Metrological Set-up For Calibrating 1D Line Scales With Sub-Micrometre Precision.
Klobucar, Rok ; Strbac, Branko ; Hadzistevic, Miodrag 等
Metrological Set-up For Calibrating 1D Line Scales With Sub-Micrometre Precision.
1. Introduction
Industry is demanding more and more rapid and accurate dimensional
measurements on diverse mechanical parts. In recent years, optical
coordinate measuring machines (CMMs) having made substantial progress
and are now often used for such applications. Especially CMMs equipped
with imaging capabilities are frequently used for fast, non-contact
measurements. Strong competition among manufacturers of such instruments
and the demand for sub-micron accuracy has led to standardised tests,
which are aimed for comparing and validating instrument performance [1].
Calibration, verification and also error correction of optical CMMs are
mainly based on measurements using reference line scales or
two-dimensional grid plates [2, 3, 4].
There are very many commercially available line scales made of
different materials (steel, brass, invar, glass, quartz, zerodur). They
can vary in length from below 1 mm to more than 1 m, and have
resolutions (pitch) from below 10 nm to 1 cm. They can be calibrated by
using different measurement set-ups, depending on their length and
precision. Set-ups for calibrating high-precision line scales normally
involve a microscope with an optical sensor for capturing and analysing
the image of a line marker and a laser interferometer as a traceable
measurement standard [5-7].
This paper introduces a measuring system developed for calibrating
line scales with measurement uncertainty of less than 10 nm over a total
length of 500 mm. The system integrates a numerically controlled
multi-axis stage, a laser interferometer, and a vision system for
detecting line position. With this measurement set-up, Abbe errors can
be reduced to negligible levels. Spatial separation between the measured
point and reference line is known as an Abbe offset [8].
Since it is possible to put optical components very close to each
other, the air dead path error of the laser interferometer is also
negligible. Software for detecting of the lines is based on earlier
design from 2009 [9, 10]. In order to improve performance and to achieve
better uncertainty, the software was improved and automatized, mechanics
and optics have been redesigned and several uncertainty components
better characterized. This facility will replace the old measurement
facility that is manually operated. A model for evaluating uncertainty
and the uncertainty budget for the demonstrated measuring system is
presented in the paper.
2. Measurement system
Measurement set-up for calibrating line scales is shown in Fig. 1.,
while its schematic diagram is shown in Fig. 2. The system integrates a
numerically controlled multi-axis stage, a laser interferometer, and a
vision system for detecting line position [11].
2.1. Numerically controlled multi-axis stage
Numerically controlled multi-axis stage is shown in Fig. 3. It was
designed and manufactured by Newport-micro controle [12] for the
Laboratory for Production Measurement (LTM), University of Maribor,
Slovenia. The measuring system designed by the LTM is intended to
perform 2D measurements on various objects, which will be fixed on a
measuring table. This research is focused in 1D measurements.
Newport's solution is based on a HybrYX-G5 stage featuring a
ceramic carriage which freely slides in X and Y axes on a precision
lapped granite reference plate, using proprietary pressure-vacuum air
bearing design. The carriage is guided along Y axis by a rigid ceramic
beam. The beam is supported and guided at each end with the ball bearing
carriages of X axis. Both X and Y axes are motorized with linear
actuators and include linear glass encoders. Both linear scale glass
encoders are LIDA403 made by Heidenhain, length 440 mm for X axis and
length 1250 mm for Y axis. This positioning system is equipped with the
optional Z-Tip- Tilt and Theta stage. It is motorized by precision
actuators equipped with miniature DC servo motors. The position system
is built on a heavy granite table, which features a precision reference
plane for the air bearing carriage. In addition, the granite structure
includes a granite gantry allowing the fixation of a vertical motorized
translation stage, which accommodates the measuring sensor, depending on
an application. Two rails mounted on the gantry equipped with sliding
carriages provide manual rough positioning capability. The granite
structure is set on a heavy welded frame equipped with ND40 passive
isolators. The position system has one XPS motion controller including
dedicated drivers for the five DC motors and the three linear motors.
