02 ConfocalDT-Guide Advantages en

Advantages and Limitations of Confocal Chromatic Sensors
Advantages of confocal chromatic measuring systems

Unlike other optical measuring procedures such as e.g. laser triangulation sensors,
confocal chromatic sensors are less known. However, confocal chromatic sensors
stand out due to maximum measurement accuracy and high dynamics while measuring
even shiny and reflecting surfaces where laser sensors are operating at their limits.
The following describes the advantages and limitations of confocal chromatic sensors.
Cavity inspection
The laser beam path of confocal chromatic sensors is compact and concentric. Unlike e.g.
laser triangulation sensors, their axial beam path avoids shadowing effects when the
sensors are mounted vertically, which enables measurements even in small sleeves and
recesses. Furthermore, Micro-Epsilon offers confocal chromatic sensors with a 90° beam
path to measure inside holes and recesses. As the beam is deflected by 90°, the sensor can
be mounted parallel to the target which makes it ideal for use in restricted installation space.
User Guideline Confocal chromatic sensors for displacement and thickness measurements Vol. 02
Copyright www.micro-epsilon.com Page 1 of 13
Extended cable lengths up to 50m
The sensor and controller are connected via a fiber optic cable. Unlike electromagnetic
measuring procedures, there is hardly any loss during signal transmission. Therefore,
cable lengths up to 50m are possible. This is how the sensor can also be installed in
critical places while the controller may be positioned in a safe distance.
Distance measurement on any surface

In contrast to laser-optical sensors, confocal chromatic sensors are almost independent
of the light reflected by the surface. Therefore, the distance can be measured from dark
and mat surfaces as well as from shiny and reflecting surfaces.
Passive sensor design – high EMC
In contrast to systems using an oscillating lens, confocalDT measuring systems from
Micro-Epsilon are entirely wear-free. As no wearing parts are installed, their
mechanical stability lasts for years. The light source is the one and only component
with limited service life. The sensors are designed for passive measurements and do
not need any electrical components. They do not give off heat, which makes them
suitable for use in sensitive environments. Therefore, these sensors are ideal for
environments with high magnetic radiation and for explosive areas.
Ready for vacuum
In some industries, measurements are to be carried out in a vacuum. Confocal
chromatic sensors are basically suitable for use in vacuum, as the sensor consists of
passive components. Therefore, the sensor does not emanate any heat. However, all
components must be suitable for use in vacuum. In a vacuum, especially in a high
vacuum (HV) and an ultra-high vacuum (UHV), conventional materials which might
contaminate the environment by outgassing must not be used.
Particularly for use in vacuum applications, Micro-Epsilon offers confocal chromatic

sensors, cables and accessories which can be used according to their respective
specification. These models are made from non-outgassing materials and the
production of vacuum suitable components takes place in low-particle clean rooms.
One-sided thickness measurement of transparent
materials
The confocal chromatic measuring principle enables one-sided thickness measurement
of transparent materials such as glass. The material thickness is detected to
micrometer accuracy using just one single sensor. The controller provides a
comprehensive materials database that is editable and expandable via the web
interface. The evaluation of up to 6 peaks enables measurements of multi-layer objects
such as laminated glass.
Multi-peak option for multi-layer objects
Thickness measurement of transparent multi-layer materials
(safety glass, solar cells, flat screens, smartphone displays)
can be solved with Micro-Epsilon’s confocal chromatic
displacement sensors which are equipped with a multi-peak
option. A six-peak evaluation enables to measure up to five
layers on their respective boundary areas. To accurately
determine the thickness of each layer, the controller retrieves
the refractive index for each layer from the material
database. Each refractive index is corrected depending on
the wavelength: three refractive values are used for
thickness calibration (beginning, end, middle of the layer).
High measuring rates for dynamic measurement tasks

