Optical measuring machine: revolution in precision measurement

An optical measuring machine opens doors to microscopic dimensions and ensures unparalleled accuracy in a wide range of applications. Whether in industry or in scientific laboratories, this technology has revolutionized the way we view and understand technology at a microscopic level.

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How does an optical measuring machine work? An optical measuring machine uses cameras and light sources to measure the geometry and dimensions of a component without contact. The component is illuminated by a special light, often in the form of a line or point laser. The camera records the reflected light and the captured data is then analyzed by software to determine the dimensions and other characteristics of the component. This enables fast and precise measurement without physical contact with the object being measured.

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Optical metrology - basics 

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Modern technology has given us the advantage of measuring and analyzing our environment and the objects we create with a high degree of precision. One method that has recently attracted a lot of attention, especially in industries where precision is of the utmost importance, is optical metrology.

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Optical metrology - Definition 

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In the world of precision measurement, optical metrology has established itself as a revolutionary method. This technology focuses on optical measurements and non-contact measurement technology, which offer a range of advantages when combined:

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• Optical measurement: As the name suggests, the method is based on optical systems, primarily the use of a high-quality camera to capture the component. Not only are simple 2D images created, but detailed 3D images of the measurement object are generated using advanced sensors and technologies such as laser scanners or fringe projection systems.

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• 3D metrology: The core of this method lies in its ability to capture the complete geometry of a component. This is done by collecting a huge amount of data points from the surface of the object to create a 3D point cloud. With this technique, complex geometric features, deviations from CAD models and other critical information can be determined in real time. Not only is 3D measurement technology highly accurate, it is also extremely fast and often able to digitize complex parts in just a few minutes or even seconds.

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• Non-contact measurement technology: A key feature of optical measurement technology is its non-contact nature. Unlike traditional tactile systems, which require a physical probe to touch and measure the surface of an object, optical metrology does not require direct contact with the object being measured. This has two main advantages: Firstly, there is no risk of damage to sensitive surfaces, and secondly, there is none of the wear and tear that can occur with physical probes.

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The integration of optical measurements, high-quality cameras and 3D measurement technologies in one system enables powerful and versatile measurement processes. This allows manufacturers and engineers to work with immense speed and accuracy, which is particularly invaluable in industries such as the automotive industry.

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History of optical metrology 

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The evolution of optical measurement is a fascinating journey through time that goes back to the very beginnings of photography. With a constant quest for ever more accurate and precise measurement, this field has developed steadily over the years.

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The origins of optical measurement lie in chemical photography. Using simple means, valid measurements could be carried out step by step on large buildings and landscape reliefs. A simple technique was used for this: a high-contrast, calibrated measuring rod was placed in the immediate vicinity of the object to be measured and both were photographed together. With the help of a high-quality camera and the subsequent development of the photo, each distance could be precisely determined by comparing it with the photographed measuring rod. This approach revolutionized the surveying of large buildings and, with the advent of cameras in aircraft, even made it possible to map topographies accurately.

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In an industrial context, optical measurement proved its usefulness in the validation of components from the very beginning. However, as long as automated and electronic measuring methods did not exist, serial optical measurement could only be used to a limited extent. One of the main methods was template testing. Here, a telltale incidence of light threw light on dimensional deviations. Although this method was very effective for flat components such as seals or undeformed thin sheets, it was less suitable for more complex geometries. Tactile measurement technology dominated here for a long time.

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More recently, however, we have been experiencing a technological change. Step by step, measurement technology for serial quality control is opening up to optical measurement methods. The fast, full-surface method of optical 3D measurement technology is particularly well suited to this and promises an exciting future in the world of precise measurement.

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What is an optical measuring machine? 

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Now you know the background to optical measurement technology. But what exactly does an optical measuring machine do? 

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An optical measuring machine is an innovative instrument that uses optical sensors to measure objects with high resolution. These devices, equipped with advanced technologies such as laser scanners, photogrammetry systems or fringe projection systems, are at the forefront of non-destructive measurement technology.

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One of the biggest advantages of these machines is the non-contact measurement. This means that the sensor is never in physical contact with the component. This approach minimizes the risk of damage or wear and tear that is often encountered with conventional tactile measuring systems. This is an indispensable advantage, especially for sensitive materials or finely crafted objects.