The X axis is dual axis composed of X1 and X2 actuators mounted on
the flanks at both ends of the granite table. X1 and X2 carriages move
the ceramic beam of the Y axes. The X axis travel range is +/- 175 mm.
It has a linear encoder with 5 nm resolution. The maximal speed is 300
mm/s., while the repeatability is 500 nm.
The Y axis is a horizontal translation stage using air bearing
technology and linear motor. The guiding beam of Y axes sub-assembly is
attached to the carriages of the X1 and X2 short travel translation
actuators. The guideways involve two parts: a large ceramic carriage and
a Y-axis guide ceramic L-shape beam. The ceramic carriage freely slides
in X and Y axes using pressure-vacuum air bearing design. The reference
planes for the air bearing carriage are the precision lapped surface of
the granite table and the vertical slide of the Y rigid ceramic beam.
The Y axis travel range is +/- 500 mm. It contains a linear encoder with
5 nm resolution. Maximum speed is 600 mm/s., while the repeatability is
100 nm.
The ZTT Theta stage is mounted on the air bearing carriage; it is
equipped at the top with the measuring platform, which allows installing
measured objects. All axes are driven by the high precision motorized
linear actuators. Three actuators are set in upright position with a
travel range of 10 mm. One actuator is set horizontally to achieve the
theta Z movement with a travel range of +/- 1[degrees]. All four
actuators are equipped with a miniature DC motor made by Fulhaber.
Z axis is a vertical motorized translation stage on the middle
carrier. It is a Newport catalogue stage reference M-IMS100V. The Z axis
travel range is 100 mm, the minimum incremental motion is 0,3 [micro]m,
the encoder resolution is 0,1 [micro]m, the maximum speed is 20 mm/s,
while the repeatability is [+ or -] 0,5 [micro]m.
2.2. Laser interferometer
Laser interferometer position measurement systems provide very
precise position or distance information [15]. Our system consists of a
laser head HP 5528A, Agilent module 55292A, and a variety of optical
components and accessories such as material sensors and air sensor. The
basic system measures linear displacement. The system uses the
wavelength of light from a low-power helium-neon laser as a length
standard. We normally set the resolution of the laser interferometer to
10 nm.
Special mounting elements were constructed for the optics used for
calibration. A schematic diagram of the laser interferometer and the
position of the optics are shown in Fig. 2. The position of the optical
elements and the moving parts are set in such way, that the measured
object axis is set in the line with the centre of the laser linear
retroreflector. It allows the Abbe errors to be reduced to negligible
levels even for the most demanding dimensional metrology tasks [13]. The
linear interferometer is fixed on the fixed part of the stage, while the
retroreflector is placed on the moving table in the horizontal
direction. Only the measured object is placed on the moving table that
can move in the vertical direction.
2.3. Vision system for detecting line position
The vision system for detecting line position consists of a zoom
microscope and a CMOS digital camera. The camera is connected to the
computer via USB 3.0 port. The CMOS camera gets the images of the line
scale and sends them to the computer software.
The software analyses the images and determinates the middle of the
line., which is defended by the operator. The software calculates the
distance in pixels. The CMOS digital camera takes 15 monochrome images
per second in resolution 2592 x 1944 pixels. The software analyses the
images in real time. The distance calculated in pixels is transformed
into micrometers [14]. The software for calculation the distance between
lines is more detailed presented by the authors in paper [10].
3. Uncertainty of measurement
Line scales are material measures made of glass, steel or other
material, on which dimensions are marked with line marks. Since the
materials have quite different temperature expansion coefficients, which
are in many cases not exactly known, they are stabilized before
calibration in the climatic room at 20 [degrees]C for 24 hours. The
measurement system must be adjusted and initialized before the
measurement. The line scale should be positioned under the camera by
moving the measurement table. The measuring system, laser
interferometer, vision system for detecting line position and line scale
should be adjusted according to the measuring direction, which is
defended by the movement of the horizontal direction of the table. The
line scale should be fixed on the adjustment table under the camera.
