Abstract This thesis describes position-sensitive devices (PSDs) and optical sensor systems suitable for industrial tracking and displacement sensing applications. The main application areas of the proposed sensors include automatic pointing of a rangefinder beam and measuring the lateral displacement of an object. A conventional tracking sensor is composed of a laser illuminator, a misfocused quadrant detector (QD) receiver and a corner cube retroreflector (CCR) attached to the target. The angular displacement of a target from the receiver optical axis is detected by illuminating the target and determining the direction of the reflection using the QD receiver. The main contribution of the thesis is related to the modifications proposed for this conventional construction in order to make its performance sufficient for industrial applications that require a few millimetre to submillimetre accuracy. The work includes sensor optical construction modifications and the designing of new types of PSDs. The conventional QD-based sensor, although electrically very sensitive, is not considered optimal for industrial applications since its precision is severely hampered by atmospheric turbulence due to the misfocusing needed for its operation. Replacing the CCR with a sheet reflector is found to improve the precision of the conventional sensor construction in outdoor beam pointing applications, and is estimated to allow subcentimetre precision over distances of up to 100 m under most operating conditions. Submillimetre accuracy is achievable in close-range beam pointing applications using a small piece of sheet reflector, coaxial illumination and a focused QD receiver. Polarisation filtering is found to be effective in eliminating the main error contributor in close-range applications, which is low reflector background contrast, especially in cases when a sheet reflector has a specularly reflecting background. The tracking sensor construction is also proposed for measuring the aiming trajectory of a firearm in an outdoor environment. This time an order of magnitude improvement in precision is achieved by replacing the QD with a focused lateral effect photodiode (LEP). Use of this construction in cases of intermediate atmospheric turbulence allows a precision better than 1 cm to be achieved up to a distance of 300 m. A method based on averaging the positions of multiple reflectors is also proposed in order to improve the precision in turbulence-limited cases. Finally, various types of custom-designed PSDs utilising a photodetector array structure are presented for long-range displacement sensing applications. The goal was to be able to replace the noisy LEP with a low-noise PSD without compromising the low turbulence sensitivity achievable with the LEP. An order of magnitude improvement in incremental sensitivity is achievable with the proposed array PSDs.

The Texas A&M Flight Research Laboratory (FRL) recently received delivery of its newest aircraft, the Velocity XL-5 RG. The Velocity can fly faster than the other aircraft owned by the FRL and does not have a propeller in the front of the aircraft to disrupt the air flow. These are definite advantages that make the Velocity an attractive addition to the FRL inventory to be used in boundary-layer stability and transition control. Possible mounting locations built into the aircraft for future projects include hard points in the wings and roof of the fuselage. One of the drawbacks of the aircraft is that it has a canard ahead of the main wing that could disrupt the incoming flow for a wing glove or research requiring test pieces mounted to the hard point in the wing. Therefore, it is necessary to understand the influence the canard and the impact of its wake on the wing of the aircraft before any in-depth aerodynamic research could be completed on the aircraft. A combination of in-flight measurements of the canard wake and Computational Fluid Dynamics (CFD) were used to provide a clear picture of the flowfield around the aircraft. The first step of the project consisted of making a 3-D CAD model of the aircraft. This model was then used for the CFD simulations in Fluent. 2-D, 3-D, inviscid, and viscous simulations were preformed on the aircraft. A pressure rake was designed to house a 5-hole probe and 18 Pitot probes that extended forward of the main wing to measure the location and strength of the canard wake at various flight conditions. There were five primary test points that were recorded at multiple times over the course of three flights. Once all of the data were collected from the flights, the freestream conditions became the inputs into the final, 3-D CFD simulations on the aircraft. The good agreement between the CFD results and the in-flight measurements provided the necessary verification of the CFD model of the aircraft. These results can be used in the future planning and execution of experiments involving the Velocity XL-5 RG.

