polar angle of each point on measuring section. Data are displayed in a polar coordinate system and fitted in a gear. Through multipoint curvature method, the roots of spline shaft are recognized automatically. Then, the dimensional change can be calculated by fitting the radius of the tooth root circle before and after rolling. Systematic error covering offset error is also analyzed and calibrated. At last, measurement test results show that the system has advantages of simple structure, high measurement precision(radius error < 0.6 μm), high measurement efficiency(measuring time < 2 s) and automatic control ability, providing a new opportunity for the efficient evaluation of various spline shafts in high-precision mechanical processing.

Non-contact angle measurement based on parallel multiplex laser feedback interferometry

We present a novel precise angle measurement scheme based on parallel multiplex laser feedback interferometry （PLFI）, which outputs two parallel laser beams and thus their displacement difference reflects the angle variation of the target. Due to its ultrahigh sensitivity to the feedback light, PLFI realizes the direct non-contact measurement of non- cooperative targets. Experimental results show that PLFI has an accuracy of 8＂ within a range of 1400＂. The yaw of a guide is also measured and the experimental results agree with those of the dual-frequency laser interferometer Agilent 5529A.

Measurement of 3db Bandwidth of Laser Diode Chips

An accurate technique for measuring the frequency response of semiconductor laser diode chips is proposed and experimentally demonstrated.The effects of test jig parasites can be completely removed in the measurement by a new calibration method.In theory,the measuring range of the measurement system is only determined by the measuring range of the instruments network analyzer and photo detector.Diodes' bandwidth of 7 5GHz and 10GHz is measured.The results reveal that the method is feasible and comparing with other method,it is more precise and easier to use.

External-cavity birefringence feedback effects of microchip Nd:YAG laser and its application in angle measurement

External-cavity birefringence feedback effects of the microchip Nd：YAG laser are presented. When a birefringence element is placed in the external feedback cavity of the laser, two orthogonally polarized laser beams with a phase difference are output. The phase difference is twice as large as the phase retardation in the external cavity along the two orthogonal directions. The variable extra-cavity birefringence, caused by rotation of the external-cavity birefringenee element, results in tunable phase difference between the two orthogonally polarized beams. This means that the roll angle information has been translated to phase difference of two output laser beams. A theoretical analysis based on the Fabry-Perot cavity equivalent model and refractive index ellipsoid is presented, which is in good agreement with the experimental results. This phenomenon has potential applications for roll angle measurement.

Numerical investigation of multi-beam laser heterodyne measurement with ultra-precision for linear expansion coefficient of metal based on oscillating mirror modulation

This paper proposes a novel method of multi-beam laser heterodyne measurement for metal linear expansion coefficient. Based on the Doppler effect and heterodyne technology, the information is loaded of length variation to the frequency difference of the multi-beam laser heterodyne signal by the frequency modulation of the oscillating mirror, this method can obtain many values of length variation caused by temperature variation after the multi-beam laser heterodyne signal demodulation simultaneously. Processing these values by weighted-average, it can obtain length variation accurately, and eventually obtain the value of linear expansion coefficient of metal by the calculation. This novel method is used to simulate measurement for linear expansion coefficient of metal rod under different temperatures by MATLAB, the obtained result shows that the relative measurement error of this method is just 0.4%.

Improved calibration method for displacement transformation coefficient in optical and visual measurements