The camera is fixed. It is adjusted in such a way, that the focus
of the camera intersects the centre of the laser linear retroreflector.
The camera is focused on the lines of the line scale by moving the
adjustment table (ZTT Theta stage) in the vertical direction. With this
procedure, the line scale axis, the images of the lines and the centre
of the laser linear retroreflector with the laser beam are positioned in
the measuring direction.
The image processing software should be initialized [10]. With the
improved software, connection to the numerically controlled multi-axis
stage and connection to the laser head, automatic measurements of
distances are possible. The measurement goal is to measure distances
between the reference line and the chosen measuring lines on the line
scale automatically. Measured data are saved into the file where they
are ready for further processing.
3.1. Mathematical model of measurement
The measured value in the calibration of a line scale is a
deviation from a nominal distance between two line centres. The distance
between two lines is calculated as a sum of laser interferometer
indication and vision system for detecting line position indication. The
vision system for detecting line position measures the distance between
the measurement point (scale mark) and the reference line. Deviation e
(measurement result) is given by the expression:
e = ([L.sub.LI] + [L.sub.V] - [L.sub.LIref]) x (1 + [[alpha].sub.m]
x [[theta].sub.m]) - N + [e.sub.cos] + [e.sub.mp] + [e.sub.ms] +
[e.sub.a] (1)
where:
e deviation (measurement result) at 20 [degrees]C
[L.sub.LI] corrected length shown by laser interferometer
[L.sub.V] distance between the measurement point (scale mark) and
reference line in the image window
[L.sub.LIref] indication on the laser in the reference (origin)
point
[[alpha].sub.m] linear temperature expansion coefficient of the
scale
[[theta].sub.m] temperature deviation of the scale from 20
[degrees]C
N nominal value (without uncertainty)
[e.sub.cos] cosine error of measurement (supposed to be 0)
[e.sub.mp] dead path error
[e.sub.ms] random error caused by uncontrolled mechanical changes
[e.sub.a] error caused by the measuring table inclination
3.2. Standard and expanded uncertainty
For uncorrelated input quantities the square of the standard
uncertainty associated with the output estimate y is given by
(2) [14]:
[u.sup.2](y) = [N.summation over (i=1)] [u.sup.2.sub.i](y) (2)
The quantity [u.sub.i](y) (i = 1, 2, ..., N) is the contribution to
the standard uncertainty associated with the output estimate y resulting
from the standard uncertainty associated with input estimate [x.sub.i]
[14]:
[u.sub.i](y) = [c.sub.i] x u([x.sub.i]) (3)
where [c.sub.i] is the sensitivity coefficient associated with the
input estimate [x.sub.i], i.e. the partial derivative of the model
function f with respect to [X.sub.i], evaluated at the input estimates
[x.sub.i] [14].
[mathematical expression not reproducible] (4)
The expanded uncertainty for the coverage factor k=2 is then:
U = [square root of ([(90 nm).sup.2] + [(1,1 x [10.sup.-6] x
L).sup.2])] (5)
4. Experimental results
The measurement accuracy of the numerically controlled multi-axis
stage was verified with the laser interferometer [10] in Y direction
over the distance (0 to 500) mm by twenty repeated measurements in
eleven positions. The absolute difference between the reference value
shown by the laser interferometer and the encoder value in the Y axis of
the measuring system is shown in Fig. 4.
Experimental standard deviation that reflects random influences is
shown in the diagram in Fig. 5. Random influences are caused by the
multi-axis stage instability, vibrations and random changes of
environmental conditions. Presented standard deviations were used in
uncertainty budged of the calibration procedure.
Measurement accuracy of the measuring system was verified on a
calibrated line scale over the distance (0 to 100) mm. Experimental
standard deviation s(L) (6):
s(L) = [square root of (1/[n - 1][n.summation over
(j=1)][([L.sub.j] - [bar.L]).sup.2])] (6)
that reflects random influences is shown in the diagram in Fig. 6.
