Incometer Topometer en 10037930

Dynamic systems for form measurement and surface inspection of engines

Precision is our business.

OPTICAL SYSTEMS LASERS & MATERIAL PROCESSING INDUSTRIAL METROLOGY TRAFFIC SOLUTIONS DEFENSE & CIVIL SYSTEMS

2Hommel-Etamic, the Industrial Metrology Division of

the Jenoptik Group, is a leading manufacturer and

system provider of high-precision, tactile and non-

tactile production metrology. The range of products

provided include total solutions for a wide range of

measurement tasks such as testing surfaces, form,

and determining dimensional tolerances throughout

all phases of the production process, for nal inspec-

tion or in a metrology lab. Our product portfolio is

rounded off by a wide range of services in consulting,

training and service, including long-term maintenance

contracts.

Hommel-Etamic. Precision is our business.

Precise measurement in engine development and

production

Our products are used in the automotive industry for

engine development - both for monitoring research

and development results and for quality control and

documentation. Our products are always up-to-date

with customer requirements. For over 25 years, major

engine manufacturers and their suppliers have been

using incometer and topometer products because they

trust their quality.

Measurement of distortion and wear of engines with

incometer technology

The piston ring and cylinder bore system has an essen-

tial in uence on the quality of modern internal combus-

tion engines. Insuf cient sealing of the combustion

chamber results in higher exhaust emissions, increased

oil consumption and increased wear. If the cylinder

bore deviates from its nominal shape, the piston ring

can only seal within the frame of its limited lling

capacity. This reduces with increasing form error of the

cylinder bore.

From early development until nal series production,

appropriate measurements and corresponding tests

concerning shape deviation of the cylinder bore are

necessary in order to guarantee the function of the

piston ring and cylinder wall system.

Our incometer systems create fast, reliable and precise

measurement data for the analysis of the cylinder

piston con guration.

Your partner for industrial metrology

Industrial Metrology

3Overview of our measuring systems

incometer V

Flexible measuring system for form and roundness

in cylinder bores. Measures cylinder distortion,

cylinder wear, temperature in uences and piston ring

dimensions in engine development and production.

incometer VS

Flexible measuring system for form and roundness.

Measures cylinder distortion, cylinder wear,

temperature in uences and piston ring dimensions

in small engines (e.g. 2-stroke engines).

incometer V110

Flexible measuring system with extended neck section

for form and roundness in cylinder bores. Measures

cylinder distortion, cylinder wear, temperature

in uences and piston ring dimensions, ideally in

extremely at V-engines.

incometer P

The multi-sensor head measures roundness and form in

engine production.

topometer for optical and tactile surface inspection

The topometer allows optical and tactile inspection of

the structure and roughness of ne-machined

(e.g. honed) surfaces in cylinder bores. It allows

complete identi cation of surface characteristics such

as honing angle, valley structure, blowhole size,

residual turning valleys, and roughness of cylinder bores

in development and production.

incometer for measuring form and roundness

Our incometer systems allow fast, precise measurement of form and roundness in cylinder bores. They are

particularly used for measurements of cylinder bores in combustion engines. Their small, compact design

enables them to be used as stationary tools in the measuring room or as mobile tools on the production line.

Measuring systems

4Flexible measuring system for form and roundness in cylinder bores

Measurement of

cylinder distortion

cylinder wear

temperature in uence

piston ring dimensioning

for engine development and production

Roundness

Straightness

Cylindricity

Parallelism

Inner diameter

Concentricity

The incometer V offers quick, accurate measure-

ments for analytic examination of cylinder piston

con gurations in engine block development.

Flexible and mobile

The incometer V has a compact design. Its clamping

mechanism makes it easy to adjust to various cylinder

dimensions, ensuring it can be used on a exible

and mobile basis during development and testing.

Its insensitivity to vibrations means it is also ideal for

measuring during production.

Convenient

The probes self-adjustment facility eliminates time-

consuming alignments of the workpiece. Any

eccentricities or inclined positions of the cylinder axes

to the measuring probe are automatically corrected

by the INCOWIN software.

incometer V

5Easy to use

The PC-driven system is controlled via the user-friendly

Windows Software INCOWIN. Measuring routines are

prede ned so only the appropriate values are

chosen and entered. This eliminates time consuming

programming. By changing the appropriate parts

(measuring tips and clamping jaws), the probe easily

adapts to different diameters.

