Metrology

The dimensional accuracy of a laser scanner has been extensively evaluated using various measurement methods and diverse reference standards. This study specifically focuses on two key considerations. Firstly, it assesses the dimensional accuracy of the laser scanner by employing another laser scanner, a handheld scanner, as the reference measurement method. Secondly, the study involves the use of three spheres fixed on each wall in both coplanar and non-coplanar positions within a laboratory room at SENAI ISI-SIM. The primary objective is to determine the dimensional accuracy between the centers of the coplanar and non-coplanar spheres up to 10 m. The comparison includes measurement uncertainties, as per ISO GUM standards, obtained using the laser scanner in a laboratory setting with controlled temperature and humidity. Analyzing non-coplanar dimensional accuracy enhances our understanding of the metrological performance of the laser scanner, particularly when assessing the dimensions of objects positioned randomly within a scanning scene. Full article

Ensuring high-quality control in laser additive manufacturing and laser welding relies on the implementation of reliable and cost-effective real-time observation techniques. Real-time monitoring techniques play an important role in understanding critical physical phenomena, namely, melt pool dynamics and defect formation, during the manufacturing of components. This review aims to explore the integration of acoustic measurement techniques with X-ray imaging for studying these physical phenomena in laser manufacturing. A key aspect emphasized in this work is the importance of time synchronization for real-time observation using multiple sensors. X-ray imaging has proven to be a powerful tool for observing the dynamics of the melt pools and the formation of defects in real time. However, X-ray imaging has limitations in terms of accessibility which can be overcome through combination with other more-accessible measurement methods, such as acoustic emission spectroscopy. Furthermore, this combination simplifies the interpretation of acoustic data, which can be complex in its own right. This combined approach, which has evolved in recent years, presents a promising strategy for understanding acoustic emission signals during laser processing. This work provides a comprehensive review of existing research efforts in this area. Full article

The imperative need to advance the development of more efficient electric motors requires the meticulous measurement of small increments while minimizing the associated uncertainty in dynamometer tests. One of the key variables in such tests is the angular speed, which is typically obtained based on encoder measurements. This paper proposes a systematic measurement uncertainty assessment method based on the Guide to the Expression of Uncertainty for the two most widely used methods for angular speed measurement, namely, the frequency and period methods. In addition, the impact of the angular speed calculation method on the efficiency test uncertainty is assessed using an automatic test rig for electric motors. Our experimental results consider both steady-state and dynamic analyses. The results show that the period measurement method provides measurements with lower uncertainty for the encoders typically used in such test rigs, about 30 times less than the uncertainty determined for the frequency measurement method. Based on these results, the choice of a proper method can drastically decrease the angular speed uncertainty, and consequently the motor efficiency uncertainty, without increasing instrumentation cost. Full article

Stitching methods allow one to measure a wider surface without the loss of resolution. The observation of small details with a better topographical representation is thus possible. However, it is not excluded that stitching methods generate some errors or aberrations on topography reconstruction. A device including confocal microscopy (CM), focus variation (FV), and coherence scanning interferometry (CSI) instrument modes was used to chronologically follow the drifts and the repositioning errors on stitching topographies. According to a complex measurement plan, a wide measurement campaign was performed on TA6V specimens that were ground with two neighboring SiC FEPA grit papers (P#80 and P#120). Thanks to four indicators (quality, drift, stability, and relevance indexes), no measurement drift in the system was found, indicating controlled stitching and repositioning processes for interferometry, confocal microscopy, and focus variation. Measurements show commendable stability, with interferometric microscopy being the most robust, followed by confocal microscopy, and then focus variation. Despite variations, robustness remains constant for each grinding grit, minimizing interpretation biases. A bootstrap analysis reveals time-dependent robustness for confocal microscopy, which is potentially linked to human presence. Despite Sa value discrepancies, all three metrologies consistently discriminate between grinding grits, highlighting the reliability of the proposed methodology. Full article

A calibration system was designed to evaluate the accuracy of linear optical encoders at the micron level in a fast and economical manner. The system uses a commercial interferometer and motor stage as the calibrator and moving platform. Error analysis is necessary to prove the effectiveness and identify areas for optimization. A fixture was designed for the scale and interferometer target to meet the Abbe principle. A five-degree-of-freedom manual stage was utilized to adjust the reading head in optimal or suboptimal working conditions, such as working distance, offset, and angular misalignment. The results indicate that the calibration system has an accuracy of ±2.2 μm. The geometric errors of the calibration system, including mounting errors and non-ideal motions, are analyzed in detail. The system could be an inexpensive solution for encoder manufacturers and customers to calibrate a linear optical encoder or test its performance. Full article