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Optical measuring machines are also characterized by their intuitive operation, which makes the measuring process more efficient and user-friendly. By combining speed, accuracy and the possibility of non-contact measurement, the optical measuring machine sets new standards and far exceeds the possibilities of traditional measuring techniques.

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Areas of application for optical measuring machines

In today's technology-driven world, optical measurement systems have become an indispensable tool for many industries. With their wide range of applications, they are revolutionizing the way we measure and inspect objects and components.

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• Quality assurance and monitoring: Optical metrology offers a robust solution for quality assurance in various industries. The ability to create 3D scans of components facilitates the production of end products. Shape and position tolerances can be visualized with 3D models, with false colour representations helping to easily identify irregularities. Thanks to the CAD data, exact deviations can be precisely displayed in a target/actual comparison.
  
  

• Automotive industry: Optical measuring machines are essential for a wide range of applications in the automotive industry. They are not only important for the initial sampling and quality control of classic sheet metal and cast steel components, but also for the inspection and dimensional testing of components such as battery trays. With the rise of electromobility, this particular application is becoming increasingly important as it provides precise data for the production and integration of battery components.
  
  
• Plastics industry: The plastics industry has also benefited from the possibilities of optical measurement technology. The main focus here is on measuring and digitizing injection-moulded and die-cast components. With the help of optical measuring systems, irregularities in the production process can be detected and corrected at an early stage, leading to more efficient and higher quality production.

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The future of optical measuring machines 

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Optical measurement technology has made considerable progress in recent times and has become indispensable, particularly in sectors such as the automotive and packaging industries. It connects the digital with the physical space, enables precise measurements of components and quickly provides digitized data. This data is further processed in CAD programs, which not only promotes the development of improved parts, but also revolutionizes quality control by detecting the smallest irregularities.

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A particular highlight of this development is the integration of augmented reality (AR). AR allows digital models obtained through optical measurements to be superimposed directly over video images of real components. This process not only facilitates direct comparison and quality documentation, but also supports the assembly of components by speeding up the assembly process.

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Future trends in optical metrology point towards closer integration into production, with defects being identified as soon as they occur. The transition from fixed to mobile measuring stations promises more flexibility, while rising customer expectations are driving the development towards more detailed quality controls at micro and nano level.

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The optical measuring machines from Q-Tech

Are you looking for maximum precision and reliability? At Q-Tech, we understand how important it is to capture every detail of your product accurately. Our advanced optical measuring machines, such as the ZEISS O-INSPECT 863 and the OGP SMARTSCOPE FLASH 200, have been specifically designed to provide you with outstanding measurement accuracy and detailed measurement of your products.

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Thanks to the combination of tactile probes and optical sensors, we can guarantee fast and precise measurement, saving you valuable time and resources. Our intuitive measurement software solutions, CALYPSO and MeasureX, enable smooth data processing and analysis so that you always have an overview.

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Our new GOM ATOS Q 5M 3D scanner is also a particular focus for us: thanks to its highly developed technology, it not only delivers precise and detailed data using the structured light projection method, but also enables fast and efficient surface analysis. In combination with the high-quality GOM Inspect Pro analysis software, this makes it an indispensable tool in areas such as quality assurance, product development and research. Its reliability and accuracy set new standards in the industry. 

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At Q-Tech, however, the focus is not only on technology, but above all on you, our customers. Our machines are an instrument to bring your product to perfection. Benefit from our know-how and let us convince you of the efficiency and accuracy of our measuring services. Q-Tech is your partner for excellent quality control.

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Conclusion 

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The optical measuring machine is a groundbreaking innovation in the world of precision measurement. Thanks to its ability to create precise 3D images of objects, this technology offers invaluable advantages such as non-contact measurements, incredible speed and absolute precision. This is proving to be indispensable, particularly in sectors such as the automotive and plastics industries.

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Having grown historically from the beginnings of photography, optical metrology has come a long way and is now on the rise with advanced technologies such as augmented reality. Future trends point to even closer integration into production processes and greater attention to detail. Companies like Q-Tech are already offering cutting-edge solutions in this area. In light of these advances, optical metrology will continue to play a key role in quality assurance and product development.

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