Measurement of cylinder distortion

The incometer V is especially suited for measuring and

evaluating the in uence of cylinder heads and gaskets

on bore distortion in combustion engines.

It can be installed on the crankshaft side for measuring

in cylinder bores with a mounted cylinder head. The

wear rates and cylinder distortions can also be monitored

during long-term testing.

Temperature distortion

Simple xturing and high speed allow for measure-

ment of engine blocks, even under high temperature

conditions. This makes it possible to analyze the critical

warm-up phase, where there are extreme temperature

differences between cylinder head and engine block.

Probe V200 with electronics

External plate for xing the probe

Mounting device

and accessories

incometer V

Form measuring system for small cylinder bores

Measurement of

cylinder distortion

cylinder wear




Roundness Parallelism

Straightness Inner diameter

Cylindricity Concentricity

The incometer VS offers rapid and reliable measure-

ment with maximum precision for detailed testing of

cylinder bores on small engines. The system has been

developed on the basis of the invometer V. The large

range of diameters from 39-100 mm enables its use in

many different engine types.

Mature system

Thanks to the scanning measuring method with up

to 14,400 points per position and up to 40 positions

(as with the incometer V), the incometer VS delivers

maximum distortion information within the markets

fastest measuring times. This and the correction of the

inclination and eccentricity of the probe to the bore

make the system unique.

For small engines

The incometer VS has been specially designed for the

measurement and analysis of cylinder distortions of

small engines (e.g. 2-stroke engines). They are mainly

used in small agricultural and forestry appliances.

Other applications include compressors in large cooling

systems. The incometer VS is predominantly used in

measuring rooms for research and development, but

can also be used in production thanks to its design.

Simple and rapid use

The INCOWIN software allows for easy adaptation

and programming of the system through a menu. This

minimizes operator training and enables its simple and

effective use. Measurement data can be saved centrally

with a network connection and easily printed out via

the document assistant.

6

Isometric form

with 40 levels

Isometric form with

automatic masking-off

External plate for

xing the probe

incometer VS

7Flexible form measuring system for special engine block geometries

Measurement of

cylinder distortion

cylinder wear






Cylindricity Concentricity

The incometer V110 is a fast, reliable and highly accurate

way to determine measuring data for analytical testing

of the cylinder-piston con guration during engine

development for engines with very dif cult installation

requirements (e.g. extremely at V-engines).

Flexible and mobile

The incometer V110s compact design and clamping

mechanism make it easy to adjust to various cylinder

dimensions, ensuring it can be used on a exible and

mobile basis during development and testing.

Simple operation and handling

The PC-controlled system is operated by the convenient

Windows software INCOWIN. Measurement routines

are pre-de ned; only corresponding values are entered

and selected. As a result, there is no need for time-

consuming programming tasks. The device can be

adapted to different diameters quickly and easily by

changing accessory parts such as measuring tips and

clamping jaws.

Convenient

The probes self-adjustment facility dispenses with

time-consuming alignments of the workpiece. Any ec-

centricities or inclined positions of the cylinder axes to

the measuring probe are automatically corrected by the

INCOWIN software.

Measuring cylinder distortion and temperature

distortions

The incometer V110 has the same characteristics as the

incometer V in this area.

incometer V110

mounted on the crankshaft side

incometer V110

8Quick measurement of form in cylinder bores

Precision measurement in seconds of

roundness

form

in production areas



Cylindricity

The incometer P quickly and reliably generates

highly accurate data of cylinder bores, directly in the

production area.

Minimal concact

High demands are placed on the system during

production-related measuring. The incometer P has

minimal direct connection with the vibrating in uences

that disrupt the object being measured.

The automatic correction of inclinations and

eccentricities by the INCOWIN software means

there are no longer any lengthy adjustment

processes, which is a signi cant factor in production.

Flexible application

The replaceable measuring tips allow the system to

be modi ed to different bore diameters quickly,

which makes it ideal for exible production lines.

Probe with 5 sensors and electronics Protocol of a cylinder block measurement

incometer P

9Simple operation

The clearly structured INCOWIN software ensures that

operating the measuring system is easy, even with

no previous experience. Once the measurements

have been taken, all procedures such as saving and

printing the results and their statistical evaluation

can be performed automatically. The advanced user

administration (optional) allows hierarchical access to

the individual functions of the INCOWIN software.