Frequency estimation is often the basis of various measurement techniques, among which optical distance measurement stands out. One of the most used techniques is interpolated fast Fourier transform due to its simplicity, combined with good performance. In this work, we study the limits of this technique in the case of real signals, with reference to a particular interferometric technique known as self-mixing interferometry. The aim of this research is the better understanding of frequency estimation performances in real applications, together with guidance on how to improve them in specific optical measurement techniques. An optical rangefinder, based on self-mixing interferometry, has been realized and characterized. The simulation results allow us to explain the limits of the interpolated fast Fourier transform applied to the realized instrument. Finally, a method for overcoming them is proposed by decorrelating the errors between the measurements, which can provide a guideline for the design of frequency-modulated interferometric distance meters. Full article

Voltage standards are widely used to transfer volts from Josephson voltage standards (JVSs) at national metrology institutes (NMIs) into calibration labs to maintain the volts and to transfer them to test equipment at production lines. Therefore, commercial voltage standards based on Zener diodes are used. Analog Devices Inc. (San Jose, CA, USA), namely, Eric Modica, introduced the ADR1000KHZ, a successor to the legendary LTZ1000, at the Metrology Meeting 2021. The first production samples were already available prior to this event. In this article, this new temperature-stabilized Zener diode is compared to several others as per datasheet specifications. Motivated by the superior parameters, a 10 V transfer standard prototype for laboratory use with commercial off-the-shelf components such as resistor networks and chopper amplifiers was built. How much effort it takes to reach the given parameters was investigated. This paper describes how the reference was set up to operate it at its zero-temperature coefficient (z.t.c.) temperature and to lower the requirements for the oven stability. Furthermore, it is shown how the overall temperature coefficient (t.c.) of the circuit was reduced. For the buffered Zener voltage, a t.c. of almost zero, and with amplification to 10 V, a t.c. of <0.01 µV/V/K was achieved in a temperature span of 15 to 31 °C. For the buffered Zener voltage, a noise of ~584 nVp-p and for the 10 V output, ~805 nVp-p were obtained. Finally, 850 days of drift data were taken by comparing the transfer standard prototype to two Fluke 7000 voltage standards according to the method described in NBS Technical Note 430. The drift specification was, however, not met. Full article

Nano-composite piezo-responsive foam (NCPF) is an inexpensive foam that can be used to measure a static load while still providing a comfortable interface. The purpose of this study was to create a modularized foam-based pressure measurement system. A measurement system was developed that uses an interdigitated electrode applied to the NCPF. Applied pressure changes the impedance of the NCPF, which, in turn, is converted into a voltage using a voltage divider. A modular measurement system is described that uses an ATtiny 1627 microcontroller to measure the pressure at nine electrodes. The nine electrode modules are controlled by an ESP32 microcontroller that aggregates the data and wirelessly transmits the data to a tablet. The modular system was demonstrated with 1008 individual electrodes. The characterization of the electrode combined with the NCPF is presented, along with optimization of the electrode geometry. Full article

Concrete structures inevitably experience cracking, which is a common form of damage. If cracks are left undetected and allowed to worsen, catastrophic failures, with costly implications for human life and the economy, can occur. Traditional image processing techniques for crack detection and measurement have several limitations, which include complex parameter selection and restriction to measuring cracks in pixels, rather than more practical units of millimetres. This paper presents a three-stage approach that utilises deep learning and image processing for crack classification, segmentation and measurement. In the first two stages, custom CNN and U-Net models were employed for crack classification and segmentation. The final stage involved measuring crack width in millimetres by using a novel laser calibration method. The classification and segmentation models achieved 99.22% and 96.54% accuracy, respectively, while the mean absolute error observed for crack width measurement was 0.16 mm. The results demonstrate the adequacy of the developed crack detection and measurement method, and shows the developed deep learning and laser calibration method promotes safer, quicker inspections that are less prone to human error. The method’s ability to measure cracks in millimetres provides a more insightful assessment of structural damage, which is, in comparison to traditional pixel-based measurement methods, a significant improvement for practical field applications. Full article

