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Technical Cleanliness Analysis (TCA)

This module enables you to evaluate particulate contamination on prepared specimen. The following standards for component cleanliness, oil cleanliness and cleanliness of medical products are supported:

  • VDA 19.1
  • ISO 16232
  • ISO 4406
  • ISO 4407
  • GB/T 14039
  • GB/T 20082
  • NAS 1638
  • SAE AS 4059
  • VDI 2083 (Blatt 1)

Overview

Technical Cleanliness Analysis (TCA) is a software module to evaluate the technical cleanliness of engine components, medical devices, and of fresh and used oils and lubricants.

Example: Technical Cleanliness Analysis (TCA) results of component cleanliness analysis: The gallery shows the detected objects classified by type and ordered top down by length with the option to switch between the display of particle type metallic-shiny (M), non-shiny (N), fibers (F) and artifacts (A). The corresponding particle types for oil cleanliness analysis are fiber (F), particle (P) and artifacts (A).
Example: Technical Cleanliness Analysis (TCA) results of component cleanliness analysis: The gallery shows the detected objects classified by type and ordered top down by length with the option to switch between the display of particle type metallic-shiny (M), non-shiny (N), fibers (F) and artifacts (A). The corresponding particle types for oil cleanliness analysis are fiber (F), particle (P) and artifacts (A).

You can perform rapid particle inspection and revision by using dedicated result views with various filter and sorting options.

Overview of Functionality

The following functional scope is covered.

Functional scope of software module ZEN core Technical Cleanliness Analysis (TCA)

  • Job templates for measurement of particulate contamination with image acquisition and as alternative from earlier acquired images. The result calculation is based on standard templates which can be adapted in the Standard Template Editor.
  • The workflow covers the following:
    • Image acquisition
    • Image analysis
    • Image processing
    • Standard-based result calculation
    • Result presentation in interactive views for fast inspection and revision of detected particles
    • Reports with results of characteristic values and standard specific methods per tested specimen
    • Automated storage of generated results in the data archive
    • Inspection and export of archived data

Functional scope for Correlative Technical Cleanliness Analysis (TCA)

In addition to the described functional scope for TCA, the following features are part of a correlative Technical Cleanliness Analysis workflow:

  • Holder calibration with L-markers.
  • Automated selection of particles from the standard template editor for SEM/EDS analysis.
  • Manual selection of particles from the gallery in the size distribution view for SEM/EDS analysis.
  • Joint particle selection table from 2. and 3. as input for S&F Find (List) tool.

Applications in Technical Cleanliness

Component Cleanliness

This application is used for evaluation of particulate contamination on inner and outer surfaces of engine components originating from the production process and environmental conditions.

The degree of surface contamination with residual dirt particles is directly linked to the function and lifetime of the engine components. Component cleanliness testing helps reducing engine failures and start-up breakdowns and improves the product quality.

The inspection is an indirect test method that requires a sampling step in which a test lot of the pre-cleaned component is taken and cleaned under defined conditions once more again. The resulting extraction fluid is filtered by a laboratory process and the residual dirt particles are collected on a filter membrane.

The particle distribution is analyzed in terms of size and type, and are expressed in cleanliness classes (level).

Relevant industrial sectors: automotive industry, automotive supplier chain, service labs, facilities for testing and verification, as well as aviation and space industry.

Environmental Cleanliness

This application is used for monitoring the cleanliness of the production environment and helps identifying potential particle sources. Processes and influencing variables which might be a source for particulate contamination can be identified, documented and monitored to guarantee clean manufacturing.

To validate the environmental and air cleanliness several particle traps are distributed close to the manufacturing and assembly sites. After a defined time period the particle traps are collected and analyzed.

The particle distribution is analyzed in terms of size and type, and are expressed in cleanliness classes (level).

Relevant industrial branches: automotive industry, the automotive supplier chain, service labs, facilities for testing and verification, as well as aviation and space industry.

Oil Cleanliness

This application is relevant for direct testing of fresh and used oils (mineral, synthetic, hydraulic) and lubricants for engines, gear boxes and hydraulic systems.

The presence of particulate contamination in lubricating and hydraulic oils interferes with its ability to lubricate and causes wear to the components. The level of contamination in the liquid has a direct bearing on the performance and reliability of the system.

For the analysis a defined amount of oil or lubricant is filtered by a laboratory process and the remaining particles are collected on a filter membrane. The particle distribution is analyzed in terms of size and type and are expressed in cleanliness classes (level).

Relevant industrial branches: the oil and lubricants manufacturer, the automotive industry, service labs, facilities for testing and verification, as well as aviation and space.

Cleanliness of Medical Devices

This application is used for evaluation of particulate contamination on medical devices originating from the production process and environmental conditions.

The degree of surface contamination with residual dirt particles might affect the tissue compatibility in terms of transplantation and the function of medical devices. Testing of cleanliness of medical devices can help reducing tissue intolerance or rejection and optimizing product quality.

The inspection is an indirect test method that requires a sampling step in which a test lot of the pre-cleaned medical device is taken and cleaned under defined conditions once more. The resulting extraction fluid is filtered by a laboratory process and the residual dirt particles are collected on a filter membrane.

The particle distribution is analyzed in terms of size and type, and are expressed in cleanliness classes (level).

By default, testing of medical products should be combined with the GxP module.

Correlative Analysis in Technical Cleanliness

This application is used for correlative analysis of particulate contamination on membrane filters and delivers complementary particle results depending on the used instrument. The correlative workflow starts with light microscopy (LM) analysis for particle detection and continues with electron microscopy (EM) and energy dispersive spectroscopy (EDS, often also called EDX) for extended material characterization on selected potential critical particles.

EM/EDS analysis extends the achievable results for LM analysis by reliable material characterization based on the element composition. The correlative approach results in an unique identification of metallic particles.