Optical and visual measurement technology is used widely in fields that involve geometric measurements,and among such technology are laser and vision-based displacement measuring modules(LVDMMs).The displacement transformation coefficient(DTC)of an LVDMM changes with the coordinates in the camera image coordinate system during the displacement measuring process,and these changes affect the displacement measurement accuracy of LVDMMs in the full field of view(FFOV).To give LVDMMs higher accuracy in the FFOV and make them adaptable to widely varying measurement demands,a new calibration method is proposed to improve the displacement measurement accuracy of LVDMMs in the FFOV.First,an image coordinate system,a pixel measurement coordinate system,and a displacement measurement coordinate system are established on the laser receiving screen of the LVDMM.In addition,marker spots in the FFOV are selected,and the DTCs at the marker spots are obtained from calibration experiments.Also,a fitting method based on locally weighted scatterplot smoothing(LOWESS)is selected,and with this fitting method the distribution functions of the DTCs in the FFOV are obtained based on the DTCs at the marker spots.Finally,the calibrated distribution functions of the DTCs are applied to the LVDMM,and experiments conducted to verify the displacement measurement accuracies are reported.The results show that the FFOV measurement accuracies for horizontal and vertical displacements are better than±15μm and±19μm,respectively,and that for oblique displacement is better than±24μm.Compared with the traditional calibration method,the displacement measurement error in the FFOV is now 90%smaller.This research on an improved calibration method has certain significance for improving the measurement accuracy of LVDMMs in the FFOV,and it provides a new method and idea for other vision-based fields in which camera parameters must be calibrated.

Measurement of the surface morphology of plasma facing components on the EAST tokamak by a laser speckle interferometry approach

The laser speckle interferometry approach provides the possibility of an in situ optical noncontacted measurement for the surface morphology of plasma facing components(PFCs),and the reconstruction image of the PFC surface morphology is computed by a numerical model based on a phase unwrapping algorithm.A remote speckle interferometry measurement at a distance of three meters for real divertor tiles retired from EAST was carried out in the laboratory to simulate a real detection condition on EAST.The preliminary surface morphology of the divertor tiles was well reproduced by the reconstructed geometric image.The feasibility and reliability of this approach for the real-time measurement of PFCs have been demonstrated.

Comparison of GUF and Monte Carlo methods to evaluate task-specific uncertainty in laser tracker measurement

Measurement uncertainty plays an important role in laser tracking measurement analyses. In the present work, the guides to the expression of uncertainty in measurement(GUM) uncertainty framework(GUF) and its supplement, the Monte Carlo method, were used to estimate the uncertainty of task-specific laser tracker measurements. First, the sources of error in laser tracker measurement were analyzed in detail, including instruments, measuring network fusion, measurement strategies, measurement process factors(such as the operator), measurement environment, and task-specific data processing. Second, the GUM and Monte Carlo methods and their application to laser tracker measurement were presented. Finally, a case study involving the uncertainty estimation of a cylindricity measurement process using the GUF and Monte Carlo methods was illustrated. The expanded uncertainty results(at 95% confidence levels) obtained with the Monte Carlo method are 0.069 mm(least-squares criterion) and 0.062 mm(minimum zone criterion), respectively, while with the GUM uncertainty framework, none but the result of least-squares criterion can be got, which is 0.071 mm. Thus, the GUM uncertainty framework slightly underestimates the overall uncertainty by 10%. The results demonstrate that the two methods have different characteristics in task-specific uncertainty evaluations of laser tracker measurements. The results indicate that the Monte Carlo method is a practical tool for applying the principle of propagation of distributions and does not depend on the assumptions and limitations required by the law of propagation of uncertainties(GUF). These features of the Monte Carlo method reduce the risk of an unreliable measurement of uncertainty estimation, particularly in cases of complicated measurement models, without the need to evaluate partial derivatives. In addition, the impact of sampling strategy and evaluation method on the uncertainty of the measurement results can also be taken into account with Monte Carlo method, which plays a guiding role in measurement planning.