Acceleration sensors are vital for assessing engineering structures by measuring properties like natural frequencies. In practice, engineering structures often have low natural frequencies and face harsh environmental conditions. Understanding sensor behavior on such structures is crucial for reliable measurements. The research focus is on understanding the behavior of acceleration sensors in harsh environmental conditions within the low-frequency acceleration range. The main question is how to distinguish sensor behavior from structural influences to minimize errors in assessing engineering structure conditions. To investigate this, the sensors are tested using a long-stroke calibration unit under varying temperature and humidity conditions. Additionally, a mini-monitoring system configured with four IEPE sensors is applied to a small-scale support structure within a climate chamber. For the evaluation, a signal-energy approach is employed to distinguish sensor behavior from structural behavior. The findings show that IEPE sensors display temperature-dependent nonlinear transmission behavior within the low-frequency acceleration range, with humidity having negligible impact. To ensure accurate engineering structure assessment, it is crucial to separate sensor behavior from structural influences using signal energy in the time domain. This study underscores the need to compensate for systematic effects, preventing the underestimation of vibration energy at low temperatures and overestimation at higher temperatures when using IEPE sensors for engineering structure monitoring. Full article

Conservation Voltage Reduction (CVR) is a potential energy management approach for increasing computer system energy efficiency. This study uniquely contributes to the field by thoroughly investigating the impact of CVR on computing devices, filling a significant gap in the existing literature. The research employs a novel experimental approach, considering the temporal variations in energy use behavior, and presents a comprehensive benchmark analysis of desktop PCs and laptops. Notable gains in processing efficiency are observed, with specific instances such as Desktop 1’s 1.53% Single-Core performance improvement and Desktop 3’s 3.19% total performance boost. Despite variations, the thermal performance of CVR-equipped devices, particularly Desktop 3 and Laptop 3, consistently demonstrates lower temperatures, indicating thermal management enhanced by 3.19% and 1.35%, respectively. Additionally, the study introduces the CVR Performance Enhancement Ratio (%), providing a unique metric for evaluating the trade-offs between energy efficiency and system performance. This research highlights the dual impact of CVR on thermal and computational elements, emphasizing its broad advantages. Integrating CVR emerges as a viable strategy for developing more durable, efficient, and sustainable computing devices, setting the stage for advancements in voltage regulation. Full article

Viscosity is a physicochemical property that evaluates the resistance that fuel offers to flow, influencing the engine’s operation and combustion process. Its control is aimed at good fuel atomization and the preservation of lubricating characteristics. Changes in viscosity can lead to wear on various parts of the engine. Viscometers typically measure the viscosity of fuels in the oil and gas industry. These instruments can measure the time it takes for a fluid to move a given distance through a pipe or the time it takes for an object of a given size and density to pass through the liquid. The traditional test method, ASTM D445, differentiates the procedure for opaque liquids from transparent ones; that is, it requires a warm-up of the sample between 60 °C and 65 °C for 1 h. This additional step can overload laboratory routines, although it is not guaranteed to have a metrologically significant effect on the final result. Thus, this study evaluated the relevance of complying with this step in the test method for the kinematic viscosity of opaque liquids using a 3² factorial experimental design. Based on the F test, p-value, confidence intervals, and percentage contribution of the sum of squares approaches concerning the regression analysis, one concluded that the warm-up time was not a relevant factor in the kinematic viscosity, specifically of very low sulphur fuel oil, Brazilian fuel oil, and atmospheric residue diluted with diesel oil, which are fluids at room temperature. Full article

For this study, a substitution principle-based impedance bridge has been developed to calibrate AC resistors in a four-terminal-pair (4TP) configuration. The calibration is performed in the full complex plane for resistances ranging from 100 mΩ to 400 Ω and frequencies of between 50 Hz and 20 kHz. The automated bridge is based on four resistors associated with two high-impedance stages. The balancing of the bridge is achieved by means of PXI modules. The bridge is automatically balanced via a simplex top-down algorithm. The new bridge is primarily used for the measurement chain of AC standard resistors defined in a 4TP configuration at LNE, which are used for routine customer calibrations. The traceability of LNE’s standard resistors when defined in a 4TP configuration is ensured by a measurement chain from a 1 kΩ reference resistor using the new bridge. The reference resistor was calibrated previously via comparison with a calculable resistor up to 20 kHz. The bridge was validated via comparison with calibration results obtained in 1983 and 2009. For a resistor of 1 Ω at 1 kHz, the uncertainty of the series resistance variation and the phase shift are less than 6 µΩ/Ω (k = 1) and 6 µrad (k = 1), respectively. Full article

