1

PROFILE
PROJECTOR

AISIRI .D (3)

MARIAM (28)

NOYONIKA .M.R (34)

SAMEEKSHA .A.V (40)

 2

Contents

1. Introduction--------------------------------------------------------------------------------------------------- 5-6

1.1. History

1.2. Work Principle

2. Features --------------------------------------------------------------------------------------------------------6-7

2.1. Projection methods

2.2. Positive or inverted images

2.3. Screen size

2.4. Magnification

2.5. Work table and accessories

3. Precision---------------------------------------------------------------------------------------------------------7
4. Advantages of profile projector -----------------------------------------------------------------------------8

5. Disadvantages of profile projectors --------------------------------------------------------------------------8

6. Applications of Profile Projector ----------------------------------------------------------------------------8

7. Benefits of Profile Projectors ----------------------------------------------------------------------------------9

8. Case Studies ------------------------------------------------------------------------------------------------------9-15

8.1. Profile Projector Ensures Precision Weld Profiles for Nuclear AMRC ----------------------------9-11
8.1.1. Accurate Measurement is Critical
8.1.2. The Nuclear Advanced Manufacturing Research Centre
8.1.3. Accurate, Repeatable Measurements
8.1.4. Meticulous Measurement of Welding Profile
8.1.5. Nuclear Components
8.1.6. World Leading Innovation Cluster
8.2. Baty Profile Projector Ensures Quality for Magnetic Technology Expert ---------------------------11-13
8.2.1. Improving Quality Inspection Capabilities
8.2.2. Traceable Reporting Measuring Complex Shapes
8.2.3. Accurate Testing of Tolerances
8.2.4. Reliable and Consistent Measurement
8.2.5. High Performance Magnetic Systems for Demanding Industries
 3

8.3. Baty Profile Projector Ensures Accuracy of Precision Medical Components ---------------------13-15
8.3.1. Measurement of Complex Radius Profiles
8.3.2. More than a Profile Projector
8.3.3. Subcontract CNC Machining
8.3.4. Bench Mount Profile Projector
 4

Fig 1

Fig 1(a)
 5

1.Introduction

An optical comparator or profile projector is a device that applies the principles of optics to
the inspection of manufactured parts. In a comparator, the magnified silhouette of a part is projected upon
the screen, and the dimensions and geometry of the part are measured against prescribed limits. It is a useful
item in a small parts machine shop or production line for the quality control inspection team.

The measuring happens in any of several ways. The simplest way is that graduations on the screen, being
superimposed over the silhouette, allow the viewer to measure, as if a clear ruler were laid over the image.
Another way is that various points on the silhouette are lined up with the reticule at the counterpoint of the
screen, one after another, by moving the stage on which the part sits, and a digital read out reports how far
the stage moved to reach those points. Finally, the most technologically advanced methods involve software
that analyzes the image and reports measurements. The first two methods are the most common; the third is
newer and not as widespread, but its adoption is ongoing in the digital era.

1.1.HISTORY

The first commercial comparator was developed by James Hartness and Russell W. Porter. Hartness' long-
continuing work as the Chairman of the U.S.'s National Screw-Thread Commission led him to apply his
familiarity with optics to the problem of screw thread inspection. The Hartness Screw-Thread Comparator
was for many years a profitable product for the Jones and Lamson Machine Company, of which he was
president.

In subsequent decades optical comparators have been made by many companies and have been applied to
the inspection of many kinds of parts. Today they may be found in many machine shops.

The idea of mixing optics and measurement, and the use of the term comparator for metrological equipment,
had existed in other forms prior to Hartness's work; but they had remained in realms of pure science (such
as telescopy and microscopy) and highly specialized applied science (such as comparing master measuring
standards). Hartness's comparator, intended for the routine inspection of machined parts, was a natural next
step in the era during which applied science became widely integrated into industrial production.
 6

1.2. Work Principle

Fig 2

The projector magnifies the profile of the specimen, and displays this on the built-in projection screen. [4] On
this screen there is typically a grid that can be rotated 360 degrees so the X-Y axis of the screen can be
aligned with a straight edge of the machined part to examine or measure. This projection screen displays the
profile of the specimen and is magnified for better ease of calculating linear measurements.
An edge of the specimen to examine may be lined up with the grid on the screen. From there, simple
measurements may be taken for distances to other points. This is being done on a magnified profile of the
specimen. It can be simpler as well as reduce errors by measuring on the magnified projection screen of a
profile projector.
The typical method for lighting is by diascopic illumination, which is lighting from behind. This type of
lighting is also called transmitted illumination when the specimen is translucent and light can pass through
it. If the specimen is opaque, then the light will not go through it, but will form a profile of the specimen.
Measuring of the sample can be done on the projection screen. A profile projector may also
have episcopic illumination (which is light shining from above). This useful in displaying bores or internal
areas that may need to be measured.