Introduction to Standards

VDA 19 Part 1; Inspection of Component Cleanliness

Particle Size Class

Size x in µm

B

5 ≤ x < 15

C

15 ≤ x < 25

D

25 ≤ x < 50

E

50 ≤ x < 100

F

100 ≤ x < 150

G

150 ≤ x < 200

H

200 ≤ x < 400

I

400 ≤ x < 600

J

600 ≤ x < 1.000

K

1.000 ≤ x < 1.500

L

1.500 ≤ x < 2000

M

2.000 ≤ x < 3.000

N

3.000 ≤ x

1. Particle Concentration Classification

Depending on the normalization parameter the particle count per size class is expressed in cleanliness level as shown in the table:

Cleanliness Level

Particle Count
per 1000cm2 or 100cm3
up to including

00

0.00

0

1.00

1

2.00

2

4.00

3

8.00

4

16.00

5

32.00

6

64.00

7

130.00

8

250.00

9

500.00

10

1000.00

11

2000.00

12

4000.00

13

8000.00

14

16000.00

15

32000.00

16

64000.00

17

130000.00

18

250000.00

19

500000.00

20

1000000.00

21

2000000.00

22

4000000.00

23

8000000.00

24

16000000.00

> 24

∞

2. Normalization

The absolute particle number is divided by a normalization factor:

  • Number of components N
  • Wetted component area A or
  • Wetted component volume V

Number of Components (N)

absolute number of particles / component number = normalized particle numbers
Result expression: normalized particle numbers

Wetted component area (A) in mm2

absolute number of particles / wetted component surface and normalization to standard area:*1000 cm2
Result expression: normalized cleanliness code

Wetted component volume (V) in cm3

absolute number of particles / wetted component surface and normalization to standard area*100 cm3
Result expression: normalized cleanliness codes

Example:

The cleanliness codes always refer to normalized and standardized particle results.

  • Number of components = 10
  • Wetted component Area = 200 cm2
  • Wetted component Volume = 50 cm3

Method: Standard Analysis

The standard analysis is fully parameterized from component extraction to filter analysis.

Advantages: The standard analysis has a good degree of result compatibility and is system and operator independent. No further agreement between customer and supplier is required.

Parameter

Description

Measurement of
particles

Length and/or width ≥ 50 µm

Length

Feret Max

Width

Feret Min

Relative image brightness

50 - 60%. Default value: 55%

Relative threshold

70%

Particle typification

Metallic shine as option (Multi Channel 90°/135°)

Contrast

Polarized light

Particle type class All does exclude fibers by default.

Specific fiber criterion based on elongated fiber length and maximum inner circle

Calculation on complete measurement area (effective filter diameter)

For more information, see Concept of Relative Image Brightness and Relative Threshold.

Method: Extended Analysis - Free Analysis

The extended analysis - free analysis is applied whenever supplementary particle information is required:

  • Smaller particle size classes
  • Particle height measurement

Any changes from the standard method must be documented in detail. You can use the extended analysis with the scope of the following:

  • Cause study for critical particles
  • Process optimization
  • Cleanliness specification beyond standard analysis, for example smaller size classes or 3rd dimension.

Parameter

Description

Measurement of particles

Length and/or width ≥ 5 µm

Length

Feret Max

Width

Feret Min

Individual relative image brightness

50 - 60%. Default value: 55%. Can be defined individually.

Individual relative threshold

70%. Can be defined individually.

Particle typification

Metallic shine as option (Multi Channel 90°/135°)

Contrast

Polarized light

Particle type class All does exclude fibers by default.

Specific fiber criterion based on elongated fiber length and maximum inner circle

Calculation on complete measurement area (effective filter diameter)

Default Values for Particle Typification

Parameter

Description

Metallic-Shiny

(Mean gray value > 200.0) or (Max. gray value ≥ 240.0)

Non-Shiny

Objects which are not fiber and not metallic-shiny.

Fiber

(Max. Inscribed Circle ≤ 50.0) and (Fiber Length/Max. Inscribed Circle > 20.0)

As a Supervisor, you can edit the values in the Standard Template Editor, see Standard Template Editor.

Occupancy Rate

The occupancy rate is a measurement value to describe the quality of the specimen preparation in terms of particle density, and the distribution of particles on the effective filter area. The calculation is performed as follows:

Sum of the particle area of all detected particles in relation to measurement frame area. Value in %.

For more information, see

3. Core parameter for size class distribution

Length = Feret Max (default use case), see Feret Maximum

Width = Feret Min (default use case), see Feret Minimum

Maximum inscribed circle = The largest circle that can be inscribed inside an area, see Diameter Maximum Inscribed Circle Filled

Fibers, see Fiber Length

VDA 19.2 Technical Cleanliness in Assembly - Environment, Logistics, Personnel and Assembly Equipment

The Illig method, as described in the VDA 19.2 standard, is used to test the cleanliness of a certain location with its environmental conditions, e.g., air or working benches. By means of particle traps the amount of sedimented particles per time unit (Illig Value) can be analyzed.

The detected particle number per size class is multiplied by a weighting factor, see the first table, summed up and normalized to calculate the Illig value, see table Illig weighting factors. The sum value is normalized to an area of ​​1000 cm2 and related to a measuring time of 1 h. The result is the Illig Value. The calculated Illig value creates a comparison basis for the collected particulate contamination at different locations over a certain time periode. With the Illig formular, larger particles are stronger weighted than smaller ones, because it is more likely that the larger ones have a higher damage potential.

Particle Size Class

Size x in µm

Weighting Factor

B

5 ≤ x < 15

0

C

15 ≤ x < 25

0

D

25 ≤ x < 50

0

E

50 ≤ x < 100

1

F

100 ≤ x < 150

4

G

150 ≤ x < 200

9

H

200 ≤ x < 400

16

I

400 ≤ x < 600

64

J

600 ≤ x < 1.000

144

K

1.000 ≤ x

400

Example calculation: Illig weighting factors

Size x in µm

Result

Weighting Factor

Weighted Particle No.