The Approach of Compensation of Air Refractive Index in Thermal Expansion Coefficients Measurement Based on Laser Feedback Interferometry

We present the thermal expansion coefficient （TEC） measurement technology of compensating for the effect of variations in the refractive index based on a Nd： YA G laser feedback system, the beam frequency is shifted by a pair of aeousto-optic modulators and then the heterodyne phase measurement technique is used. The sample measured is placed in a muffle furnace with two coaxial holes opened on the opposite furnace walls. The measurement beams hit perpendicularly and coaxially on each surface of the sample. The reference beams hit on the reference mirror and the high-refiectivity mirror, respectively. By the heterodyne configuration and computing, the influences of the vibration, distortion of the sample supporter and the effect of variations in the refractive index are measured and largely minimized. For validation, the TECs of aluminum samples are determined in the temperature range of 29-748K, confirming not only the precision within 5 × 10-7 K-1 and the accuracy within 0.4% from 298K to 448K but also the high sensitivity non-contact measurement of the lower reflectivity surface induced by the sample oxidization from 448 K to 748 K.

Development of 2D Temperature and Concentration Measurement Method Using Tunable Diode Laser Absorption Spectroscopy

Exhaust gas temperature is an important factor in NOx, THC and PM emissions of engines. Especially 2D temperature and concentration distribution plays an important role for the engine efficiency. A thermocouple is intrinsically a point temperature measurement method and noncontact 2D temperature distribution cannot be attained by thermocouples. Recently, as a measurement technique with high sensitivity and high response, laser diagnostics has been developed and applied to the actual engine combustions. With these engineering developments, transient phenomena such as start-ups and load changes in engines have been gradually elucidated in various conditions. In this study, the theoretical and experimental research has been conducted in order to develop the noncontact and fast response 2D temperature and concentration distribution measurement method. The method is based on a Computed Tomography （CT） method using absorption spectra of water vapor at 1388 nm. It has been demonstrated that the method has been successfully applied to engine exhausts to measure 2D temperature distributions.

Mirror Mapping of Laser Interferometer Measurement System on Ultra-precise Movement Stage

The accuracy and repeatability of the laser interferometer measurement system （LIMS） are often limited by the mirror surface error that comes from the mirror surface shape and distortion. This paper describes a new method to calibrate mirror map on ultraprecise movement stage （UPMS） with nanopositioning and to make a real-time compensation for the mirror surface error by using mirror map data tables with the software algorithm. Based on the mirror map test model, the factors affecting mirror map are analyzed through geometric method on the UPMS with six digrees of freedom. Dam processing methods including spline interpolation and spline offsets are used to process the raw sampling data to build mirror map tables. The linear interpolation as compensation method to make a real-time correction on the stage mirror unflatness is adopted and the correction formulas are illuminated. In this way, the measurement accuracy of the system is obviously improved from 40 nm to 5 nm.

Measurement of Refractive Index Ranging from 1.42847 to 2.48272 at 1064 nm Using a Quasi-Common-Path Laser Feedback System

Wavelength 1064 nm is one of the most widely used laser wavelengths in industries and science. The high-precision measurement of the refractive index of optical materials at 1064 nm is significant for improving the optical design. We study the direct measurement of refractive index at 1064nm of lasers, including cMcium fluoride （CaF2）, fused silica and zinc selenide （ZnSe）, whose refractive indices cover a large range from 1.42847 to 2.48272. The measurement system is built based on the quasi-common-path Nd：YAG laser feedback interferometry. The thickness can be measured simultaneously with the refractive index. The results demonstrate that the system has absolute uncertainties of ~10-5 and ~10-4 mm in refractive index and thickness measurement, respectively.

Laser triangulation measurement of the level in a coal silo

Laser triangulation theory was used to develop a novel contact-free method for measuring the coal level in a silo under harsh environmental conditions found in coal mines, such as the presence of dense dust, high humidity, and low illumination. A laser source and a camera were mounted at the top of the silo. The laser spot projected into the silo was imaged by the camera. The pinhole imaging principle allows the level to be found from the lateral shift of the spot image on the sensor. A pre-calibrated look-up table of the coal depth versus spot position was used to obtain the depth. The measurement accuracy depends on the step size used during pre-calibration. The actual application of a device designed according to these principles shows that it is easy to implement. The detection of the coal level in a silo at the low illumination level found in coal mines is demonstrated.