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Spatial coordinate measurement systems play an important role in manufacturing and certification processes. There are many types of coordinate measurement systems including electronic theodolite networks, total station systems, video photogrammetry systems, laser tracking systems, laser scanning systems, and coordinate measuring machines. Each of these systems produces coordinate measurements containing some degree of uncertainty. Often, the results from several different types of measurement systems must be combined in order to provide useful measurement results. When these measurements are combined, the resulting coordinate data set contains uncertainties that are a function of the base data sets and complex interactions between the measurement sets. ISO standards, ANSI standards, and others, require that estimates of uncertainty accompany all measurement data. This research presents methods for quantifying the uncertainty fields associated with coupled spatial measurement systems. The significant new developments and refinements presented in this dissertation are summarized as follows: 1) A geometrical representation of coordinate uncertainty fields. 2) An experimental method for characterizing instrument component uncertainty. 3) Coordinate uncertainty field computation for individual measurements systems. 4) Measurement system combination methods based on the relative uncertainty of each measurement's individual components. 5) Combined uncertainty field computation resulting from to the interdependence of the measurements for coupled measurement systems. 6) Uncertainty statements for measurement analyses such as best-fit geometrical shapes and hidden-point measurement. 7) The implementation of these methods into commercial measurement software. 8) Case studies demonstrating the practical applications of this research. The specific focus of this research is portable measurement systems. It is with these systems that uncertainty field combination issues are most prevalent. The results of this research are, however, general and therefore applicable to any instrument capable of measuring spatial coordinates. / Ph. D.

Nowadays, the need for three-dimensional miniaturized components is increasing in many areas, such as electronics, biomedics, aerospace and defence, etc. To support the demands, various micro-scale fabrication techniques have been further introduced and developed over the last decades, including micro-electric-mechanical technologies (MEMS and LIGA), laser ablation, and miniature machine tools (mMTs). Each of these techniques has its own benefits, however miniature machine tools are superior to any others in enabling three-dimensional complex geometry with high relative accuracy, and the capability of dealing with a wide range of mechanical materials. Thus, mMTs are emerging as a promising fabrication process. In this work, various researches have been carried out based on the mMTs. The thesis presents micro-machining, in particular, micro-milling force model and three relevant subsystems for miniature machine tools (mMTs), to enhance machining productivity/efficiency and dimensional accuracy of machined parts. The comprehensive force model that predicts micro-endmilling dynamics has been developed. Unlike conventional macro-machining, the cutting mechanism in micro-machining is complex with high level of non-linearity due to the combined effects of edge radius, size, and minimum chip thickness effect, etc., resulting in no chip formation when the chip thickness is below the minimum chip forming thickness. Instead, part of the work material deforms plastically under the edge of a tool and the rest of the material recovers elastically. The developed force model for micro-endmilling is effective to understand the micro-machining process. As a result, the micro-endmilling force model is helpful to improve the quality of machined parts. In addition, three relevant subsystems which deliver maximum machining productivity and efficiency are also introduced. Firstly, ultrasonic atomization-based cutting fluid application system is introduced. During machining, cutting fluid is required at the cutting zone for cooling and lubricating the cutting tool against the workpiece. Improper cutting fluid application leads to significantly increased tool wear, and which results in overall poor machined parts quality. For the micro-machining, conventional cooling methods using high pressure cutting fluid is not viable due to the potential damage and deflection of weak micro-cutting tools. The new atomization-based cutting fluids application technique has been proven to be quite effective in machinability due to its high level of cooling and lubricating. Secondly, an acoustic emission (AE)-based tool tip positioning method is introduced. Tool tip setting is one of the most important factors to be considered in the CNC machine tool. Since several tools with different geometries are employed during machining, overall dimensional accuracy of the machined parts are determined by accurate coordinates of each tool tip. In particular, tool setting is more important due to micro-scale involved in micro-machining. The newly developed system for tool tip positioning determines the accurate coordinates of the tool tip through simple and easy manipulation. At last, with the advance of the 3D micro-fabrication technologies, the machinable miniaturized components are getting complex in geometry, leading to increased demand on dimensional quality control. However, the system development for micro-scale parts is slow and difficult due to complicated detection devices, algorithm, and fabrication of a micro-probe. Consequently, the entire dimensional probing system tends to become bulky and expensive. A new AE-based probing system with a wire-based probe was developed to address this issue with reduced cost and size, and ease of application. / Graduate

This Master‘s thesis deals with an aplication of computed tomography as the technology for quality control check of the plastic parts made by the injection molding process. The analyses were performed on two different types of plastic parts. These parts were delivered by two companies and they included the drawing documentation and CAD models. These plastic parts were analyzed according to their qualitative requirements. The analyses included evaluation of the geometric tolerances and porosity analysis with numerical and graphical evaluation. The new module for tool correction ,which is part of VGStudio Max, was tested on parts that were not in accordance with the required tolerances. Afterwards the new corrected geometries were exported. At the end of this Master’s thesis the porosity comparison was assessed between two different voxel resolution CT data. This comparison shows the complexity of this phenomenon and the importance of voxel resolution settings.

This study analyzes current trends in metrology in the field of portable coordinate measuring machines and describes current methods for measurement system and process evaluation. Obtained knowledge is applied, in order to evaluate the capability of measurement system, which consists of articulated measurement arm and measurement standard.