BOREINSPECT^TM system

for 3D bore measurement

NOVACAM^TM BOREINSPECT^TM system is a modular, non-contact optical bore measurement system that provides micron-precision 3D measurements of bore interiors and other hard-to-reach spaces. Its rotational scanner probe easily enters tight spaces to acquire their complete inside geometry at high speed. The BOREINSPECT system:

Measures inside diameter (ID) features such as undercuts, chamfers, threads, rifling, O-ring grooves, splines, lands, and edge breaks
Enables fully configurable automated bore measurement
Produces 3D point cloud data for calculating GD&T parameters
Can measure dimensional or surface defects such as porosities, cracks, burrs, or scratches
Can measure roughness as well as thickness of semi-transparent coatings

Videos

BOREINSPECT system in action

Valve body bores – automated 3D bore measurement (automotive)

Video content: RS2, a non-contact rotational scanner and a key component of the BOREINSPECT bore measurement system, measures the 3D inner diameter of several valve body bores as part of a fully automated bore inspection.

Benefits: Fully automated 3D bore measurement, interactive 3D analysis of valve bores, measurements of distance, absolute position, cylindricity, surface/dimensional defects, roughness, geometric tolerances of internal features, dimensional deviations, and more

Airfoil 3D inspection (aerospace)

Video content: MICROCAM-3D airfoil scanner (BOREINSPECT bore measurement system) delivers micron-precision 3D optical measurements of hard-to-reach places.

Benefits: fully automated inspection of complete component geometry, airfoil trailing and leading edge, 3D modeling, micron-precision defect detection, dimensional deviations, geometric tolerances, measurement of distances.

Turbine blade – high-speed 3D metrology (aerospace)

Video content: RS2, a non-contact rotational scanner and a key component of the BOREINSPECT bore measurement system, enters the complex geometrical structures of turbine blades to completely acquire their dimensional geometry down to the micron.

Benefits: fully configurable automated scanning sequences, detection of surface or dimensional defects, characterization of EDM slots and air holes (control of fan-out angle, etc.),tolerance analysis, dimensional deviations, geometric tolerances, datum alignment capability, and more.

Bore ID chatter measurement (automotive)

Video content: Demo of a non-contact chatter gauge built by an integrator using RS2 rotational scanner (part of NOVACAM BOREINSPECT bore measurement system), NOVACAM Chatter Analysis Software, and a robotic arm. This temporary automated gauge was used to measure the chatter in 16,000 turbo shafts over 4 weeks while the client was troubleshooting a faulty manufacture line.

Inspection achievements: Fully automated bore measurement and chatter analysis, 45 second inspection cycle time, 65% of parts salvaged from a faulty manufacture line, downtime of a major automotive production line avoided.

Cylinder bore measurement

Video content: BOREINSPECT non-contact bore measurement system measures a cylinder bore, providing micron-precision 3D measurements of the bore interior.

System benefits: Fully automated cylinder bore measurement, 3D measurements of GD&T parameters, chatter, roughness, and defects with one single probe. Configuration with 18 mm diameter rotational probe is ideal for 5 to 15 cm (2″ to 6″) diameter bores such as engine cylinders, actuator cylinders, etc.

Note: If a tube/cylinder bore you need to measure also needs to be measured on the outside, this can be achieved either by mounting the BOREINSPECT system rotational scanner on a gantry or by using NOVACAM TUBEINSPECT system, which measures both the ID and OD of tubes mounted on a motorized spinning fixture.

Overview

Overview of features and benefits

Bore measurements

Optical, non-contact, non-destructive
High speed: Up to 100,000 3D point measurements per second
3D inside diameter (ID) measurements: diameter, circularity, cylindricity, runout, taper, distortion, straightness
High-aspect-ratio features: undercuts, threads, O-ring grooves, cross-holes
Micron resolution and excellent sensitivity and measurement repeatability

Imaging options

Line profiles
3D visualization for interactive analysis of bore measurements
Height and intensity images of “unfolded” surfaces
Cross-sections of semi-transparent materials
Deviation maps

3D image of measured rivet hole ID (4.5 mm diameter) shows a burr defect

Benefits

Bore measurement system that is easily integrated in lab, shop, or fully-automated industrial inspection setups
Reduces cycle time of bore measurement: the rotational scanner spins the probe at up to 30 rotations per second, and obtains up to 100,000 3D measurements per second. Each measurement represents a 3D topographic point.
Flexible options for evaluating inspected parts: measured features can be compared to CAD drawings or to a user-defined set of locations, nominals, and tolerances
Simple scan definition and execution: Define the scan sequence once by teaching the system with a joystick. The scan definition can later be executed with the push of a button.
Time-saving automated reporting: Following a scan, go-no-go bore measurement reports can be produced and results logged in a manner compatible with industry-standard mechanisms.
Adaptable to harsh environments
No consumables are needed: Optical probes do not come in contact with the measured surfaces, and therefore do not wear out like contact probes. Accidental damage is rare-probes are designed to be rugged.