Environmental noise pollution is nowadays one of the most serious health threats. The impact of noise on the human body depends not only on the sound level but also on its spectral distribution. Reliable measurements of the environmental noise spectrum are often hampered by the very high price of top quality measuring devices. This paper explores the possibility of using much cheaper audio recorders for the frequency analysis. Comparative research was performed in laboratory and field conditions, which showed that, with some limitations, these devices can be useful in analyzing the frequency of environmental noise. This provides an opportunity for reducing the cost of noise analysis experimental work. Full article

The main challenges in 3D metrology involve measuring TSVs etched with very high aspect ratios, where the via depth to diameter ratio approaches 10:1–20:1. In this paper, we introduce an innovative approach to enhance our in-house spectroscopic reflectometer module by integrating aperture technology, resulting in a substantial amplification of interference signals. Our system offers the flexibility to conduct measurements on an average number of TSVs, individual TSVs, or specific periodic arrays of TSVs. Additionally, we demonstrate the utility of the spectroscopic reflectometer as a non-destructive, high-speed metrology solution for in-line monitoring of TSV etch uniformity. Through a series of experimental trials in a reactive ion etch (RIE) process, we show that leveraging feedback data from the reflectometer leads to marked improvements in etch depth uniformity. Full article

Weather disturbances pose a significant challenge when estimating the energy production of photovoltaic panel systems. Energy production and forecasting models have recently been used to improve energy estimations and maintenance tasks. However, these models often rely on environmental measurements from meteorological units far from the photovoltaic systems. To enhance the accuracy of the developed model, a measurement Internet of Things (IoT) prototype was developed in this study, which collects on-site voltage and current measurements from the panel, as well as the environmental factors of lighting, temperature, and humidity in the system’s proximity. The measurements were then subjected to correlation analysis, and various artificial neural networks (ANNs) were implemented to develop energy estimations and forecasting models. The most effective model utilizes lighting, temperature, and humidity. The model achieves a root mean squared error (RMSE) of 0.255326464. The ANN models are compared to an MLR model using the same data. Using previous power measurements and actual weather data, a non-autoregressive neural network (Non-AR-NN) model forecasts future output power values. The best Non-AR-NN model produces an RMSE of 0.1160, resulting in accurate predictions based on the IoT device. Full article

Human bones store elements such as calcium, phosphorus, and strontium, and accumulate toxic elements such as lead. In vivo measurements of elemental bone concentration can be done using X-ray fluorescence (XRF) techniques. Monte Carlo (MC) simulations of X-ray interactions were predominantly employed in this field to develop calibration methods that linked XRF measurements to concentrations. A simple and fast two-dimensional K-shell X-ray fluorescence model was developed to compute the KXRF signal of elements in bone and overlying soft tissue samples. The model is an alternative to MC methods and can guide future bone XRF studies. Contours of bone and soft tissue cross sections were elliptical and only KXRF signals from absorption of primary photons were considered. Predictions of the model were compared to Sr KXRF measurements using the bare lamb bone (LB) and the LB with overlying leather. XRF experiments used a small X-ray beam, silicon X-ray detector, and three positioning stages. Linear attenuation coefficients of the leather and LB were measured and used in the model. Measured and model-derived values of the Sr X-rays leather attenuation and Sr Kβ/Kα ratio agreed, but estimated bone Sr concentrations were likely overestimated. Results, approximations, future work directions, and applications were discussed. Full article

This article provides a report of the recent workshop on “The metrology of quantities which can be counted” organised jointly by the International Committee for Weights and Measures’ Consultative Committees for Amount of Substance (CCQM) and for Units (CCU). The workshop aimed to trigger a discussion on counting and number quantities across the metrological community so that a common understanding of counting and a common nomenclature could be achieved and there was clarity on the differences between these increasingly important concepts. This article details the background to the workshop, provides a summary of the presentations given and the discussions on the topics raised. It also reports the conclusions, agreed actions and next steps resulting from the workshop. Full article