5 ≤ x < 15

--

0

0

15 ≤ x < 25

--

0

0

25 ≤ x < 50

1620

0

0

50 ≤ x < 100

374

1

374

100 ≤ x < 150

57

4

228

150 ≤ x < 200

43

9

387

200 ≤ x < 400

15

16

240

400 ≤ x < 600

7

64

448

600 ≤ x < 1.000

2

144

288

1.000 ≤ x

3

400

1200

Result:

3165

Normalized for 1000 cm2 and 1 h × 0.39 *

1234

Illig Value [1/1000] cm2 h

Applying the Illig formular

1h / measuring time [h] × 1000 cm2/ measuring area [cm2] = 0.39

Time of sedimentation: 1 week = 168 h
Measuring area (лr2) 15.2 cm2

Measuring area: Filter membrane area used for analysis.
Sedimentation time [h]: Defined the time frame of the sample exposure to air.

VDI 2083 Part 21; Cleanroom Technology. Cleanliness of Medical Devices in the Manufacturing Process

Particle Size Class

Size x in µm

B

5 ≤ x < 15

C

15 ≤ x < 25

D

25 ≤ x < 50

E

50 ≤ x < 100

F

100 ≤ x < 150

G

150 ≤ x < 200

H

200 ≤ x < 400

I

400 ≤ x < 600

J

600 ≤ x < 1.000

K

1.000 ≤ x < 1.500

L

1.500 ≤ x < 2000

M

2.000 ≤ x < 3.000

N

3.000 ≤ x

1. Particle Concentration Classification

Depending on the normalization parameter the particle count per size class is expressed in cleanliness level as shown in the table:

Cleanliness Level

Particle Count
per 1000cm2 or 100cm3
up to including

00

0.00

0

1.00

1

2.00

2

4.00

3

8.00

4

16.00

5

32.00

6

64.00

7

130.00

8

250.00

9

500.00

10

1000.00

11

2000.00

12

4000.00

13

8000.00

14

16000.00

15

32000.00

16

64000.00

17

130000.00

18

250000.00

19

500000.00

20

1000000.00

21

2000000.00

22

4000000.00

23

8000000.00

24

16000000.00

> 24

∞

2. Normalization

The absolute particle number is divided by a normalization factor:

  • Number of components N
  • Wetted component area A or
  • Wetted component volume V

Number of Components (N)

absolute number of particles / component number = normalized particle numbers
Result expression: normalized particle numbers

Wetted component area (A) in mm2

absolute number of particles / wetted component surface and normalization to standard area:*1000 cm2
Result expression: normalized cleanliness code

Wetted component volume (V) in cm3

absolute number of particles / wetted component surface and normalization to standard area*100 cm3
Result expression: normalized cleanliness codes

Example:

The cleanliness codes always refer to normalized and standardized particle results.

  • Number of components = 10
  • Wetted component Area = 200 cm2
  • Wetted component Volume = 50 cm3

Method: Standard Analysis

The standard analysis is fully parameterized from component extraction to filter analysis.

Advantages: The standard analysis has a good degree of result compatibility and is system and operator independent. No further agreement between customer and supplier is required.

Parameter

Description

Measurement of
particles

Length and/or width ≥ 50 µm

Length

Feret Max

Width

Feret Min

Relative image brightness

50 - 60%. Default value: 55%

Relative threshold

70%

Particle typification

Metallic shine as option (Multi Channel 90°/135°)

Contrast

Polarized light

Particle type class All does exclude fibers by default.

Specific fiber criterion based on elongated fiber length and maximum inner circle

Calculation on complete measurement area (effective filter diameter)

For more information, see Concept of Relative Image Brightness and Relative Threshold.

Method: Extended Analysis - Free Analysis

The extended analysis - free analysis is applied whenever supplementary particle information is required:

  • Smaller particle size classes
  • Particle height measurement

Any changes from the standard method must be documented in detail. You can use the extended analysis with the scope of the following:

  • Cause study for critical particles
  • Process optimization
  • Cleanliness specification beyond standard analysis, for example smaller size classes or 3rd dimension.

Parameter

Description

Measurement of particles

Length and/or width ≥ 5 µm

Length

Feret Max

Width

Feret Min

Individual relative image brightness

50 - 60%. Default value: 55%. Can be defined individually.

Individual relative threshold

70%. Can be defined individually.

Particle typification

Metallic shine as option (Multi Channel 90°/135°)

Contrast

Polarized light

Particle type class All does exclude fibers by default.

Specific fiber criterion based on elongated fiber length and maximum inner circle

Calculation on complete measurement area (effective filter diameter)

Default Values for Particle Typification

Parameter

Description

Metallic-Shiny

(Mean gray value > 200.0) or (Max. gray value ≥ 240.0)

Non-Shiny

Objects which are not fiber and not metallic-shiny.

Fiber

(Max. Inscribed Circle ≤ 50.0) and (Fiber Length/Max. Inscribed Circle > 20.0)

As a Supervisor, you can edit the values in the Standard Template Editor, see Standard Template Editor.

Occupancy Rate

The occupancy rate is a measurement value to describe the quality of the specimen preparation in terms of particle density, and the distribution of particles on the effective filter area. The calculation is performed as follows:

Sum of the particle area of all detected particles in relation to measurement frame area. Value in %.