2. Features
2.1. Projection methods

1. Vertical projectors: The main axis is parallel to the plane of the screen. They're most common, and
suitable for flat parts or smaller work-pieces.
2. Horizontal Projector: The main axis is perpendicular to the plane of the projection screen. They are
mainly medium and large, and suitable for shaft parts or heavy work-pieces with large volume,
 7

although having a horizontal table below without a hole for light transmission can be convenient for
small machines that use a silhouette lighting arrangement.

2.2. Positive or inverted images

For the simplest profile projector, the product's inverted image, also known as mirror image, will be
displayed on the screen.
In order to facilitate the measurement, sometimes we will deliberately add a plus-image system, changing
the inverted image into a positive one, but it will undoubtedly increase the cost and reduced the
measurement accuracy.

2.3. Screen size

As for selection of screen size, you should carefully consider whether the entire part must be appeared on
the screen. If it can achieve the purpose via segment observation, it's no need for large screen. Every
projector manufacturer has a wide range of screen sizes to choose.

2.4. Magnification
The magnification of lens is fixed. Different part of measured piece often request different magnification.
But the projector factory standard configuration is usually with only one lens, you must purchase according
the real needs.

2.5. Work table and accessories

Work table is used to place and hold the measured piece. Its own volume, X, Y travel and carrying capacity
are critical. Meanwhile, for the convenience of holding workpiece, it will be need to buy a rotary table, V-
holder and other accessories.
Besides, the projector must also have a flexible and stable focusing mechanism and large working distance
(the top surface of the workpiece and the lens pitch). Select appropriate data processing mode: all optical
measuring projectors on market, without exception, have been digitized. We must focus on its data
processing capabilities.

3.Precision
Current commercially available optical measuring projectors' theory accuracy, because the optical lens and
gratings are on similar quality, are also similar. Therefore, there's no need to deliberately pursue high
precision.

4.ADVANTAGES OF PROFILE PROJECTOR

 8

Profile projector is primarily utilized for measuring the dimensions of the component. In the manufacturing
process, it is very crucial to test each and every material before incorporating the same. In order to ensure
high quality in your production line, making the best use of Profile Projectors in the industry will be
beneficial. Therefore, it is important for the manufacturer to understand the advantages and applications of
profile projectors in industries.
This instrument captures the image of the component and then magnifies it to many folds. The magnified
images are then projected to the operator from where the dimensions required are digitally recorded and
displayed.

Hence, Profile Projector can magnify every minute details of the component to offer you a clear picture of
the product and save you from transmitting the errors into the production line.

5. Disadvantages of profile projectors

The limitation of using profile projector as a fixed device forms a disadvantage of it, while instruments such
micrometer or calipers can be used to reach for measuring far and joint accessible components and it is large
and bulky and usually require a cart to transport from place to place, also the device requires power for
operation.

6. Applications of Profile Projector

•For inspecting shape and sizes of the PET bottles and their defects.
There are some defects which cannot be analyzed by naked eyes. Moreover, uneven shapes can be measured
to bring uniformity to the whole batch.

•For inspecting surface deformities in the automotive industry.

Surfaces of automobiles carry minute defects, like scratches and dents. These defects can be easily
magnified using profile projector.

•For inspecting minute flaws in glassware.

High-end glassware is crafted with precision. Any defect may decrease the mechanical stress and increase
the brittleness.

•For inspecting components with irregular shapes and sizes.

Not every component can be measured with a micrometer, sometimes due to the delicate nature of the
product. Thus, this instrument cut down the challenge of measuring uneven shapes and surfaces.