Easy handling and fast measurement

To take a measurement, the incometer P is inserted into

the cylinder bore. Plastic guide rails are integrated into

the measuring head to avoid damage to the cylinder

wall. A centering collar on the incometer P unit and a

xture plate mounted on the engine block are coupled

together by a clamping lever. This ensures that the

incomter P is in the correct measuring position on the

engine block. After starting the measurement, the

head begins a scanning rotation of 360. Measurement

values from each sensor are taken simultaneously at a

constant speed. This means it only takes a few seconds

to measure the cylinder bore, and the measured values

are immediately available. The head can optionally be

used with up to seven sensors.

Mobile use

Thanks to its small size and light weight, the incometer P

is ideal for use on different production lines.

9

Inserting of the probe

Fixing of the probe

Radial plot of a cylinder boreIsometric plot of a cylinder measurement Axial plot of a cylinder bore

incometer P

10

The advantages of INCOWIN at a glance

Multi-tasking Windows application

User-friendly interface

Central data backup possible via network operation

Rapid setup of all customer speci c requirements

High-resolution scanning measurement

Software options for R&D and production

Optimum system portability with notebook PC

Upgrading of older systems possible

The control and evaluation software INCOWIN offers

all the advantages of the Windows environment:

A user-friendly interface, simple creation of new

measuring reports and network-compatibility for data

backup.

There are also several display options to make it easier

to analyze results. The screen and printout forms can

be designed freely and customized to your company.

Dynamic measurement

The system offers extensive measuring functions and is

equipped with a standardized high-resolution scanner.

It has a maximum of 14,400 steps and allows

evaluations of up to 1024 measuring points per

position. Scanned axial measurements are also

possible with a maximum of 600 measuring points per

millimeter.

This ensures a very high-resolution and detailed

representation of the actual geometry of the cylinder

bore. The high data density allows standardized lter

methods to be used (e.g. Fourier and Gauss lter or

median lter for eliminating individual outliers) with a

wide variety of choices.

Despite this high resolution, measuring time for

the scanning method is only approx. 10 seconds per

measurement position.

Control and evaluation software for incometer

Clearly arranged desktop

INCOWIN

11

Language selection

The INCOWIN software is available in three languages

(German, English, and French). You can select the

user language you require during the application. The

printing language can also be selected independently

of this setting.

Optimal mobility

The INCOWIN control and evaluation software can

be used in a multi-task environment. The overall logic

is generated on the INCO2 interface card, which is

installed in the EC110 electronics unit. A serial inter-

face cable is used to connect the computer and EC110

electronics unit, thereby enabling mobile operation of

the incometer system with a notebook.

Retro t possibilities

Measuring systems not equipped with the INCO2 inter-

face and the EC110 electronics can be retro tted at any

time. Depending on the age and technological status

of the system, the extent of the retro tting differs and

must be de ned individually.

Range of functions can be customized individually

The standard INCOWIN software version can be

enhanced by optional software packages to provide

customized functions, ensuring maximum transparency.

Of ine software (option)

This module allows external (of ine) evaluation and

analysis of measurement data on a separate computer.

Numerous support toolsPrint preview

INCOWIN

12

Wear measurement

To determine and measure the wear in TDC of cylinder

bores, the bore is measured in high-resolution with

equally distributed axial scans. Measurement results

can be displayed in a wide range of display options.

Measuring temperature distortion

Rapid cylinder measurement (only approx. 1-3 minutes)

means, it is also possible to use the incometer

to measure hot engines ( 100 C). Temperature

distortions can therefore be measured on live

objects, and not just simulated.

Fourier analysis

Distortions are calculated using the Fourier analysis

for a more precise description of the cylinder form.

Coef cients can be calculated for the 255th order and

displayed as a graph for better clarity.

Copy & paste/Data export

Graphs and parameter lists can easily be pasted into

other Windows applications to customize reports and

documentation. Alternatively, data can be exported

into a different format (jpg, txt, etc.).

Differentiation

For analyzing changes of the distortion with different

con gurations of the cylinder head, cylinder head seal,

and crank case, or for heat distortion evaluations, a

difference value for measurements that were carried

out at different times can be generated in order to

compare the results directly.

Data import

External data (Polar, Cartesian or as Fourier coef -

cients) can be imported into the INCOWIN software,

evaluated with the same algorithms as the normal

measurements, and compared with the incometer

measurements.