Applications

Metrology Applications

3D bores measurements for industry and R&D

Quality control
Automated 3D production inspection, geometric dimensioning and tolerancing (GD&T)
Statistical process control (SPC)
Research and development (R&D) inspection
Reverse engineering and part-to-CAD
Maintenance, repair and operations (MRO)
Profilometry in harsh environments

Typical bore measurements

Full ID geometry: GD&T : diameter, circularity, cylindricity, taper, runout, straightness, etc.
Deviation from CAD model
High-aspect-ratio features: steps, O-ring grooves, undercuts, threads, channels, sharp edges, steep slopes, and cross-holes
Volume loss: surface wear or other damage
Defects: corrosion, pitting, cracking, denting, scratching, porosity
Surface roughness: linear (axial or circumferential) roughness, or area roughness
Thickness of semi-transparent materials: single-layer or multilayer films

Examples of bore measurement applications

Measurement, visualization, and GD&T inspection of ID surfaces in:

Parts made by casting, high-precision drilling, deep gun drilling, injection molding, 3D printing, additive manufacturing
Extrusion dies, feed-through holes, conical bores, blind bores
Automotive industry engine components: valve body bores, valve seats, cylinder blocks, cylinder heads, camshafts, crankshafts, drive shafts, combustion chambers, die cast parts, and more
Aerospace industry: rivet holes and countersinks in aircraft fuselage assembly, valve bores, cylinder bores, manifolds, and other engine components featuring bores, slots, or other hard-to-reach spaces
Aerospace and industrial gas turbine engines: compressor and turbine airfoils and vanes, vane rings, duct or nozzle throats, shafts
High-precision machining: bores, barrels, tubes and slots in parts for defence, industrial, medical equipment, nuclear, oil and gas, power generation, transportation (train and marine as well as aerospace and automotive) sectors

Gallery

Gallery (click images for close-up)

Cast engine block 3D measurement

Automotive valve body 3D bore measurement

Following the execution of a fully automated inspection sequence, all 4 measured bores are displayed and analyzed. Automated go-no-go reporting evaluates acquired bore measurements with respect to user-specified criteria.

Turbocharger impeller – inner thread measurements

Airfoil 3D measurements

Turbine stator blade (nozzle guide vane) 3D metrology

Software

System Software

The BOREINSPECT system comes with NOVACAM high-performance data acquisition software, which is PC Windows^®-based and user-friendly for scan programming.

NOVACAM data acquisition software

The system simultaneously generates 3 data sets from the same scan: 3D point cloud, light intensity image, and height image. The height and light intensity images facilitate defect detection. STL file format is also available.

ID measurements are generated in three formats: 3D point cloud, intensity map, and height map.

For full GD&T analysis of measured parts, a turnkey solution is available with PolyWorks Inspector^TM metrology software that may be purchased with the system.

Go-no-go reporting is easily programmed and automated.

Example of an automated bore measurement report with GD&T measurements and pass/fail values

Users benefit from capabilities such as a quick visual comparison (deviation map) of the acquired part measurements to pre-specified tolerances or to the CAD of the part.

3D bore measurement data analysis using PolyWorks Inspector. Here the bore ID is viewed as a deviation map.

Visualizing the scan data may be accomplished by importing the data into various third party visualization and numerical analysis software, such as PolyWorks Inspector, Geomagic, ImageJ, SolidWorks, Octave, MatLab, Mathematica, IDL, or IGOR Pro.

Deriving application-specific measurements from the 3D point cloud is available through a selection of in-house and third party software. Novacam supports the following options:

	Novacam in-house software	3rd party software, such as
Dimensional measurements (GD&T parameters)		PolyWorks Inspector (turnkey solution) Geomagic
Roughness and surface analysis		TrueSurf, MountainsMap
Thickness
Chatter (vibration)
Volume loss
Defects	Custom-developed*
* Novacam offers the option of custom data processing, reporting, and defect detection programs that can be written based on client requirements.

An application programming interface (API) is available for system integrators and OEMs to accommodate a wide variety of online and offline bore measurement applications. Exported results may be integrated with data loggers and SPC software.

