Christian Pape

Optical derotator for scanning vibrometer measurements on rotating objects

In this paper we present an optical derotator for scanning vibrometer measurements on rotating objects. The main part of an optical derotator is a rotating prism. Several concepts are known from literature. We have chosen a Dove prism because it can derotate the rotation of the specimen by simply watching through the prism, which rotates with half the speed. The design of our derotator is presented in this paper as well as a discussion of the system performance. In addition we show experimental measurement results on a fan rotating with 3000 rpm.

Automated calibration of an optomechanical derotator using 6-axes parallel kinematics and industrial image processing algorithms

A concept for an optomechanical derotator is presented. The derotator allows optical measurements of rotating objects during operation. To guarantee a stationary optical image, the optical axis of the derotator needs to be coaxially aligned to the rotational axis of the measured object. The correlation between the movement of the optical image and a miscalibration is explained by a mathematical model. The movement of the optical image is tracked with a high-speed camera. Approximating the tracked path as a Limacon of Pascal, a parameter corresponding to the magnitude of the miscalibration is identified. This parameter is minimized by modifying the position and the orientation of the derotator with a hexapod. The limitations of this procedure are analyzed and further approaches are discussed.

Two-step phase shifting in fringe projection: modeling and analysis

This work proposes a two-step phase-shifting algorithm as an improvement of fringe projection profilometry. Considering the working process of fringe projection, the captured fringe image is formulated with two variables, i.e. surface reflectivity and phase value. And a phase shift of 3π/2 is introduced to get the two-step phase-shifting. After appropriate variable substitution, expressions of two fringe images can be transformed into two equations corresponding to a line and a circle respectively. With this circle-line model, the characteristic of solution and the phase error due to non-zero ambient light are analyzed. Then the approach of error compensation is proposed based on estimation of the real fringe contrast and non-linear least square optimization. The validity of the proposed approach is demonstrated with both simulations and experiments.

Multi-DOF compensation of piezoelectric actuators with recursive databases

Abstract Piezoelectric actuators are subject to nonlinear effects when voltage-driven in open-loop control. In particular, hysteresis and creep effects are dominating nonlinearities that significantly deteriorate performance in tracking control scenarios. In this paper, we present an online compensator suitable for piezoelectric actuators that is based on the modified Prandtl-Ishlinskii model and utilizes recursive databases for the compensation of nonlinearities. The compensator scheme is furthermore extended to systems with more than one degree of freedom (DOF) such as Cartesian manipulators by employing a decoupling control design to mitigate inherent cross-coupling disturbances. In order to validate our theoretical derivations, experiments are conducted with coupled trajectories on a commercial 3-DOF micro-positioning unit driven by piezoelectric actuators.

Temperature measurements on fast-rotating objects using a thermographic camera with an optomechanical image derotator

Increasing requirements concerning the quality and lifetime of machine components in industrial and automotive applications require comprehensive investigations of the components in conditions close to the application. Irregularities in heating of mechanical parts reveal regions with increased loading of pressure, draft or friction. In the long run this leads to damage and total failure of the machine. Thermographic measurements of rotating objects, e.g., rolling bearings, brakes, and clutches provide an approach to investigate those defects. However, it is challenging to measure fast-rotating objects accurately. Currently one contact-free approach is performing stroboscopic measurements using an infrared sensor. The data acquisition is triggered so that the image is taken once per revolution. This leads to a huge loss of information on the majority of the movement and to motion blur. The objective of this research is showing the potential of using an optomechanical image derotator together with a thermographic camera. The derotator follows the rotation of the measurement object so that quasi-stationary thermal images during motion can be acquired by the infrared sensor. Unlike conventional derotators which use a glass prism to achieve this effect, the derotator within this work is equipped with a sophisticated reflector assembly. These reflectors are made of aluminum to transfer infrared radiation emitted by the rotating object. Because of the resulting stationary thermal image, the operation can be monitored continuously even for fast-rotating objects. The field of view can also be set to a small off-axis region of interest which then can be investigated with higher resolution or frame rate. To depict the potential of this approach, thermographic measurements on a rolling bearings in different operating states are presented.

Digital image processing algorithms for automated inspection of dynamic effects in roller bearings

Unstable movement in roller bearings like cage or roller slip can lead to damages or eventually even to an early break of the bearing. To prevent slip, inadequate operating states should be avoided. Therefore, it is necessary to study the dynamic behavior of the bearing. Unfortunately, there is only a limited range of measurement methods for the dynamic of bearing components. Two possible approaches are using solely a high-speed camera or the combination of an optomechanical image derotator and a high-speed camera. This work focuses on a proposal which is suitable for both. Initially, the influence of the rotational velocity in the images is eliminated. In the next step the measurement data is reduced to a region of interest which displays a particular rolling-element. A rolling element is equipped with a linear marker which, in the next stage, is segmented by a thresholding method to multiple regions. The region representing the marker is extracted from the background and the position is calculated by a Principle Component Analysis. Depending on the shift of the angular position and the lag time between two images, the rotational velocity of the rolling element is calculated. Thus, it is possible to determine whether the rolling element is operating under ideal conditions. In conclusion, it can be said that this approach enables a simple and flexible non-invasive method to depict the occurrence of roller slip in roller bearings.

Automatic Stabilization of an Adaptive Feedback Control for Noise Cancelling In-ear Headphones

Headphones with an integrated active noise cancellation system have been increasingly introduced to the consumer market in recent years. When exposing the human ear to active noise sources in this striking distance, the ensuring of a safe sound pressure level is vital. In feedback systems, this is coupled with the stability of the closed control loop; stable controller design is thus essential. However, changes in the control path during run-time can cause the stable control system to become unstable, resulting in an overdrive of the speakers in the headphones. This paper proposes a method, which enables the real-time analysis of the current system state and if necessary stabilizes the closed loop while maintaining the active noise reduction. This is achieved by estimating and evaluating the open loop behavior with an adaptive filter and subsequently limiting the controller gain in respect to the stability margin.

6D-Measurement System for the Position Determination of a Robot End-Effector

The project “Micro-Macro-Kinematics”, which is currently running at the Institute of Measurement and Automatic Control of the Leibniz Universitat Hannover, deals with the development and analysis of a robotic system, which is able to manipulate micro-objects with an accuracy of 1-2 micrometers in a 3D-workspace of 10 cubic millimeters. For this purpose it is necessary to determine the position and orientation of the robot end-effector with high accuracy and in real time.