Software options for research and development

Wear measurement

Fourier analysis

Differentiation

INCOWIN

13

Block measurement and complete evaluation

For measuring a complete crank case with one-time

input of the reference data. The operator is guided

through the entire measuring procedure via diagrams.

All cylinder measurements of a crank case are saved to

a single le. The evaluation contains the printout of the

form parameters for all cylinders in a table and provides

a graphic display of the radial and axial measurement

and the isometries for all cylinders on one page. The

user can specify the maximum number of graphs per

page (max. 20).

Data transfer to qs-STAT

The qs-STAT-interface certi ed by Q-DAS allows the

measurement results to be transferred to a statistics

package for further process data analysis.

Determining the absolute diameter

For determining the absolute diameter of the cylinder

of a crank case. The incometer must be calibrated to

the nominal dimension of the cylinder diameter before

each measurement. This calibration is implemented in a

special support, which either has integrated calibration

rings or a support plate with integrated calibration rings

for assembly on the cylinder head seal surface. Another

option is production of a calibration cylinder with the

nominal dimensions of the cylinder bore.

Advanced user administration

For creating different users and user groups with their

own pro les. Individual users can each be assigned to a

speci c group. Access to the software can be protected

for each user by a personal password.

Automatic functions

For automating processes such as data backup,

printing, etc., in order to reduce errors resulting from

incorrect inputs or user mistakes.

Software options for production

Block measurement

qs-STAT-interface

User administration

INCOWIN

14

Surface inspection system for cylinder bores

Measurement and assessment of surface features

such as

Crosshatch-angles

Dimension of surface structure

Area of blowholes

Stroke reversal radius

Laser honing structures

Roughness

of cylinder bores in R&D and production areas

The topometer is the ideal inspection system for fast,

precise, and reliable testing of nely machined

(e.g. honed) surfaces of cylinder bores during develop-

ment, tests and production. Optical testing of

surface structure characteristics and tactile testing

of surface roughness is carried out using a compact

measuring probe.

High exibility

The topometer is available in two versions: The basic

model for pure optical testing, and the advanced

version, which includes roughness measurement. It is

possible to upgrade the basic model with the func-

tions from the advanced version. The probes have a

working length of 150 mm or 210 mm, and can be

used in bores from 60 mm cylinder diameter. Different

bore diameters can be modi ed by simply replacing

adapter collars. These are also used for positioning and

centering the probe.

Easy handling

The complete system is controlled centrally via a PC

that is equipped with additional circuit boards for

digital image processing and roughness measurements.

The TOPOWIN software is clearly structured and guides

the user through the measuring program step-by-step.

topometer

15

All important functions (e.g. motorized axial positioning

or setting the zoom and regulating illumination) are

either carried out directly on the probe itself or using

the input function on the PC. The radial positioning of

the probe in the cylinder is set manually. As soon as

the probe is inserted into the cylinder bore, the

enlarged image of the surface appears on the monitor.

Complete evaluation of the cylinder surface

With a great number of optical measurements and

roughness analyses at every desired position, the

system allows a complete evaluation of the cylinder.

Other standards are also available. Sensitive, adjustable

light sources provide good illumination of the surface

section to be inspected.

Mobile use in production

The topometer size and weight mean the system is

ideal for mobile use on site. A special mobile workshop

vehicle ensures the system can be transported easily

within the production area.

Industrial housing for use in production environments

Lighting unit and roughness probe

topometer

Display of surface roughness pro leDisplay of the cylinder surface, angle de nition

16

The user-friendly TOPOWIN software enables measure-

ment of such values as the honing angle, mean width

of the pro le elements and the curve radii, and the size

of silicon crystals, blowholes or other defects.

Optical measurements and roughness measurements in

the optical range are possible via automatic reposition-

ing of the probe. The results are available on the screen

within a few seconds and can then be documented.

High inspection rates

A reference eld with the respective tolerance widths

is displayed on the screen for fast inspection of the

honing angle. The user places the reference image at

the crossing of an angle and can determine whether

the target honing angle is correct.

Documentation

A color printer provides an immediate printout of the

screen section, including the reference lines displayed

and the determined measurement data of the surface.

The numerical and graphical output of the roughness

indicators and the pro les can be combined with the

screen evaluations in one report to provide compact

and informative documentation.

