Gear contours in silhouette: isolate teeth, bore and openings
A blue backlight turns the gear into a dark outline against a bright field. The source image exposes the tooth perimeter, centre bore and circular openings together, providing a clear starting point for a contour-inspection trial.
A clean silhouette supports edge finding; calibration makes those edges useful for gauging.
Real camera capture
- MethodBlue transmitted backlight
- EvidenceReal application-lab capture
- SetupSource light identified; imaging kit proposed
- AcceptanceValidate on your own parts
Explore it in 3D
Camera and available lens CAD are published models. Lens and light envelopes use printed dimensions. The linked station uses its published base size and column height; carriage, brackets, fittings, parts and spacing are illustrative. Confirm load, travel, fasteners and clearances before ordering. Light paths explain the arrangement and do not simulate optical performance. Representative part geometry is illustrative, not reconstructed inspection evidence.
Lighting application-lab catalog capture
What the camera saw
Cropped from the source test sheet; original test annotations are retained. Captures are not generated or enhanced. Drag a comparison slider, or open any image full size.
The challenge
Bright metal finish can hide where a tooth ends when front lighting produces local glare.
A usable outline still needs distortion calibration, a stable part plane and a defined reject condition.
How it was solved
Place the gear between the blue LS-BKL-0725 and the camera so the outside edge interrupts the illuminated field.
Use the proposed camera and macro lens to test contour extraction. For tight absolute tolerances, evaluate telecentric optics and a calibrated measurement process separately.
The proposed full-sensor field at 0.03x exceeds the light area. Use a centred 2400 × 1700 px software inspection crop (276 × 195.5 mm) within the illuminated region; the 3D viewing volume shows that inspection region. This does not require a camera hardware-ROI mode.
Why it works
- 1
Transmission reduces dependence on the reflective finish of the gear face.
- 2
The same silhouette can expose missing material and hole placement, but the supplied image is not a gauge repeatability study.
Lighting application-lab catalog capture
Evidence you can inspect
The tooth perimeter, centre opening and circular holes are visible as high-contrast edges.
The source captions this trial as gear dimension inspection with LS-BKL-0725 in blue; no numerical accuracy is stated.
A source imaging example, not proof of a calibrated gear-measurement system or a specified minimum tooth defect.
From image contrast to a production decision
What to validate on your part
- 01
Cover the tooth variation
Include acceptable chamfers, burrs and finish variations alongside known damaged teeth.
- 02
Calibrate at the part plane
Use a traceable target and check scale and distortion across the full gear image.
- 03
Repeat the placement
Measure sensitivity to part height, tilt and rotation before defining dimensional limits.
From the demo to your test bench
Parts in this setup
LightTested
LS-BKL-0725
300 x 200 mm Side back light source (LS-BKL-0725)
Blue 300 × 200 mm side backlight identified in the gear example; printed housing 332 × 232 × 10.5 mm.
$719.00
In proposed setup
CameraOur pick
MV-CS050-10GM(NPOE)
Hikrobot MV-CS050-10GM(NPOE) 5 MP GigE area scan camera, IMX264, Gen 2 basic version, Mono, Without PoE
5 MP monochrome global-shutter camera for a bench contrast trial; confirm sampling, sensitivity and exposure on the actual part.Not available in the United States. Available for delivery to other countries.
$819.00
In proposed setup
LensOur pick
LS-FFL-1454
16mm, F2.8, 1.1", C-mount, Macro lens (52 mm (-0.25X) to 546 mm (-0.03X)) (LS-FFL-1454)
Proposed 16 mm C-mount macro lens. The illustration uses its printed 0.03x magnification at 546 mm working distance. The proposed camera sensor gives a derived 281.52 × 235.52 mm field. Confirm field, focus and residual distortion on the actual sample; this is not calibrated measurement accuracy. Inspect only a centred 2400 × 1700 px software crop (276 × 195.5 mm) inside the backlight area; the whole sensor field is not illuminated.
$319.00
In proposed setup
Camera test stationOur pick
LS-MNT-0101
Camera stand with XZ adjustment and glass tray, height 800 mm (LS-MNT-0101)
800 mm column, 600 × 450 mm breadboard, XZ adjustment, glass tray and two lighting holders as listed. Proposed bench fixture; confirm loads, travel and camera/lens clamps.
$629.00
In proposed setup
"Tested" identifies the part named in the source. "Our pick" is a proposed alternative or supporting part. Confirm colour, optics, controllers, power supplies, cables and mounting before ordering.
The set-up
| Lighting | Blue transmitted backlight |
|---|---|
| Test light | LS-BKL-0725, blue |
| Emitting area (printed) | 300 × 200 mm |
| Camera and lens | Source versions not identified; current proposed parts below |
| 3D spacing | Illustrative, to be confirmed on the sample |
| Derived proposed field | 281.52 × 235.52 mm = sensor dimensions / 0.03x; source field not supplied |
| Illuminated inspection ROI (proposed) | 2400 × 1700 px software crop = 276 × 195.5 mm at 0.03x; full sensor field extends beyond this light, so exclude the unilluminated margins |
| Mounting (proposed) | LS-MNT-0101; 800 mm column, 600 × 450 mm base, glass tray and two light holders |
Mount the optics with intent
The station is an optical test bench, with its two lighting holders included in the catalog listing. The 3D column and base follow the published height and footprint. Carriages, clamps and part supports are schematic: confirm camera screw pattern, lens support, light fasteners, permissible load and actual travel before ordering.
Complete the electrical system
Select a controller against the exact light voltage, drive mode and power, then confirm camera data/power/I/O cables and a suitable PC. These are not silently added to the proposed optical kit.
Build this system
Start from this setup, adapt it to your part.
The configurator opens with this study's camera, lens, light and station picked. Swap any part, check fit and price, then buy or ask for a quote.
Camera and available lens CAD are published models. Lens and light envelopes use printed dimensions. The linked station uses its published base size and column height; carriage, brackets, fittings, parts and spacing are illustrative. Confirm load, travel, fasteners and clearances before ordering. Light paths explain the arrangement and do not simulate optical performance. Representative part geometry is illustrative, not reconstructed inspection evidence.
Metal parts and machining
Related case studies
Metal parts and machining
Spring-window appearance in a clutch plate
Use the spring-window pattern for appearance and prove mechanical function separately.Light in sourceLS-BKL-1302 · whiteExplore the study
Metal parts and machining
Cutting-bit end-face appearance
Prove the local end-face signal before assigning a wear or damage threshold.Light in sourceLS-SDL-0045 · blueExplore the study
Metal parts and machining
Scratch contrast on a machined cylinder
A curved surface needs a tested angular coverage plan.Proposed light housing (spec)440 × 50 × 117.13 mmExplore the study
Make the next trial specific.
Tell us the part size, smallest defect or tolerance, available working distance, material and line speed. Include what a good part and a reject look like.
About this case study: the photos and camera images come from the application laboratory of the maker of the lighting and optics we sell, imaged on the parts shown; your results depend on your part, camera and set-up. This is an application-lab study, not a LumaSpec customer deployment. Source figures are reported results; proposed components require a fresh trial. The 3D scene illustrates the arrangement and does not simulate imaging performance.