The diagram also represents the deviation of measured values from the
reference and estimated standard uncertainty. These results characterize
the measuring system which will allow calibrations of length
measurements without laser interferometer. Measuring results represent a
linear characteristic. It is possible to compensate the error with the
appropriate error mapping. From the results, we can see that it is
possible to improve the measurement uncertainty.
5. Conclusion
The main result of the presented research is a verified measuring
set-up for calibrating precise line scales. The system integrates a
numerically controlled multi-axis stage, a laser interferometer, and a
vision system for detecting line position.
The presented procedure for calibrating line-scales with lengths up
to 500 mm, with the measuring uncertainty expressed by (5) has already
been accredited by the national accreditation body. In respect to the
previous measurement set-up, we have improved the measuring system with
new automatic numerical controlled multi-axis stage, better camera and
better environmental conditions. Better calibration and measurement
capability (CMC) was achieved and approved. The calibration,
verification and also error correction of optical CMMs is mainly based
on measurements using reference line scales or two-dimensional grid
plates. Our further work will focus on calibrating 2D optical grids and
step gauges. One of the final goals of this validation phase was to
determine uncertainty of measurement in calibration and verification of
new automatic high resolution measuring set-up for calibrating precise
line scales.
DOI: 10.2507/28th.daaam.proceedings.076
6. Acknowledgment
The authors acknowledge the financial support from the Slovenian
Research Agency (research core funding No. P2-0190), as well as from
Metrology Institute of the Republic of Slovenia (funding of national
standard of length; contract No. C3212-10-000072). The research was
performed by using equipment financed from the European Structural and
Investment funds (Measuring instrument for length measurement in two
coordinates with sub-micrometer resolution; contract with MIRS No.
C2132-13-000033).
7. References
[1] Meli, F. (2013). Calibration of photomasks for optical
coordinate metrology, Physikalisch-Technische Bundesanstalt (PTB), doi:
10.7795/810.20130620C
[2] Mariko, K.; Tsukasa, W.; Makoto, A., & Toshiyuki, T.
(2015). Calibrator for 2D Grid Plate Using Imaging Coordinate Measuring
Machine with Laser Interferometers, International Journal of Automation
Technology, Vol. 9, No. 5, pp. 541-545, doi: 10.20965/ijat.2015.p0541
[3] Acko, B.; Brezovnik, S.; Crepinsek-Lipus, L. & Klobucar, R.
(2015). Verification of statistical calculations in interlaboratory
comparisons by simulating input datasets, International journal of
simulation modelling, Vol. 14, No. 2, pp. 227-237, doi:
10.2507/IJSIMM14(2)4.288
[4] Acko, B.; Sluban, B.; Tasic, T. & Brezovnik, S. (2014).
Performance metrics for testing statistical calculations in
interlaboratory comparisons, Advances in Production Engineering &
Management, Vol. 9, No. 1, pp. 44-52, doi: 10.14743/apem2014.1.175
[5] Flugge, J.; Koning, R.; Weichert, Ch.; HaBler-Grohne, W.;
Geckeler, R. D.; Wiegmann, A.; Schulz, M.; Elster, C. & Bosse, H.
(2009). Development of a 1.5D reference comparator for position and
straightness metrology on photomasks, Proc. SPIE 7122, Photomask
Technology 2008, doi:10.1117/12.801251
[6] Acko, B. (2012). Final report on EUROMET Key Comparison
EUROMET.L-K7: Calibration of line scales, Metrologia, Vol. 49, doi:
10.1088/0026-1394/49/1A/04006
[7] Lassila, A. (2012). MIKES fibre-coupled differential dynamic
line scale interferometer, Measurement Science and Technology, Vol. 23,
No. 9, doi: 10.1088/0957-0233/23/9/094011
[8] Leach, R. (2015). Abbe Error/Offset, CIRP Encyclopaedia of
Production Engineering, Springer, Berlin, DE, 1-4, doi:
10.1007/978-3-642-35950-7_16793-1
[9] Klobucar, R. & Acko, B. (2016). Experimental evaluation of
ball bar standard thermal properties by simulating real shop floor
conditions, International journal of simulation modelling, Vol. 15, No.