7. Benefits of Profile Projectors

 9

•Minute details can be assessed very easily as the images are magnified. Small defects like scratches and
burrs also get highlighted. Defect identification can be done very easily.
•During analysis of the components, there are some indention marks left on the test object. These marks can
be easily analyzed and identified using this instrument. These might be very minute indentions but can
create a considerable effect on the end product.
•The profile projectors are used for several measuring at a time which saves time and energy.
Presto’s Profile Projector is one of the best testing instruments that offer a projection of high-resolution
images of the test specimen for better quality check process. It can deliver maximum advantages and fulfil
all applications of profile projectors in industries.

8. Case Studies
8.1. Profile Projector Ensures Precision Weld Profiles for Nuclear AMRC
The welding team at the Nuclear AMRC is using a Baty SM300 GMR vertical profile projector to ensure the
quality of weld profiles on sub-components used in nuclear applications.

The profile of a completed weld is really important to the performance of the weld in service. Welding profiles,
therefore, must be thoroughly checked to identify any discontinuities through both visual and machine inspection,
in order to evaluate acceptance or rejection depending on the acceptance criteria.

Fig 3
8.1.1. Accurate Measurement is Critical
John Crossley M.InstNDT, NDT Technology Lead at the Nuclear AMRC said: “The accurate measurement of weld
profiles is absolutely critical to the work we do. Everything we manufacture must meet the very highest levels of
quality due to the extreme conditions that components are exposed to. Some of our welding work ends up as
part of containment flasks at the Sellafield nuclear fuel reprocessing and nuclear decommissioning site,
therefore accuracy and quality is very important.”

8.1.2. The Nuclear Advanced Manufacturing Research Centre

Located on the Advanced Manufacturing Park (AMP) in South Yorkshire, on the border of Sheffield and
Rotherham, The Nuclear Advanced Manufacturing Research Centre (Nuclear AMRC) helps UK manufacturers
win work across the nuclear sector. The centre’s manufacturing innovation capabilities and supply chain
development services are open to all UK manufacturers, from specialist SMEs to top-tier OEMs.
 10

A profile is taken of every weld using dental putty, which is manipulated to create an impression of the weld
profile, and then measured to ensure the quality of the surface finish that has been created during the welding
process. The Nuclear AMRC uses a Baty SM300 GMR vertical profile projector to ensure that the weld profiles
meet the required criteria and surface finish requirements, which has a large travel range of 150mm x 50mm as
standard, and a linear scale stage with 0.001mm resolution.

8.1.3. Accurate, Repeatable Measurements

John Crossley continued: “The Baty profile projector is really easy to use and does exactly what we need it to.
We trust it to deliver accurate, repeatable measurements, meaning that we can be confident in our quality
procedures, and pass this confidence onto our customers.”
Typically imported via Bowers Shanghai, the Baty SM300 GMR is a high quality profile projector that is fully
checked and calibrated to Baty standards. It boasts a fine ground glass screen for clear image with cross hair
lines and chart clips, built-in profile and surface illumination, and a display-readout unit.

8.1.4. Meticulous Measurement of Welding Profiles

Each measurement is logged by the Nuclear AMRC, and parameters for tolerances strictly met in order for the
part to be accepted. If the profile of the weld is too convex or too concave it will be rejected. The weld profile
must not exceed a certain level of concavity in order to be compliant with British Standards. For example,
depressions in the welding joint can be a result of too much heat during the process, and can make the pipe
surface weak by putting additional stress on the join. It is, therefore, important that each welding profile is
measured meticulously.
The welding team at the Nuclear AMRC develops advanced and innovative joining and cladding
techniques tailored to the nuclear industry. Nuclear power plants require extremely high levels of quality and
assurances, and many key components must be manufactured by joining together large sub-components in a
way that is resistant to corrosion, and that maintain material integrity under extreme conditions whilst in service.

8.1.5. Nuclear Components

Fig 4
Welding solutions are a complex task on this scale, with welded joints between thick-walled nuclear
components often requiring over 100 weld passes using standard techniques. Then there is the
repeated heating and cooling that the joint may be exposed to, this can have a significant effects
 11

on the properties of the material around the joint, potentially harming the long-term performance of
the component.
The quality of joints and the surface thickness must be specified for fracture mechanic properties.
Pipes are typically used as part of steam generator pipes and high pressure feed line pipes, meaning
that they must meet tight tolerances in order to be deemed acceptable for use in these critical
environments.