For more information, see

3. Core parameter for size class distribution

Length = Feret Max (default use case), see Feret Maximum

Width = Feret Min (default use case), see Feret Minimum

Fibers, see Fiber Length

ISO 4406 Hydraulic Fluid Power. Fluids. Method for Coding the Level of Contamination by Solid Particles

Particle Size
Class

Size x in µm

Class 1

5 ≤ x < ∞

Class 2

15 ≤ x < ∞

1. Particle Concentration Classification

Depending on the normalization parameter the particle count per size class is expressed in contamination level as shown in the table:

Contamination Level

Particle Count
per 100ml
up to including

0

1.00

1

2.00

2

4.00

3

8.00

4

16.00

5

32.00

6

64.00

7

130.00

8

250.00

9

500.00

10

1000.00

11

2000.00

12

4000.00

13

8000.00

14

16000.00

15

3200.000

16

64000.00

17

130000.00

18

250000.00

19

500000.00

20

1000000.00

21

2000000.00

22

4000000.00

23

8000000.00

24

160000000.00

25

320000000.00

26

640000000.00

27

130000000.00

28

250000000.00

>28

∞

2. Normalization

The absolute particle number is divided by the applied oil volume and standardized to 100 ml.

Default Values for Particle Typification

Particle Type

Description

Fiber

Length (Feret Max) > 100 µm
and
Length/Width (Feret Max/Feret Min) > 10 µm

Particle

If the particle is not in the range of Fiber, it is a particle.

As a Supervisor, you can edit the values in the Standard Template Editor, see Standard Template Editor.

Occupancy Rate

The occupancy rate is a measurement value to describe the quality of the specimen preparation in terms of particle density, and the distribution of particles on the effective filter area. The calculation is performed as follows:

Sum of the particle area of all detected particles in relation to measurement frame area. Value in %.

For more information, see

3. Core parameter for size class distribution

Length = Feret Max (default use case), see Feret Maximum

Width = Feret Min (default use case), see Feret Minimum

GB/T 14039 Hydraulic Fluid Power. Fluids. Method for Coding the Level of Contamination by Solid Particles

GB/T 14039:2002 is based on ISO 4406:1999.

Particle Size
Class

Size x in µm

Class 1

5 ≤ x < ∞

Class 2

15 ≤ x < ∞

1. Particle Concentration Classification

Depending on the normalization parameter the particle count per size class is expressed in contamination level as shown in the table:

Contamination Level

Particle Count
per 100ml
up to including

0

1.00

1

2.00

2

4.00

3

8.00

4

16.00

5

32.00

6

64.00

7

130.00

8

250.00

9

500.00

10

1000.00

11

2000.00

12

4000.00

13

8000.00

14

16000.00

15

3200.000

16

64000.00

17

130000.00

18

250000.00

19

500000.00

20

1000000.00

21

2000000.00

22

4000000.00

23

8000000.00

24

160000000.00

25

320000000.00

26

640000000.00

27

130000000.00

28

250000000.00

>28

∞

2. Normalization

The absolute particle number is divided by the applied oil volume and standardized to 100 ml.

Default Values for Particle Typification

Particle Type

Description

Fiber

Length (Feret Max) > 100 µm
and
Length/Width (Feret Max/Feret Min) > 10 µm

Particle

If the particle is not in the range of Fiber, it is a particle.

As a Supervisor, you can edit the values in the Standard Template Editor, see Standard Template Editor.

Occupancy Rate

The occupancy rate is a measurement value to describe the quality of the specimen preparation in terms of particle density, and the distribution of particles on the effective filter area. The calculation is performed as follows:

Sum of the particle area of all detected particles in relation to measurement frame area. Value in %.

For more information, see

3. Core parameter for size class distribution

Length = Feret Max (default use case), see Feret Maximum

Width = Feret Min (default use case), see Feret Minimum

ISO 4407 Hydraulic Fluid Power - Fluid Contamination - Determination of Particulate Contamination by the Counting Method Using an Optical Microscope

Particle Size
Class

Size x in µm

Class 1

2 ≤ x < ∞

Class 2

5 ≤ x < ∞

Class 3

15 ≤ x < ∞

Class 4

25 ≤ x < ∞

Class 5

50 ≤ x ∞

Class 6

100 ≤ x ∞

1. Particle Concentration Classification

Depending on the normalization parameter the particle count per size class is expressed in contamination level as shown in the table:

Contamination Level

Particle Count
per 100ml
up to including

0

1.00

1

2.00

2

4.00

3

8.00

4

16.00

5

32.00

6

64.00

7

130.00

8

250.00

9

500.00

10

1000.00

11

2000.00

12

4000.00

13

8000.00

14

16000.00

15

3200.000

16

64000.00

17

130000.00

18

250000.00

19

500000.00

20

1000000.00

21

2000000.00

22

4000000.00

23

8000000.00

24

160000000.00

25

320000000.00

26

640000000.00

27

130000000.00

28

250000000.00

>28

∞

2. Normalization

The absolute particle number is divided by the applied oil volume and standardized to 100 ml.

Default Values for Particle Typification

Particle Type

Description

Fiber

Length (Feret Max) > 100 µm
and
Length/Width (Feret Max/Feret Min) > 10 µm

Particle

If the particle is not in the range of Fiber, it is a particle.

As a Supervisor, you can edit the values in the Standard Template Editor, see Standard Template Editor.

Occupancy Rate

The occupancy rate is a measurement value to describe the quality of the specimen preparation in terms of particle density, and the distribution of particles on the effective filter area. The calculation is performed as follows:

Sum of the particle area of all detected particles in relation to measurement frame area. Value in %.

For more information, see

3. Core parameter for size class distribution

Length = Feret Max (default use case), see Feret Maximum

Width = Feret Min (default use case), see Feret Minimum

GB/T 20082 Hydraulic Fluid Power - Fluid Contamination - Determination of Particulate Contamination by the Counting Method using an Optical Microscope

GB/T 20082:2006 is based on ISO 4407:2002.

