Surface Topography Characterization Using a Simple Optical Device and Artificial Neural Networks

State-of-the-art methods for quantifying wear in cylinder liners of large internal combustion engines for stationary power generation require disassembly and cutting of the examined liner. This is followed by laboratory-based high-resolution microscopic surface depth measurement that quantitatively evaluates wear based on bearing load curves (also known as Abbott-Firestone curves). Such reference methods are destructive, time-consuming and costly. The goal of the research presented here is to develop nondestructive yet reliable methods for quantifying the surface topography. A novel machine learning framework is proposed that allows prediction of the bearing load curves representing the depth profiles from reflection RGB images of the liner surface. These images can be collected with a simple handheld microscope. A joint deep learning approach involving two neural network modules optimizes the prediction quality of surface roughness parameters as well. The network stack is trained using a custom-built database containing 422 perfectly aligned depth profile and reflection image pairs of liner surfaces of large gas engines. The observed success of the method suggests its great potential for on-site wear assessment of engines during service.