Measuring and testing technology: From laser scanners to idler roller test benches

We offer independent idler testing for manufacturers and users of idlers. In accordance with the DIN 22112, SAB 1313 and DIN ISO 21940 test standards, we determine the running resistance, concentricity tolerance and balancing quality of idlers, among other things. We have the necessary measurement technology for this.

On our modern test bench for measuring running resistance, we can test idlers with a maximum diameter of 400 mm and an axle length of up to 1650 mm.

The electronics laboratory has two workstations for soldering work. For fine soldering work, we use the STEMI 305 stereo microscope from ZEISS, which enables depth perception even in the magnified range.

In addition to laboratory power supplies for the voltage supply and frequency generators for signal generation, an analog and digital oscilloscope are available for signal analysis.

Measuring devices for luminescence and spectral measurements are also available.

Our optical table is suitable for all types of measurement setups where high accuracy is required. It protects sensitive test setups from vibrations. In the laboratory, the measuring equipment is also protected from light.

We have used the optical table in the IntegrAD and MiniVib research projects, among others, to investigate the torque of drive shafts.

We are also able to realize measuring constructions with very fine settings on behalf of our industrial customers.

At IPH, we use the ATOS Core optical 3D scanner from the manufacturer GOM for the 3D measurement of small and medium-sized objects such as forged parts or additively manufactured components.

With the Atos Core 80 sensor, components within a measuring range of 80 x 60 mm can be measured with an accuracy of 15 micrometers. The Atos Core 500 sensor can measure components within a measuring range of 500 x 380 mm with an accuracy of 65 micrometers. The measurement data obtained is converted into a 3D object on the computer, which can be exported as an STL file, for example.

The actual geometry recorded in this way can be compared with the target geometry of the component using software in order to check compliance with component tolerances and assess the surface quality.

Copies and spare parts can also be produced using the 3D scanner. The components are scanned, converted into a CAD file and transferred to the 3D printer, which produces an exact copy. After scanning, damaged components can be virtually repaired in CAD software, after which an undamaged replacement part can be printed out.

We record and evaluate the surface quality of 3D-printed components using the VR-5000 3D profilometer from KEYENCE DEUTSCHLAND GmbH.

The device takes images from various positions and angles and can therefore record the 3D profiles of surfaces very accurately. We use the profilometer to measure the roughness of both additively manufactured components and forged components. The surface can be measured with a resolution of up to 0.1 micrometers.

We use the EinScan HX mobile laser scanner from Shining3D to measure objects such as tools. The handheld scanner is robust, very flexible and can measure areas of any size to an accuracy of 40 micrometers. The laser scanner records the object as a point cloud, which can then be loaded into a CAD program and processed there.

We use the laser scanner, for example, to examine the wear condition of forging dies. The tools are measured on site at the customer's premises and can remain installed during the inspection. In the CAD program, we compare the actual geometry with the target geometry and the difference corresponds to the tool wear.

We use the following measurement technology to objectively record the environmental conditions at the workplace:

• Sound level meter to record noise pollution at the workplace
• Luxmeter to record the lighting conditions at the workplace
• Measuring device for recording air quality (e.g. humidity, air temperature, CO2 concentration)

The measurement data helps to evaluate the working conditions and ergonomics in production facilities on behalf of our customers.

As part of the ergonomics assessment at the workplace, we can use the Bodymedia Sensewear upper arm belt to measure calorie consumption and the metabolic equivalent and thus objectively record the physical strain on employees in production.

After the ergonomics optimization for our customers, we can carry out the measurement again and check whether the optimization measures have achieved their goal of reducing the physical workload.