System components

NOVACAM^TM BOREINSPECT^TM bore measurement system is a fiber-based modular system that comprises 1) Optical side-looking probe, 2) Rotational scanner (RS), 3) MICROCAM^TM-3D/4D interferometer, 4) Inspection station, 5) PC, 6) Motion controller(s) for probe rotation and for other required motion components (not shown), and, optionally, (7) Multiplexing hardware (not shown).

The inspection capabilities of the BOREINSPECT system are determined jointly by its components:

1) Optical probe

The side-looking optical probe is rotated while being advanced inside the tight space to measure its complete inside geometry in a spiral pattern.

Scanning setup

Probe characteristics

Bore diameter range (mm)	Probe diameter (mm)	Probe standoff options**	Spot size (µm)	Probe length*** (mm)
1-4.5	0.55*	Fixed	15-35	50-250
2-6	1.05	Fixed
4-14	3.05	Fixed/Adjustable
6-30	4.6	Fixed/Adjustable
19-131	17.8	Fixed/Adjustable
32-250	30.5*	Fixed/Adjustable
Non-standard-diameter probes. Other custom probes with non-standard diameters, lengths, light spot sizes, and light beam angles (different from the standard 90°) are built upon request. Custom probes for extreme temperatures, high pressures, or other hostile environments are also built upon request. Standoff is the distance from the probe OD (outside diameter) to the focal point. With fixed-standoff probes, standoff is fixed at manufacture time. When selecting this type of probe, clients must choose a subset of the bore diameter range equivalent to twice the scanning depth range of the selected Microcam interferometer. With adjustable-standoff probes, the standoff may be adjusted programmatically between scans of various sections of the bore. When selecting this type of probe, clients must choose a subset of the bore diameter range smaller than or equal to 50 mm. The client then has precise focus control within the chosen subset of the bore diameter range. **Maximum probe length may be limited by mechanical constraints. Probes as long as 2 m have been built.

2) Rotational scanner (RS)

The rotational scanner advances and spins the side-looking optical probe selected to suit the application. The RS housing enclosure is robust and shop-floor ready.

Rotational scanner models

	RS0	RS1	RS2

Range of bore diameters measured	1-6 mm	6-260 mm	4-131 mm
Distinguishing aspect	Ideal for applications involving extra-small bores, where user-exchangeable probes are required	Ideal for extra- wide bores	Lightest model with the fastest rotational speed. The most popular RS for a wide variety of applications.
Motion & displacement capability	Rotation + linear (Z-axis) + optional X/Y-axis
User-replaceable probes	Yes	No	No
Extended range option with adjustable standoff probes	No	Yes	Yes
Rotational speed	Up to 10 rotations/second (600 RPM)	Up to 2 rotations/second (120 RPM)	Up to 30 rotations/second (1,800 RPM)
Approximate size of rotational probe enclosure (depth x width x height) (does not include probe or stages)	120 x 115 x 90 mm 4½" x 4½" x 3½"	140 x 130 x 180 mm 5½” x 5” x 7”	170 x 64 x 76 mm 7” x 2½” x 3”
Approximate weight	1.9 kg (4.2 lb) without probe and centralizer (probe stabilizer)*	3.8 kg (8.5 lb) including standard ø4.6 mm probe	1.2 kg (2.5 lb) including standard ø4.6 mm probe
*The centralizer in the shown configuration includes the breadboard and adds approximately 2.6 kg (5.7 lb).

3) MICROCAM interferometer

NOVACAM MICROCAM interferometer provides the light source to the RS probe and processes the optical signal received back from it. The RS and the interferometer are connected with an optical fiber.

MICROCAM interferometer models

	MICROCAM-3D		MICROCAM-4D
General characteristics
Technology	low-coherence interferometry
Light wavelength	1310 nm, infrared
Size of interferometer enclosure box (depth x width x height)	4U rackable enclosure 445 x 445 x 178 mm
Non-contact measurements
Depth of field	depends on selected probe parameters, see table "Standard probe characteristics" above
Scanning depth range options *	3.5 mm	7 mm	5 mm
Acquisition (A-scan) rate	2.10 kHz	1.05 kHz	100 kHz
Axial (Z-axis) resolution	< 0.5 µm
Light spot size (Lateral [XY-axis] resolution)	2.2 - 146 µm, depends on selected probe parameters, see table "Standard probe characteristics" above
Standoff distance	0.5 - 100 mm for standard probes up to 1 m for non-standard probes
Repeatability	< 1 µm
Thickness measurements
Thickness measurement range (in Air, IR = 1.0)	10 µm - 3.5 mm	10 µm - 7 mm	20 µm - 5 mm
Typical materials for thickness measurements	glass, polymers, multi-layer films, coatings, plastics, silicone, liquids, specular or non-specular
Sample reflectivity	0.1 - 100%
*To further increase maximum scanning depth, a mechanical displacement axis is available.

