Investigation of an Inline Inspection Method for the Examination of Cylinder-like Specular Surfaces Using Deflectometry

Abstract

An optical measuring method is presented, with which it is possible to measure and evaluate reflective cylindrical surfaces using a combination of deflectometry and subsequent reconstruction of the surface. The system is set up and tested on rolling elements of cylindrical roller bearings. However, it is not limited to this use case and can be applied to other cylindrical specular surfaces. The system distinguishes itself from existing test methods through the combination of high-resolution three-dimensional defect measurement with a very short recording time, and offers the possibility of introducing tolerance limits in the production of cylindrical specular surfaces. With this method, it is possible to record a defect with the dimensions of 1.3mm by 1.8mm within 5 s and to reconstruct the absolute depth. The resolution of the system is below 10 μm in both X- and Y-direction, and is therefore sufficiently accurate to detect typical surface defects such as scratches, dents, or deformations. To validate the measured values of the system, the results of an artificially generated 10.35 μm deep defect location were compared with those of a highly accurate mechanical stylus measurement.