Questions You Should Know about Surface Inspection System For Steel

There's a number of different ways to check flatness of a surface plate. The task is to quantify departure from a true plane. If the plate can be located on a truely rigid substrate you can use a single level positioned in succession as Richard King suggests. When I say rigid I refer to solid masonry or steel structure to solid bearing on a concrete floor, that is zero deflection in response to the moving mass of a master precision level. A two level system or autocolimator/mirror is level insensive so all that's needed is a reasonably sturdy stand or bench but that's more equipment.

A Mahr Repeat-o-Meter (and shop made equivalents) is a first rate method of determining short pitch error (rolled off edges, worn areas etc) but it has to be first referenced to a known flat. A Repeat-o-Meter detects only departure from a sphere. A flat surface can be thought of as a sphere of infinite radius. If you're lucky enough to zero it from a flat surface then you can check the whole plate but it's seldom you will be that lucky.

To my mind the minimum equipment way for a home shop or small shop guy to check a surface plate for flatness is the one master precision level method but is also time consuming and skill and care intensive. A master precision level usually registers 0." per 10" (1/50,000 slope) where the graduations are 2mm or 0.100" between the lines. With care, you can eyeball the bubble ends with respect to the graduation to some fraction. If you noose a hair around the vial and nudge it into position to mark the bubble end you can read the level to a far finer degree perhaps consistant to 0." in 10" (1/100,000 slope).

But you have to be excrutiatingly careful of influencing the level with heat conducted from your hands or radiated from your body. If you can map the local undulations of the granite flat using the one or two level system you have variations of 0." per foot identified. Then you have to these variations on paper like soundiungs on a nautical chart then connect similar figures to make contours of equal elevation. This can be as good as a professional calibration as a metorlogy lab if it weren't for all that excrutiatingly careful work, days fo squinting and stooping, and the fact the calibration was not conducted by a disinterested third party.

An autocollimator also detects shallow slopes from point to point that can be reduced to a contour map, A differential level, laser interferometry, etc are alternative methods of the same thing.

Personally I'd haul the plate to a cal lab and let them calibrate/lap the plate to my specs then I'ill have a certified flat, a map of of its surface flatness, and a current certificate of calibration.

The question is how fussy are you?

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The surface inspection is largely carried out by automatic inspection systems. Cameras and sensors form the core. Powerful lenses pick up external surfaces and pass the images on to a PC, which processes them digitally. One approach has proven itself in practice: Based on predefined criteria, the software used recognizes minimal and gross deviations. The data are compared with reference images or target values. If irregularities occur, it is very likely that it is scrap. Surfaces can also be scanned using laser technology, and three-dimensional images are created in the computer. Test systems decide within a few seconds whether products are defective or not.

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With enormous computer capacities, efficient microchips and high-resolution cameras, the visual surface inspection can be carried out even with fast production processes. The process comes into its own with short test times, provided the equipment used meets the requirements. The recordings are often made by several cameras and from different perspectives, so that products can be almost completely displayed in one operation. The surfaces do not have to be smooth and even; goods by the meter such as latex, fabrics, plastic films and cables can also be tested.

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