Automotive Motor Shaft Runout Detection with VM-S-100
1. Project Requirements and Specifications
Measurement Parameter: Shaft radial runout
Shaft Diameter: 5mm
Rotational Speed: 2 revolutions per second (120 RPM)
Accuracy Requirement: 10μm (0.01mm)
Integration: Production line automated equipment
Environmental Conditions: Industrial manufacturing environment
2. Technical Solution Design
2.1 Optical System Configuration
Two VibroMicro VM-S-100 units arranged orthogonally (90° configuration)
Right-angle mirrors installed at laser output ports
Compact optical path design for space-constrained production environments
2.2 Measurement Principle
Dual-laser differential measurement technique
Real-time acquisition of X and Y axis displacement data
Synchronized sampling at 100 kHz sampling rate
Circular trajectory reconstruction from orthogonal components
3. System Implementation
3.1 Hardware Integration
Sensing System:
2 × VibroMicro VM-S-100 Laser Doppler Vibrometers
Precision right-angle mirror mounts
Vibration-isolated optical platform
Mechanical Integration:
IP54-rated protective enclosures
Quick-disconnect mounting interfaces
Integrated air purge system for optical surfaces
Control System:
Industrial PLC for equipment synchronization
High-speed data acquisition cards
Real-time processing industrial computer
3.2 Software Architecture
Data Acquisition Module:
Synchronized dual-channel sampling
Real-time data buffering and processing
Automatic trigger synchronization with rotation
Analysis Algorithm:
# Real-time runout calculation
def calculate_runout(x_displacement, y_displacement):
# Circular trajectory reconstruction
instantaneous_radius = np.sqrt(x_displacement**2 + y_displacement**2)
# Runout analysis
runout_value = np.max(instantaneous_radius) - np.min(instantaneous_radius)
return runout_value
Quality Judgment:
Real-time runout value display
Automatic pass/fail determination
Statistical process control (SPC) data output
4. Performance Validation
4.1 Accuracy Verification
Reference Standard: Laser interferometer calibration
Measurement Repeatability: ±2μm
Reproducibility: ±3μm
Long-term Stability: ±4μm over 8-hour operation
4.2 Production Line Performance
Cycle Time: 3 seconds per measurement
Uptime: >99.5%
False Acceptance Rate: <0.1%
False Rejection Rate: <0.5%
5. System Advantages
5.1 Measurement Performance
Non-contact Operation: No mechanical loading on shaft
High Resolution: 1μm displacement resolution
Wide Bandwidth: DC to 20kHz frequency response
Absolute Measurement: Independent of surface characteristics
5.2 Production Suitability
Robust Design: Suitable for industrial environments
Easy Integration: Standard industrial communication interfaces
Low Maintenance: No consumables or regular calibration
Flexible Configuration: Adaptable to different shaft sizes
5.3 Quality Assurance
Quantitative Data: Objective measurement results
Complete Traceability: Data logging for each unit
Real-time Monitoring: Instant fault detection
Process Control: SPC capability for trend analysis
6. Implementation Results
6.1 Measurement Data
Typical Runout Values: 15-25μm for qualified products
Rejection Threshold: >35μm
Measurement Consistency: σ < 2μm within batch
6.2 Production Impact
Quality Improvement: Reduced field failures by 65%
Cost Reduction: Decreased manual inspection labor by 80%
Efficiency Gain: Increased testing throughput by 400%
Process Control: Enabled real-time manufacturing feedback
7. Conclusion
The dual-VibroMicro VM-S-100 orthogonal measurement system provides an optimal solution for automotive motor shaft runout detection in production environments. The non-contact approach ensures measurement accuracy while withstanding industrial conditions. The system meets all specified requirements for accuracy, speed, and reliability, delivering significant improvements in quality control efficiency and product reliability. This configuration can be readily adapted to various rotating component inspection applications throughout the automotive industry.