The confocal measuring principle enables high
speed measurements. Depending on the models and
components used, the controllers of different
manufacturers provide different measuring rates.
Controllers from Micro-Epsilon offer with up to 70kHz
the highest measuring rate in the world. However, it
is important to adapt the exposure to the respective
surface. Therefore, controllers from Micro-Epsilon
operate based on a exposure control feature which
uses the previous measuring cycle offering the
fastest surface adaptation available.
Inspecting the finest of surface structures based on
distance measurements and intensity evaluation
Confocal chromatic measuring systems are used for displacement and distance
measurements but can also be applied for intensity evaluation. Surface properties can
be determined to micrometer accuracy using this intensity evaluation. Scratches and
slightest unevenness can be detected reliably which would not be possible with just
distance evaluation.
Another option, in addition to distance measurement, is to perform measurements

using signal intensity, which enables the visualization of the finest of structures. With
constant exposure time, additional information about the surface evaluation can be
made which would not be possible with just distance measurement. This example
shows a measurement onto a flat grinded surface. The distance values (middle)
provide a different result than the intensity evaluation (right).
Limitations of the Confocal Chromatic Measuring
Principle
Influence by multiple reflections
With roughened, reflecting surfaces, whose roughness is smaller than the size of the
light spot, multiple reflections might distort the measurement result. Depending on the
reflection of the target or the surface structure, multiple peaks might occur on the CCD
line. However, the measurement is always based on the signal with the highest
intensity. If the signal with the highest intensity originates from the reflection of an
edge, the measurement result is faulty.
Clean environment
Just like all optical measuring principles, confocal chromatic sensors require a clean
environment. Strong dust, mist and smoke interrupt the beam and allow no precise
measurement to be made.
Tilted target position
With shiny measurement objects with varying geometries such as e.g. edges in
grooves, the sensor cannot be installed in a 90° angle. This is called a tilt angle where
only a part of the reflected light returns to the sensor. Depending on the sensor, a
permissible tilt angle range is defined in which sufficient light can be reflected. Sensors
from Micro-Epsilon equipped with a large lens system allow a maximum tilt angle of 34°
with reflecting surfaces. With diffuse reflecting surfaces, a tilt angle up to 60° is
permissible.
Tip: With diffuse surfaces, the proportion of light reflected is higher which enables a
larger tilt angle. Sensors with a high numerical aperture (NA) are less sensitive to tilt
angles.
Minimum thickness with transparent targets
For thickness measurements, several peaks in the video

signal are evaluated. In order to ensure sufficient
evaluation of the single peaks, a certain minimum distance
from one another is required. With regard to the target, this
means that the object to be measured needs a certain
thickness in order to be able to evaluate the peaks
separately. Depending on the sensor and measuring
range, the minimum thickness of a layer recommended by
Micro-Epsilon is 5% of the measuring range.
Deviating thickness with curved, transparent materials (e.g. bottle glass)
The refraction index of the transparent material depends on the focused wavelength.
The refraction index changes with the distance between the sensor and the target. If
the target is farther away from the sensor, the wavelengths used for thickness
measurement are not the same as with a short distance from the sensor.
When measuring the thickness of curved objects, the change of this distance
considerably influences the measurement
accuracy. Changing material thickness and a
varying distance between the target and the
sensor produce faulty measurement values.
Micro-Epsilon’s confocal chromatic controllers
are equipped with a thickness calibration
feature. Refractive indices of different
materials are stored in the materials database
in the controller. This enables precise
thickness measurements even with varying
measurement distances.
Sensor housing increases with larger measuring range
Confocal chromatic displacement sensors have measuring ranges

from 0.3mm to 30mm. However, the sensor dimensions increase
with larger measuring ranges as the lens system changes
accordingly.
Confocal chromatic miniature sensors
For measuring ranges from 0.4mm to 10mm, Micro-Epsilon developed sensors which
are equipped with gradient index lenses. Therefore, miniaturized designs with a
diameter of just 4mm are possible. However, these do not achieve the same luminous
intensity as sensors with discrete lens.

02 ConfocalDT-Guide Advantages en

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

02 ConfocalDT-Guide Advantages en

Uploaded by

Copyright:

Available Formats

Advantages and Limitations of Confocal Chromatic Sensors

Advantages of confocal chromatic measuring systems

Distance measurement on any surface

Particularly for use in vacuum applications, Micro-Epsilon offers confocal chromatic

High measuring rates for dynamic measurement tasks

Another option, in addition to distance measurement, is to perform measurements

Influence by multiple reflections

For thickness measurements, several peaks in the video

Confocal chromatic displacement sensors have measuring ranges

Confocal chromatic miniature sensors

You might also like