8.1.6. World Leading Innovation Cluster

Engineers and specialists at the Nuclear AMRC work directly with companies to
develop innovative techniques and optimised processes for large-scale high-precision manufacturing.
The centre also provides a range of supply chain development support to help manufacturers
enter the nuclear market and compete worldwide.
Backed by industry leaders and government, the Nuclear AMRC is owned by the University of
Sheffield, and forms part of a world-leading innovation cluster alongside the AMRC, Castings
Technology International and AMRC Training Centre.

8.2. Baty Profile Projector Ensures Quality for Magnetic Technology

Experts

Fig 5
Bowers Group has provided Eclipse Magnetics with a Baty SM350 FT2-E Profile Projector and Fusion Software for
the accurate testing of tolerances on a range of magnets and magnetic components. As leading experts in magnetic
technology, Eclipse Magnetics manufactures a wide range of high performance magnetic materials, finished products, and
magnetic assemblies, as well as a range of over 20,000 off-the-shelf standard magnetic products available in stock.

8.2.1. Improving Quality Inspection Capabilities

The Baty SM350 FT2-E Profile Projector has greatly improved Eclipse Magnetics’ quality inspection
capabilities. As well as checking the tolerances of stock parts, Eclipse Magnetics regularly uses the profile
projector to measure fundamental components that make up liquid filters; high intensity magnetic
separators used in pressurised transfer lines for the food industry. One of the components regularly tested is
 12

a collar that fits onto a length of magnetic tubing. The precision and accuracy of this collar is imperative to
the secure reinforcement of this tubing, and a key factor in the effective operation of the product. Tolerances
are tight, and therefore, precision measurement is key.
The Baty SM350 FT2-E Profile Projector is also used to measure magnetic blocks and disks that are used
as part of OEM magnetic assemblies for a variety of industries that typically require extremely strict
tolerances. Ensuring precise sizing, traceable reporting, and tolerance conformity is, therefore, imperative.
Customer demand for FAIR reports has also been satisfied with the Fusion Software, delivering a traceable
reporting system that offers customers evidence of tolerance parts.

8.2.2. Traceable Reporting Measuring Complex Shapes

Eclipse Magnetics Quality Engineer Paul Hampson said: “The Baty SM350 FT2-E Profile Projector has
enabled us to measure complex shapes, radii and angles, which we have never had the capability to measure
before. Although we have always been confident that our products are highly accurate and meet stated
dimensions, the assurances we get from the Baty SM350 FT2-E Profile Projector allow us to provide
concrete evidence to our customers. In the unlikely event that discrepancies are raised, we can produce
reports to show that we have met the highest quality standards.”

8.2.3. Accurate Testing of Tolerances

The accurate testing of tolerances on stock parts is a necessity for ensuring Eclipse Magnetics’ high quality
standards. In addition, ensuring the tight tolerances of key components that make up Eclipse Magnetics’
products is not only imperative to the reliability, safety and operation of the products, it is also necessary to
provide customers with assurances that quality standards are met and tolerances are proven.

The readings obtained from the Baty SM350 FT2-E enables Eclipse Magnetics to prove to customers that
components are within quoted tolerances. The addition of the Fusion Software to the profile projector also
enables Eclipse Magnetics to generate graphical representations and instant detailed reports showing the
feature name, nominal dimension, actual, error, upper and lower limits, including a green pass or red fail
label for each measured dimension in tabulated format. Geometric tolerance details can also be displayed
along with a thumbnail view of the part and batch/customer information, and the entire report can be
duplicated as an Excel workbook for email purposes.
 13

8.2.4. Reliable and Consistent Measurement

Paul Hampson continued: “The measurement accuracy of the profile projector is reliable and
consistent. The unit is also very user friendly and requires minimal training. As a validating and
checking tool it’s perfect for us; the accuracy it provides and is capable of achieving is absolutely
outstanding.”
Eclipse Magnetics has over 100 years of experience in the design and manufacture of high performance
magnetic systems, serving worldwide markets with innovative solutions such as Industrial
Filtration, Foreign Body Removal, Customised Magnetic Assemblies, Lifting and
Handling, Workholding, Workshop Tools and Heating System Filtration.

