Physically running a diamond point across a ground metal component provides direct, repeatable surface profile data. The pocket-sized QualiSurf™ I carries out this measurement using a 5 µm diamond stylus paired with a piezoelectric pickup transducer. Here is what takes place beneath the instrument housing during a test run:
[ 5µm Diamond Stylus Dragging Across Metal ]
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┌──────────────────────────────────────────────────┐
│ Piezoelectric Pickup Transducer │
│ (Translates physical motion to clean voltage) │
└────────────────────────┬─────────────────────────┘
│
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┌──────────────────────────────────────────────────┐
│ High-Speed DSP & RC Analog Filter │
│ (Wipes away broad surface waves) │
└────────────────────────┬─────────────────────────┘
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┌──────────────────────────────────────────────────┐
│ OLED Display & Audio Beep Indicator │
│ (Outputs instant Ra, Rz, Rq, and Rt parameters) │
└──────────────────────────────────────────────────┘
- The Piezoelectric Transducer Sensor: As the 5 µm diamond tip glides over microscopic peaks and ditches on your metal component, it applies mechanical force to an internal crystal assembly. That physical motion converts directly into a clean electrical signal that shifts with every tiny surface bump.
- DSP Processing & Audio Beep Status: The internal high-speed processor digitizes the voltage signal and triggers an audible beep signal informing the operator as soon as each measurement cycle completes.
- Filtering Micro-Scratches From Waviness: Quality inspection focuses on the tiny scratch marks left by cutting tools rather than broad component curvature. The internal RC analog filter applies standard cut-off limits, such as 0.25 mm, 0.80 mm, or 2.50 mm, to filter out broad structural waves, isolating the fine microscopic surface texture.
Tactile Profilometer Hardware Configurations
Depending on workpiece access and inspection location, tactile contact profilometry utilizes specific hardware setups:
| Instrument Variant | Operating Configuration | Primary Practical Advantage | Ideal Shop-Floor Application |
|---|
| Pocket-Sized Integrated Stylus (QualiSurf™ I) | Integrated 5 µm diamond tip with internal piezoelectric pickup | Maximum mobility; operates horizontally, vertically, or upside down | On-site inspection of shafts, flat stock, and open grooves |
| Detached Split-Type Probe (QualiSurf™-600) | Main processing unit separated from the probe via an extension cable | Easy access inside cramped engine compartments or tight internal recesses | Narrow bores, deep channels, and crowded machine setups |
| Multi-Parameter System (QualiSurf™ II / II-S) | Advanced tactile pickup supporting up to 45 parameters with graphical display | Detailed profile analysis for factory metrology rooms and full batch records | Formal QA/QC labs and comprehensive audit reporting |
Core Surface Roughness Parameters (Ra, Rz, Rq, Rt)
The bright OLED screen on the QualiSurf™ I reports four standardized roughness metrics:
- Ra (Arithmetic Average Roughness, ISO): The primary global benchmark. It calculates the mean height variation across all peaks and valleys within the evaluation length, providing a single balanced summary score.
- Rz (Maximum Profile Height, DIN): Evaluates the peak-to-valley distances across sampling lengths. It immediately highlights isolated tool marks or deep scratches that an average score might mask.
- Rq (Root Mean Square Roughness, RMS): Squares the height deviations before averaging. This assigns greater weight to deep scratches, making it ideal for detecting unexpected surface flaws.
- Rt (Total Peak-to-Valley Height): The total vertical distance between the highest peak and the deepest valley across the entire continuous evaluation length.
Calibration & Metrology Standards Compliance
To maintain lab-grade precision on active production lines, tactile roughness testers rely on direct reference block calibration and standardized filtering algorithms:
- Single-Touch Keypad Calibration: Placing the stylus on a certified reference block and pressing the front-panel CAL button prompts the internal processor to adjust its gain matrix to match factory specs.
- Adherence to Global Standards: Internal processing algorithms strictly follow established international metrology standards, including ISO 4287, ISO 4288, ISO Class 3 limits, DIN 4768, JIS B0601, and ANSI B46.1. This ensures that shop floor readings correspond directly to specifications used by suppliers worldwide.
Workpiece Geometry & Multi-Directional Operation
Machined components feature varied profiles that require adaptable sensor positioning:
- Flat Surfaces: Ground, milled, or lapped metal plates and blocks.
- Cylindrical & Conical Profiles: Outer turned shafts, rollers, pins, and outer cones.
- Grooves & Recesses: Internal channels and slot features wider than 80 × 30 mm.
With its versatile housing design operating horizontally, vertically, or anywhere in between, the QualiSurf™ I allows operators to verify CNC parts, turned shafts, and incoming raw stock directly on the shop floor.