Data transfer to qs-STAT (option)

The qs-STAT-interface allows measurement results

to be transferred to a statistics package for further

analysis.

Control and evaluation software for topometer

Main window

Measurement functions

main window

TOPOWIN

17

Measurement and evaluation of laser-structured surfaces

(option)

In combustion engines, grooves can be cut into the upper

reverse area of the piston with a laser to reduce wear

rates. This creates a higher oil pressure volume for improved

lubrication of the piston rings.

This software module makes it easy to determine the geo-

metric dimensions of the laser hone structures. A measuring

assistant guides the user through the measuring process.

Automatic positioning at preselected inspection heights

(option)

This software module allows the user to preselect speci c

measuring heights, which are then used to automatically

carry out a sequence of several roughness measurements.

Analysis of laser hone structures

TOPOWIN

Sample printout

18

Technical data

HOMMEL-ETAMIC incometer incometer V incometer VS incometer P V80 V115 V150 V200 V110 VS100 P100

Diameter of the cylinder* 65 155 mm 39 100 mm 60 110 mm

Clamping length min. 20 mm 20 mm 25 mm 30 mm 40 mm ext. xture ext. xture

Axial measuring range 80 mm 115 mm 150 mm 200 mm 110 mm 100 mm max. 300 mm

Measuring path on the circumference 360 360 360

Radial measuring range 400 m 500 m 500/1000 m***

Resolution 0.1 m 0.1 m 0.1 m

Number of measured values per rotation 14,400/1,024 14,400/1,024 14,400/1,024

Number of sensors 1 1 max. 7

Repeating accuracy

Roundness 1.0 m 1.0 m 1.0 m

Cylinder form 1.5 m 1.5 m 1.0 m

Parallelism 1.5 m 1.5 m

Measuring accuracy

Roundness 1.0 m 2.0 m 1.0 m

Cylinder form 1.5 m 2.0 m 1.5 m

Parallelism 1.5 m 2.0 m

Temperature range of use** 20 40 C 20 40 C 20 40 C

Power supply 230 V / 50 Hz 230 V / 50 Hz 230 V / 50 Hz

115 V / 60 Hz 115 V / 60 Hz 115 V / 60 Hz

Power consumption 150 W 150 W 150 W

Weight of the sensor 2.9 kg 1.9 kg 8 kg***

* Further diameters on demand ** Measuring of the warm distortion on demand (up to 130C) *** Dependant on diameter

Product range for incometer min/max Height / Depth Width of part Laboratory Of ine

Cylinder bore 39 155 mm 200 mm 200 mm incometer VS incometer P incometer V

Cylinder liners 39 155 mm 200 mm 200 mm incometer VS incometer P incometer V

Camshaft bearing bore 39 100 mm 100 mm 100 mm incometer VS

incometer

19

Technical data

HOMMEL-ETAMIC topometer O150 / O210 OR150 / OR210

Diameter* 60 110 mm

Axial measurement length 150 / 210 mm

Optical zoom 30 120 times (on the screen)

Test zone (approx.) 40 times: 5.0 x 5.0 mm

100 times: 1.1 x 1.0 mm

120 times: 0.8 x 0.8 mm

Resolution CCD camera 752 (H) x 582 (V)

Presentation on the screen 512 (H) x 512 (V)

Illumination Direct / indirect

Axial position Motor-driven

Radial position Manual

Focus adjustment Motor-driven

Power supply 230 V / 50 Hz

115 V / 60 Hz

Power consumption 200 W

Operating modes Scanning mode Scanning mode

Measuring mode Measuring mode

Roughness measuring

Evaluation (optic) Hone angle

Stroke reversal radius

Spaces / width of grooves

Detection of porous spots

Tolerance zone (angle)

Metric / inch

Laser structure (optional)

Evaluation (Roughness) All standard parameters

according to DIN and ISO such as

Ra, Rpk, Rvk, Tpi etc.

Documentation Axial height of view

Set magni cation

Date / time

Parts identi cation

* Further diameters on demand

topometer

1003

7930

0

4/2

00

9

Subject to change without notice.

Group companies, af liates and representation worldwide

www.hommel-etamic.com

GermanyFranceSwitzerland

Our global presence.SpainCzech RepublicUnited States

MexicoChinaSouth KoreaIndia

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Incometer Topometer en 10037930