3, pp. 511-521, doi: 10.2507/ijsimm15(3)10.356
[10] Druzovec, M.; Acko, B.; Godina, A. & Welzer, T. (2009).
Robust algorithm for determining line centre in video position measuring
system, Optics and Lasers in Engineering, Vol.47, pp. 1131-1138, doi:
10.1016/j.optlaseng.2009.06.017
[11] Klobucar, R. & Acko, B. (2017). Automatic high resolution
measurement set-up for calibrating precise line scales, Advances in
Production Engineering & Management, Vol. 12, No. 1, pp. 88-96, doi:
10.14743/apem2017.1.242
[12] Newport Corporation. Air Bearing Solution Guide, from
https://www.newport.com/g/air-bearing-solution -selection-guide,
Accessed on: 2017-06-15
[13] Koning , R.; Weichert, C.; Kochert, P.; Guan, J. & Flugge,
J. (2013). Redetermination of the Abbe Errors' Uncertainty
Contributions at the Nanometer Comparator, In: Proceedings of the 9th
International Conference, Smolenice, Slovakia, pp. 171-174
[14] EA-4/02. Evaluation of the uncertainty of measurement in
calibration, from http://www.
european-accreditation.org/publication/ea-4-02-m-rev01-september-2013,
Accessed on: 2017-06-18
[15] Lipus, L.C.; Budzyn, G.; Rzepka, J. & Acko, B. (2016).
Calibration capability with laser frequency standard, DAAAM
International Scientific Book 2016, pp. 197-206, doi:
10.2507/daaam.scibook.2016.18
Caption: Fig. 1. Measurement set-up for calibrating line scales
Caption: Fig. 2. Schematic diagram of measurement set-up for
calibrating line scales
Caption: Fig. 3. Numerically controlled multi-axis stage
Caption: Fig. 4. Absolute deviation between laser values and
encoder value
Caption: Fig. 5. Standard deviation on measurement positions
Caption: Fig. 6. Deviation of measured values from reference and
estimated standard uncertainty
Table 1. uncertainty budget for calibration of line scales
Value Estimated Standard
[X.sub.i] value Uncertainty Distribution
[L.sub.LI] 0 mm 13 nm + normal
0,2x[10.sup.-6]L
[L.sub.V] <5 pm 25 nm normal
[L.sub.LIref] 0 mm 9 nm normal
[[alpha].sub.m] [10.sup.-5] 1,15x[10.sup.-6] rectangular
[degrees][C.sup.-1] [degrees][C.sup.-1]
[[theta].sub.m] 0[degrees]C 0,05 [degrees]c normal
[e.sub.cos] 0 0 nm normal
[e.sub.mp] 0 9 nm rectangular
[e.sub.ms] 0 30 nm normal
[e.sub.a] 0 13 nm rectangular
Value Sensitivity Uncertainty
[X.sub.i] coefficient contribution
[L.sub.LI] 1 13 nm +
2,5x[10.sup.-7]L
[L.sub.V] 1 25 nm
[L.sub.LIref] -1 9 nm
[[alpha].sub.m] 0,05 [degrees]CxL 0,06x[10.sup.-6]xL
[[theta].sub.m] [10.sup.-5] 0,05x[10.sup.-5]]xL
[degrees][C.sup.-1]xL
[e.sub.cos] 1 0 nm
[e.sub.mp] 1 9 nm
[e.sub.ms] 1 30 nm
[e.sub.a] 1 13 nm
Total: [square root of
([(45 nm).sup.2] +
[(5,6 x [10.sup.-7]
x L).sup.2])]
COPYRIGHT 2018 DAAAM International Vienna
No portion of this article can be reproduced without the express written permission from the copyright holder.
Copyright 2018 Gale, Cengage Learning. All rights reserved.