4) Inspection station

Inspection station configurations are application-dependent and can be supplied by Novacam. Fixturing for the part is not included.

For lab and shop floor inspection, BOREINSPECT system setups typically include an inspection station with scanner displacement in 2, 3, or 4 axes. Granite tables are optionally available and recommended for some applications.

For automated inline industrial inspection, BOREINSPECT system rotational scanners may be integrated with precision stages or robots (as a robot end-effector) to support high-volume continuous flow manufacturing. The BOREINSPECT system can also be integrated with third-party CMMs (coordinate-measuring machines) and CNC (computer numerical control) machines.

5) PC, monitor and joystick

The BOREINSPECT system comes with a PC, monitor, mouse, and joystick.

6) Motion controller(s)

Motion controllers are included. Depending on the number of additional motion axis required, the motion controller(s) are housed in a 2U, 3U, or 4U rackable enclosure.

7) Hardware for multiplexing support (optional)

Optical switches are available for multiplexing up to 8 probes to a single MICROCAM interferometer. Multiplexed probes may be used one at a time. This option brings additional return on investment (ROI) to many installations.

Additional info

Standard system configuration

A standard configuration of the BOREINSPECT^TM system includes:

RS2 rotational scanner with a standard 4.6 mm-diameter side-looking probe (for inspection of bores up to 660 mm (26″) deep)
MICROCAM-3D profilometer
3-axis inspection station and 3-axis motion controller
PC with NOVACAM acquisition software
1 year warranty

Instrument safety

MICROCAM-3D/4D systems feature an in-probe red laser pointer (650 nm wavelength) for alignment purposes.
MICROCAM-3D/4D systems are Class 1M Laser products, with < 20 mW of infrared and < 5 mW of in-probe laser pointer.

MicroCam profilometers are Class 1M laser products

BOREINSPECT system in the news

The BOREINSPECT bore measurement system was featured in the following tech magazine articles:

“3D imaging enables high-speed bore inspection” (Vision Systems Design magazine, January 25, 2018)
“3D imaging technology inspects hard-to-reach spaces” (Vision Systems Design magazine, January 16, 2018)
“Automated Rivet Hole Inspection and 3D Measurement” (Metrology news, March 13, 2020)

FAQ

Frequently asked questions

How long does it take to measure a bore?

Scan time depends on the bore size, bore length, and what aspects of the bore you need to measure. The scanner rotates at 1,800 rotations per minute (or 30 rotations/second) and the BOREINSPECT system (with MICROCAM-4D interferometer) acquires 100,000 3D measurements per second, or roughly 1 million 3D topography points in 10 seconds. The user selects the rotation and acquisition speeds and the pitch of the spiral, which together determine the number of points that will be acquired and the time the scan will take. In general, dimensional measurement (for GD&T) require the least amount of points and can be achieved the fastest. Roughness callouts may take 3 to 4 seconds each. Defect detection requires the most amount of points, of course depending on the size of defect you are looking for. For help on estimating the time required to scan your sample, please contact us.

Is the system easy to use?

Yes. The scanning sequence (recipe) can be programmed with a joystick and can be recalled at later times with the push of a button. See our how-to video on how to measure bore ID dimensions.

Is the system able to work right on production floor?

Yes. Both inline and robot setups are possible.

Can the BOREINSPECT system give us automated measurements and reports?

Yes.

I noticed the probe spins. Is runout an issue and does it affect the scan data?

No, runout is not an issue. Gauge rings are used to calibrate the probe and validate the results. The system provides micron-level diameter measurement repeatability.

Does the BOREINSPECT system rotational scanner (RS) probe have to be on the centerline of the bore?

The BOREINSPECT RS probe should be positioned close to the centerline of the bore (within a mm) to capture the entirety of the features. For irregularly-shaped objects or slots or crevices, the RS probe can acquire the entire surface by scanning from several positions.

BOREINSPECTTM system

for 3D bore measurement

BOREINSPECT system in action

Valve body bores – automated 3D bore measurement (automotive)

Airfoil 3D inspection (aerospace)

Turbine blade – high-speed 3D metrology (aerospace)

Bore ID chatter measurement (automotive)

Cylinder bore measurement

Related links

METROLOGY APPLICATIONS

DISCOVER

PRODUCTS

SERVICES & SUPPORT

UPCOMING EVENTS

NEWS

CONTACT

FOLLOW US

BOREINSPECT^TM system