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Shadow Projection And Profile Projection Method

The document discusses two inspection methods for machine parts: Shadow Projection and Profile Projection. Shadow Projection uses light to create a shadow for quick checks of external shapes, while Profile Projection magnifies the image for detailed measurements, including internal features. Both methods are essential in quality control, particularly in automotive manufacturing, to ensure parts meet specifications.

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Vipul Bhardwaj
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© © All Rights Reserved
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Download as PDF, TXT or read online on Scribd
435 views

Shadow Projection And Profile Projection Method

The document discusses two inspection methods for machine parts: Shadow Projection and Profile Projection. Shadow Projection uses light to create a shadow for quick checks of external shapes, while Profile Projection magnifies the image for detailed measurements, including internal features. Both methods are essential in quality control, particularly in automotive manufacturing, to ensure parts meet specifications.

Uploaded by

Vipul Bhardwaj
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Shadow Projection And Profile Projection Method

Imagine you have a machine part that needs to be inspected to ensure it has the correct
shape and size. Instead of physically measuring it with calipers or micrometers (which might
be difficult for complex shapes), we can use light to create a shadow or an image and analyze
it.

There are two main ways to do this:

1. Shadow Projection Method


2. Profile Projection Method

1. Shadow Projection Method


Think about how shadows work. If you place an object in front of a light source, it creates a
shadow on the ground or a wall. The shape of the shadow can tell us a lot about the object.

How It Works

 A parallel beam of light is directed at the machine part.


 The part blocks some light, creating a shadow on a screen or sensor behind it.
 The shape of the shadow is analyzed to check for size, defects, or deformations.

Example

Imagine inspecting a gear. If there’s a missing tooth or a deformation, it will appear as a


problem in the shadow.

Where It’s Used

 Checking edges, holes, and cracks in machine parts.


 Ensuring the shape of cutting tools is correct.
 Detecting deformations or burrs in manufacturing.

Advantages

✔ Simple and fast


✔ Works well for flat or simple parts
✔ No contact, so no risk of damage

Limitations

Cannot measure internal features


Works best with opaque parts (not transparent)
2. Profile Projection Method
Now, imagine using a magnifying glass to look at the shadow more closely and compare it to
a reference shape. This is what a profile projector (optical comparator) does.

How It Works

 The machine part is placed on a stage inside a projector.


 A light source passes through or around the object, projecting a magnified image
onto a screen.
 The operator or software compares the projected shape to a standard reference.

Example

Suppose you are checking a screw thread. The profile projector will magnify the thread
shape, allowing you to check if the angles and spacing match the design.

Where It’s Used

 Inspecting gears, screws, and cam profiles.


 Checking small and complex parts in automotive and aerospace industries.
 Measuring internal and external features.

Advantages

✔ Works with both simple and complex shapes


✔ Can magnify small details for better accuracy
✔ Suitable for transparent materials

Limitations

Needs a trained operator


Requires proper calibration

Comparison Table
Feature Shadow Projection Profile Projection
What it Projects a shadow to check Projects a magnified profile for detailed
does shape analysis
Best for Edges, holes, cracks Gears, threads, cam profiles
Measures External shape only Both internal and external features
Accuracy High Very high (with magnification)
Complexity Simple More advanced
Final Thoughts

 Use Shadow Projection if you just need to check the outer shape and edges of a part.
 Use Profile Projection if you need detailed measurements and internal feature
analysis.

Both methods are widely used in quality control to ensure that machine parts are
manufactured correctly.

Would you like a real-world application or an example setup for a specific part?

Let’s go through a real-world application of both Shadow Projection and Profile


Projection using an example of inspecting a gear in an automotive factory.

Example: Inspecting a Gear in an Automotive Factory


A car manufacturer produces metal gears for use in transmissions. These gears must have
precise teeth, correct dimensions, and no defects to function properly. Quality control
engineers use shadow projection and profile projection to inspect them.

Using Shadow Projection for Quick Inspection

Goal: Quickly check if the gear has the correct outer shape and no missing or deformed
teeth.

Process:

1. The gear is placed in front of a collimated light source (a parallel beam of light).
2. The shadow of the gear is projected onto a screen.
3. The projected shape is compared to a reference template.
4. If a gear tooth is missing, worn out, or misaligned, the shadow will show an irregular shape.

Example Result:

If the shadow matches the reference, the gear passes the test.
If a tooth is too short, bent, or missing, the shadow will have gaps, and the gear is
rejected.

When is Shadow Projection Used?

✔ When you need a quick and simple check of external shape.


✔ Ideal for fast-moving production lines.
✔ Works for parts where only outer dimensions matter.
2 ⃣ Using Profile Projection for Detailed Measurement

Goal: Measure the exact dimensions of the gear teeth and ensure they meet strict
specifications.

Process:

1. The gear is placed inside a profile projector (optical comparator).


2. A light source shines through or around the gear, creating a magnified profile on a screen.
3. The projected profile is compared to a standard reference overlay.
4. Digital encoders and software measure angles, radii, and distances.

Example Result:

If the tooth angles and spacing are correct, the gear passes.
If a gear tooth is too wide, too narrow, or misaligned, the deviation is detected, and the
gear is rejected.

When is Profile Projection Used?

✔ When high precision is needed, especially for complex shapes.


✔ Ideal for inspecting gears, screws, camshafts, and precision components.
✔ Works for both external and internal features.

Comparison of the Two Methods in Gear Inspection


Feature Shadow Projection Profile Projection

Purpose Quick shape check Detailed measurement

What it detects Missing teeth, outer shape errors Tooth angles, spacing, internal features

Speed Very fast Slower but precise

Precision Moderate Very high

Equipment Needed Light source, screen Optical comparator, digital software

Final Conclusion

In an automotive factory, they might first use Shadow Projection to quickly filter out
defective gears. Then, they use Profile Projection for detailed measurements on selected
samples to ensure perfect quality.

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