Particle Size
Class

Size x in µm

Class 1

2 ≤ x < ∞

Class 2

5 ≤ x < ∞

Class 3

15 ≤ x < ∞

Class 4

25 ≤ x < ∞

Class 5

50 ≤ x ∞

Class 6

100 ≤ x ∞

1. Particle Concentration Classification

Depending on the normalization parameter the particle count per size class is expressed in cleanliness level as shown in the table:

Cleanliness Level

Particle Count
per 100ml
up to including

0

1.00

1

2.00

2

4.00

3

8.00

4

16.00

5

32.00

6

64.00

7

130.00

8

250.00

9

500.00

10

1000.00

11

2000.00

12

4000.00

13

8000.00

14

16000.00

15

3200.000

16

64000.00

17

130000.00

18

250000.00

19

500000.00

20

1000000.00

21

2000000.00

22

4000000.00

23

8000000.00

24

160000000.00

25

320000000.00

26

640000000.00

27

130000000.00

28

250000000.00

>28

∞

2. Normalization

The absolute particle number is divided by the applied oil volume and standardized to 100 ml.

Default Values for Particle Typification

Particle Type

Description

Fiber

Length (Feret Max) > 100 µm
and
Length/Width (Feret Max/Feret Min) > 10 µm

Particle

If the particle is not in the range of Fiber, it is a particle.

As a Supervisor, you can edit the values in the Standard Template Editor, see Standard Template Editor.

Occupancy Rate

The occupancy rate is a measurement value to describe the quality of the specimen preparation in terms of particle density, and the distribution of particles on the effective filter area. The calculation is performed as follows:

Sum of the particle area of all detected particles in relation to measurement frame area. Value in %.

For more information, see

3. Core parameter for size class distribution

Length = Feret Max (default use case), see Feret Maximum

Width = Feret Min (default use case), see Feret Minimum

SAE AS 4059 Revision G Aerospace Fluid Power - Contamination Classification for Hydraulic Fluids

Particle Size Class
According to SAE AS 4059 Rev. G, Table 1.1

Size x in µm

Class 1

5 ≤ x < 15

Class 2

15 ≤ x < 25

Class 3

25 ≤ x < 50

Class 4

50 ≤ x < 100

Class 5

100 ≤ x

Particle Size Class
According to SAE AS 4059 Rev. G, Table 2.1

Size x in µm

Class 1

1 ≤ x < ∞

Class 2

5 ≤ x < ∞

Class 3

15 ≤ x < ∞

Class 4

25 ≤ x < ∞

Class 5

50 ≤ x < ∞

Class 6

100 ≤ x < ∞

1. Particle Concentration Classification

Depending on the normalization parameter the particle count per size class is expressed in contamination level as shown in the table:

Particle Count per 100ml up to including, according to SAE AS 4059, Table 2.1
*These values differ from the standard values (0/0/1/1). With the standard values an automated assignment to a contamination level is not possible.

Contamination Level

5 ≤ x < 15

15 ≤ x < 25

25 ≤ x < 50

50 ≤ x < 100

100 ≤ x

00

125.00

22.00

4.00

1.00

0*

0

250.00

44.00

8.00

2.00

0.50*

1

500.00

89.00

16.00

3.00

1.00*

2

1.000.00

178.00

32.00

6.00

1.50*

3

2000.00

356.00

63.00

11.00

2.00

4

4000.00

712.00

126.00

22.00

4.00

5

8000.00

1425.00

253.00

45.00

8.00

6

16000.00

2850.00

506.00

90.00

16.00

7

32000.00

5700.00

1012.00

180.00

32.00

8

64000.00

11400.00

2025.00

360.00

64.00

9

128000.00

22800.00

4050.00

720.00

128.00

10

256000.00

45600.00

8100.00

1440.00

256.00

11

512000.00

91200.00

16200.00

2880.00

512.00

12

1024000.00

182400.00

32400.00

5760.00

1024.00

>12

∞

∞

∞

∞

∞
Particle Count per 100ml up to including, according to SAE AS 4059 Rev G, Table 2.1.
*These values differ from the standard values (0/0/1/1). With the standard values an assignment to a contamination level is not possible.

Contamination Level

1 ≤ x < ∞

5 ≤ x < ∞

15 ≤ x < ∞

25 ≤ x < ∞

50 ≤ x < ∞

100 ≤ x < ∞

000

195.00

76.00

14.00

3.00

1.0

0.00*

00

390.00

152.00

27.00

5.00

1.5

0.25*

0

780.00

304.00

54.00

10.00

2.00

0.50*

1

1560.00

609.00

109.00

20.00

4.00

1.00*

2

3120.00

1217.00

217.00

39.00

7.00

1.50

3

6250.00

2432.00

432.00

76.00

13.00

2.00

4

12500.00

4864.00

864.00

152.00

26.00

4.00

5

25000.00

9731.00

1731.00

306.00

53.00

8.00

6

50000.00

19462.00

3462.00

612.00

106.00

16.00

7

100000.00

38924.00

6924.00

1224.00

212.00

32.00

8

200000.00

77849.00

13849.00

2449.00

424.00

64.00

9

400000.00

155698.00

27698.00

4898.00

848.00

128.00

10

800000.00

311396.00

55396.00

9796.00

1696.00

256.00

11

1600000.00

622792.00

110792.00

19592.00

3392.00

512.00

12

3200000.00

1245584.00

221584.00

39184.00

6784.00

1024.00

>12

∞

∞

∞

∞

∞

∞

2. Normalization

The absolute particle number is divided by the applied oil volume and standardized to 100ml.

Default Values for Particle Typification

Particle Type

Description

Fiber

Length (Feret Max) > 100 µm
and
Length/Width (Feret Max/Feret Min) > 10 µm

Particle

If the particle is not in the range of Fiber, it is a particle.

