Construction and investigation of a roughness and shape measuring device with a rotating optoelectronic stray light sensor for use on ball studs

Abstract

The objective of the project is the determination of the measurement capacity and the analysis of a ball stud machine. This ball stud machine measures the roughness and profile of the ball studs. The technology used in ball stud measurement is the scattered light method. The scattered light method is a technique used to measure surfaces passively (reflection of emitted light). The project starts from the improvement of a real measuring machine from a well-known auto parts company. The project carried out consists of the analysis and verification of the measurement values of this technology. It also includes the mechanical and electronic installation of the machine, as well as the programming and adjustment of the motors. These evaluations follow the standards of the German automotive industry to determine the consistency of measurements. As Optosurf does not have a ball stud machine model in its facilities, the first functional tests of the software and the new design are carried out on another machine called the OptoShaft TT. This machine has a multipurpose function within the company and achieves values very close to those of the real machine. This project also includes a construction design in Solidworks that allows the measurement of ball studs on standard Optosurf multipurpose machines.