8.2.5. High Performance Magnetic Systems for Demanding Industries

Based in Sheffield with offices across the world, Eclipse Magnetics manufactures a wide range of high
performance magnetic materials and finished products and magnetic assemblies, including neodymium
magnets, samarium cobalt magnets, ferrite magnets and alnico magnets. Extensive facilities allow Eclipse
Magnetics to provide customised magnetic assemblies design and build solutions working to precise client
specifications, as well as a range of over 20,000 off-the-shelf standard magnetic products which are
available in stock.

Eclipse Magnetics’ magnets and magnetic assemblies are widely used in a wide variety of industries
including automotive, food, steel, communications, aerospace and engineering, as well as in commercial
office and retail premises. Eclipse Magnetics also has considerable expertise in producing magnetic
assemblies for the electronics, automotive, aerospace, pumps, audio equipment, sensors and security
sectors.

8.3. Baty Profile Projector Ensures Accuracy of Precision

Medical Components
As part of the Bowers Group, Baty International Ltd has supplied CTPE Ltd with a Baty R14 FT-2E profile
projector to ensure the accuracy of complex machined components used for scientific and medical
applications. Based in Mildenhall, Suffolk, CTPE Ltd manufactures a variety of turned and milled
components, ranging from simplistic to complex parts. The vast majority of parts are small sized, and many
are used in medical diagnostic equipment such as blood gas analysers, and in specialist scientific
instruments for laboratories.
 14

8.3.1. Measurement of Complex Radius Profiles

Fig 6

CTPE required an accurate and repeatable measurement method that would enable the business to
measure features on components that they were unable to measure with hand measuring instruments such as
micrometres and calipers. CTPE needed to measure complex radius profiles on turned parts, and features
such as blended radiuses and angles, which are impossible to measure with traditional hand measuring
equipment. A more sophisticated method of measurement was needed, as many of the parts manufactured
have extremely tight tolerances.
Bowers Group supplied CTPE with a Baty R14 FT-2E profile projector in order to improve its machining
accuracy and quality inspection capability for complex machined components. CTPE’s CNC setters and
operators now use the machine to perform first article inspections, and the Operations Manager regularly
uses the profile projector for final inspection of components, ensuring precise consistency and the highest
quality product.

8.3.2. More than a Profile Projector

Alex Taylor, Operations Manager at CTPE Ltd said: “We have been putting our Baty R14 to good use
lately! It is so much more than a projector; this 2D optical measuring system produces full SPC data and
inspection reports.”
Bowers Group also supplied CTPE with Fusion software with a touch screen monitor for use on the profile
projector. The Fusion metrology software enables CTPE to produce accurate inspection reports at the
touch of a button, automatically saving all relevant data from inspections.
Alex continued: “The software allows us to produce inspection reports at the machine, and save all
relevant data from inspections on the spot, which saves time having to write the data into our own reports.
Being touch screen, the machine is also very easy to use. The touch screen and software were one of the
main factors that made us choose the Baty R14, and it’s been a good decision.”
 15

8.3.3. Subcontract CNC Machining

With over 25 years’ experience providing subcontract CNC machining, CTPE Ltd has built a reputation of
manufacturing high quality, precision components to industry leading companies. Established in 1989 as a
precision engineering company offering prototypes and small batches, CTPE has grown to become
a leading sub-contract supplier for machined components to the Scientific and Medical industries. The
most important thing on CTPE’s list of priorities is quality, with the company being fully committed to
continuous investment in the latest in CNC manufacturing technology, ensuring the ability to provide a
complete solution for the supply of high quality components.

8.3.4. Bench Mount Profile Projector

The Baty R14 FT-2E is a bench mount profile projector with a 340mm screen, combining high accuracy
non-contact measurement and inspection with a large 175mm x 100mm measuring range. Its horizontal light
path configuration is ideally suited to machined parts, and the compact and robust lightweight chassis makes
the R14 ideal for workshop environments.
Alex added: “So far we have found the R14 to be very accurate and are regularly measuring down to below
10 microns. We plan to have it serviced and calibrated every year for ongoing accuracy and longevity. The
profile projector gets used on an almost daily basis.”
16
17