As a Supervisor, you can edit the values in the Standard Template Editor, see Standard Template Editor.

Occupancy Rate

The occupancy rate is a measurement value to describe the quality of the specimen preparation in terms of particle density, and the distribution of particles on the effective filter area. The calculation is performed as follows:

Sum of the particle area of all detected particles in relation to measurement frame area. Value in %.

For more information, see

3. Core parameter for size class distribution

Length = Feret Max (default use case), see Feret Maximum

Width = Feret Min (default use case), see Feret Minimum

Particle Test Standard (CC with OC) (2010) Slide D45

Provides a standard template for microscope system validation.

Comparison of Standards

Comparison by

Component Cleanliness

Oil Cleanliness

Relevant standards
  • VDA 19.1
  • VDA 19.2
  • ISO 16232
  • VDI 2083, Part 21 (medical products)
  • Particle Test Standard (CC) Slide D45
  • ISO 4406
  • ISO 4407
  • GB/T 20082
  • GB/T 14039
  • NAS 1638
  • SAE AS 4059

Job templates

Job template Component Cleanliness Testing (Loaded Images) is supplied with the software.

In the TCA Workflow Editor, you can create individual job templates. You have the following options:

  • Component Cleanliness Testing
  • Component Cleanliness Testing with ML Object Classification
  • Component Cleanliness Testing with ML Object Classification (Loaded Image)
  • Component Cleanliness Testing with S&F
  • Component Cleanliness Testing with S&F and ML Object Classification
  • Component Cleanliness Testing with HM
  • Component Cleanliness Testing with S&F and HM
  • Component Cleanliness Testing with ML Object Classification and HM
  • Component Cleanliness Testing with S&F and ML Object Classification and HM
  • Technical Cleanliness (VDA 19.2 Joint Result)

In the TCA Workflow Editor, you can create individual job templates. You have the following options:

  • Oil Cleanliness Testing
  • Oil Cleanliness Testing (Loaded Images)
  • Oil Cleanliness Testing with S&F
  • Oil Cleanliness Testing with HM
  • Oil Cleanliness Testing with S&F and HM

Effective area

Complete flow through area must be analyzed; i.e. extrapolation of results is not allowed

Extrapolation is allowed; e.g. scan D35 and extrapolation to D41

Normalization
  • Component number (N)
  • Wetted component area (A)
  • Wetted component volume (V)

Applied oil volume (V)

Result interpretation

Focus on large particles and often in practice also on metallic-shiny particles.

Focus mainly on particle count

Analysis (in practice)

Particle size distribution and particle type (metallic-shiny, non-shiny, fiber)

Particle size distribution and particle types (particles and fibers)

Average particle size

5 µm up to ≥ 3000 µm

1 µm up to > 100 µm

Particle size distribution

Differential particle counts
Example:
≥ 5 - 15 µm;
≥ 15 - 25 µm

Methods:

  • Standard
    (50 µm and larger objects)
  • Extended
    (5 µm and larger objects)
  • Differential particle counts
  • Cumulative particle counts
    Example:
    ≥ 5 µm
    ≥ 15 µm

No specific methods.

Cleanliness classes (levels or codes)

One cleanliness code table valid for all particle size classes.

Depending on the standard, one cleanliness code table is valid for all particle size classes or individual code tables per particle size class.

Relative image brightness (Luminosity) & Relative threshold

Image brightness adjustment using the luminosity value and image analysis setting with a corresponding relative threshold.

Image brightness adjustment by exposure time or luminosity and image analysis setting via independent definition of a threshold range or relative threshold.

Image acquisition and camera sensor pixel polarization (default setting)

One multichannel image with Pol- 90° and Pol-135°.

For more information, see Polarization Method.

One single-channel image with Pol-90° (with Axiocam 705 pol). With other Axiocams, polarization contrast is required.

Occupancy rate

Results refer to the complete measurement frame area (=effective filter area).

Results refer to the complete measurement frame area (=effective filter area).

For more information, see Common Characteristics.

Understanding the Technical Background

POL Camera Technology

Component Cleanliness Analysis is usually not only focused on particle counting results, but also on the differentiation by particle type.

Using a microscope, the established analysis is performed by sequential acquisition of two images. One image is recorded with the parallel orientation of two polarizer and a further image is recorded with the two polarizer in 90° orientation to each other (crossed polarization).

Metallic particles appear dark black when using crossed polarization whereas non-metallic particles often change their appearance from gray to darker gray or even do not show any reaction on polarization. This effect is used to differentiate between metallic-shiny and non-shiny particles.

The new camera technology with on-chip polarization allows parallel acquisition of one dual channel image with both directions of polarization at the same time. This leads to time reduction by 100% for the image acquisition step.

This functionality is only available when using the Axiocam 705 pol.

The component cleanliness job templates are designed to analyze images acquired with the Axiocam 705 pol.

Applying Polarization Channel

The POL camera is a black and white camera and offers beside the raw image four selectable directions of polarization: 0°, 45°, 90°, 135° to acquire a multi-channel image. The raw image shows all directions of polarization. In color mode the images are displayed in false-color.

After image acquisition, the selected directions of polarization are extracted from the raw image and provided as multi-channel image.

The default value for multi-channel images shall be Single Channel. This is valid for all TCA job templates.

If single channel is not activated, the merged image is displayed. The merged image is an additive image of all selected channels and therefore much brighter than the single channel images.

  1. Axiocam 705 pol is installed.
  2. In the Extended Camera tool > Mode section, the camera mode B/W is selected.
  3. In the Extended Camera tool > Mode section, Live speed high is selected.
  4. In the Extended Camera tool > Model Specific section, the channels 90° and 135° are selected.
  5. On the Display tab, Single Channel is activated. It is not possible to display more than one channel at the same time. You can switch between the two image channels to differentiate immediately between metallic and non-metallic particles. The Pol-90° channel and one additional channel, i.e. 0°, 45° 135° is mandatory for correct differentiation of the particle types metallic-shiny and non-shiny.
  1. To display metallic particles bright shining, in the Image View, on the Display tab, select Pol-135 channel. Note: Depending on the particle surface and its orientation on the filter membrane, it might be that only smaller areas of the metallic particle appear bright shining. This is a general effect using polarization and is independent of the applied technology.
    Note: Also, the 0° or the 45° channel can be selected to display metallic particles bright shining, but it is recommended to use the 135° channel. In this setting, metallic particles are not outshined which leads to a better image quality in the report. Furthermore, foamed filter membranes show less reflections.
  2. In the image, the metallic particle is displayed in Pol-135 channel.
  3. To display metallic particles dark black, in the Image View, on the Display tab, select Pol-90.
  4. In the image, the metallic particle is displayed in Pol-90 channel.

Example: Non-metallic particle

Non-metallic particles do not react on polarization with a change in brightness from silver white to dark black. In most of the cases you can observe a change from gray to darker gray, even for those materials with reflecting brighter areas. They never get dark black when using crossed polarization.

Example: non-metallic particle is displayed in Pol-135
Example: non-metallic particle is displayed in Pol-135
Example: non-metallic particle is displayed in Pol 90
Example: non-metallic particle is displayed in Pol 90

Concept of Relative Image Brightness and Relative Threshold

The Relative Image Brightness (Luminosity) is adjusted to 55% which means that the filter background indicated by the largest peak (gray value with the highest intensity in pixel counts) appears in the middle of the gray value range:

Relative image brightness is adjusted to a Luminosity value of 55%. (Source: ISO 16232)
Relative image brightness is adjusted to a Luminosity value of 55%. (Source: ISO 16232)

The Relative Threshold is set at 70% referring to the Relative Image Brightness (Luminosity) setting.

Relative threshold is adjusted to a value of 70%. (Source: ISO 16232)
Relative threshold is adjusted to a value of 70%. (Source: ISO 16232)

For information on setting the relative image brightness (Luminosity), see Camera Tool and Light Path Editing Tool.

For information on relative threshold, see Particle Segmentation Tool (Components).

Concept

Concept TCA

With the operating concept of the TCA module, pre-defined measurement workflows are adapted by the supervisor for the everyday routine of the operator. The performance of a measurement can be automated to such an extent that only the project data need to be entered and the entire analysis process can run automatically. Due to these automated workflows, the operator's influence on the measurement results can be reduced to a minimum. In addition to the quality gained, the time necessary for the measurement is reduced as well. Supervisors and operators can focus on their specific tasks.

The operation of the module is based on the following operating concept:

  • Modifying and managing standard templates (Supervisor)
  • Copy and edit pre-configured standard templates in order to adapt the particle size classification. Define specific acceptance criteria for particle results based on allowed particle numbers per size class or individual mathematical conditions in terms of length and/or width.
  • Note that under Manage Templates you can edit the find pre-defined standard templates: one per standard and method.
  • For more information, see Standard Template Editor. For more information regarding available standards, see Introduction to Standards.
  • Note that for the initial operations you must select in the Standard Selection workbench (in the first step of your job template), the desired standard templates.
  • Modifying and managing job templates (Supervisor)
  • Copy and edit pre-configured TCA job templates in order to adapt the workflow to your needs and to the operator routine task, manage job templates, inspect and approve job results.
  • Note that under Job Mode you find pre-defined job templates for the assessment of particulate contamination according to the standards.
  • For more information, see Introduction to Standards.
  • Running Job templates (Operator)
  • Run TCA job templates created by the supervisor. Inspect and revise particle results if required by using the result views.

Note: In the role of a supervisor it is possible to perform functionalities of the operator.

General Workflow preparations

The following pre-defined job templates are included in the software, when you have licensed the TCA module. In this documentation, the procedure according to the existing, pre-defined job templates are described. The following job templates are available by default:

Parameter

Description

Component Cleanliness

You analyze loaded images or acquire images of filter membranes with particulate contamination originating from engine components or medical devices.

Oil Cleanliness

You analyze loaded images or acquire images of filter membranes with particulate contamination originating from fresh and used oils and lubricants, e.g. hydraulic, gear oils, or engine oils.

As a Supervisor, you can access/edit the job template in Job Mode.

The job templates always contain four major tasks:

  • Filling out an Input Form
  • In this step, the operator must fill out the input form with user and specimen specific information.
  • Image Acquisition
  • Image acquisition of the pre-defined specimen area.
  • Performing the Analysis
  • In this step, particles are extracted by image segmentation and analyzed according to the selected standards. The detailed workflow is described in the following sections.
  • Creating a Report
  • After the analysis, a report is generated containing the job results with characteristic values according to the selected standards.

Once you have finished the job, it is saved, and you can check it in the Browse Results view, see Browse Results.

For more information, see Job Mode.

Retraining a Model for TCA

To customize the pre-trained TCA Component Cleanliness Object Classification Model, you extend the provided ML (machine learning) ML based model by retraining with your own acquired images saved in a conventional TCA job run. To do so, export the archived image to your local file system.

NOTICE

notice

Existing images in a pre-trained model

Do not remove existing images in a pre-trained ML (machine learning) based model, because the training information added with the corresponding image will be deleted from the model.

  1. The TCA Object Classification images are installed using the Microscopy Installer.
  2. The Manage Templates mode is selected.
  1. From the Show drop-down list, select Intellesis Object Classification Models.
  2. The models are displayed.
  3. Select the desired TCA Object Classification model, and click Copy and Edit .
  4. The Intellesis Object Classification workbench is displayed showing the mandatory particle type classes for TCA.
  5. Click Import from Archive or Import Images if you want to import the image from your local disc.
  6. The browser opens.
  7. Select the exported image from the file system for training, and click Open. Be aware that the images you use for training were acquired with the same channel combination that is used in the selected model.
  8. The image and a table containing the IDs of the objects in the image are displayed in the Center Screen Area.
  9. In the classes list, select a class, and in the image, click on an object that belongs to this particle type class. Repeat this for a certain number of particles.
  10. You have labeled the object and assigned it to the selected class indicated by the same color of the corresponding particle type class.

  11. Click Train & Classify.
  12. The model is retrained based on the labeling. A prediction is displayed in the table.
  13. Review the predictions. To do so, in the table, sort the Prediction column table class and then click a predicted object in the table. Check that the algorithm has correctly labeled the object in the image. If you are not sure whether an object is metallic-shiny or not, on the Display tab, activate Single Channel, and activate Pol-135. The metallic-shiny particles will appear with white areas. By selection of the Pol-90 channel, metallic particles must appear black throughout.
    If the results are not precise enough, label additional objects. Click again Train & Classify.
  1. The model is retrained based on the labeling. The model is available at Manage Templates > Intellesis Object Classification Models, e.g. Model Name (1). To change the model name, in the Properties area, click , and change the name.

Note that you must select the retrained model again in the TCA job template > Intellesis Object Classification workbench > Intellesis Object Classification tool.

Standard Template Editor

The standard template editor provides so-called Standard Templates. A Standard Template defines rules for the particle size classification and definitions for acceptance criteria. The results based on these definitions are displayed in the Size Distribution view, see also Size Distribution View.

For each of the supported standards one pre-configured standard template per method is provided. A wizard guides you through the configuration in the standard template editor, see Opening Standard Templates.

For more information on the supported standards for technical cleanliness, see Introduction to Standards.

You can select all standard templates in the job template using the Standard Selection Tool, see also Technical Cleanliness Standard Selection Tool.

As a Supervisor, you can copy and edit standard templates to address company internal guidelines. You can adapt the size classification and define individual acceptance criteria. Note that the standard template is also saved in XML-format as a .cztct file on your local drive under <C:\ProgramData\Carl Zeiss\ZENCore\UserArchive\Technical Cleanliness Standards>.

Work in the Standard Template Editor

To adapt the data according to your needs, set the value ranges for each particle size class in the Center Screen Area. Add acceptance criteria or select certain particle size classes for the particle height measurement in a subsequent job run. To select additionally particle size classes for EM/EDS measurement, active licenses for ZEN Connect and ZEN connect 2D add-on are required.

You can modify the existing size classification by length or width. This includes the option to add or delete size classes generating your own customized size classification.

Modify the selected standard template by the following:
- Changing the size classification for length or width. The default values are Feret Max and Feret Min.
- As an option: changing the measurement parameter for length and width. This is only recommended for standard independent particle size classification.
- Defining acceptance criteria for allowed particle number per size class.
- Defining acceptance criteria according to the logic defined. These criteria are based on mathematical conditions for particle length and/or width. The default values are Feret Max and Feret Min.

You save the standard template any time by leaving the standard template editor by clicking Home and then saving your changes.

Understanding Approval Rating

To receive an approval rating in the Size Distribution view, the Supervisor must define the acceptance criteria in the standard template and load subsequently the standard template into the desired job template. You can define either acceptance criteria based on particle counts per size class or directly based on particle size.

Select the required normalization parameter in the standard template. The normalization value for N, A or V you define in the Standard Specific Settings workbench of the job template.
Note: Any time you modify a standard template, you must reload it to the job template.

The analysis results are displayed in the Size Distribution view as well as in the Report in tables and charts. For the Operator it is possible to inspect the results in the Size Distribution view in detail and to use the NOK button to filter and to identify rapidly potentially process critical particles.

For information on the Size Distribution view, see Size Distribution View.

Settings in the standard template by the Supervisor

  1. In Manage Templates, in the Standard Template Editor, open the desired standard template to edit it, see Opening Standard Templates.
  2. Decide whether you want to rate the approval based on the number of particles per size class or per particle size, see Defining Basic Template Settings.
  3. Modify the particle size classes for length, and or width, if required; select the parameter (absolute, N, V, A) to which the approval rating is related to and define your particle limit values per size class. You can assign the allowed number of particles, either per particle type or you decide that all particle types should have the same allowed value for number of particles. These are the acceptance criteria for the approval rating of the detected particle counts per size and type class. See Defining Length and Width Classes (Workbench Area) and Defining Length and Width Classes (Center Screen Area).
  4. Alternatively, you can define the allowed particle size in length and width for each particle type, see Defining the Approval Logic.

Settings in the job template by the Supervisor

  • In the Standard Specific Settings workbench, in the Normalization Parameter tool, decide whether the Operator shall be able to select normalized calculation or not. You carry out a normalization, for example, setting the number of particles of several components in a ratios you obtain an average value normalized for the defined number of components value is then used for the approval rating. The normalized value is used as base for approval rating and cleanliness level assignment. See Normalization Parameter (Components) Tool or Normalization Parameter (Oil Cleanliness) Tool.
  • Open the job template and import the standard with the approval rating settings you have defined, see Technical Cleanliness Standard Selection Tool.

Job run by the Operator

  1. Run the job.
  2. If the Supervisor has enabled it, in the Standard Specific Settings workbench, in the Normalization Parameter tool, you can enter normalization values (N, V, A) to compare the results.
  3. In the next step, in the Size Distribution view, the absolute number of particles per size class or the normalized results based on the settings in the previous step are displayed. In this step you monitor the results of the settings for the approval rating: according to the definition in the standard template.
  4. The results are rated as follows:
    • Particle counts exceeding the defined allowed number of particles per size class (=acceptance criterion) are rated as n.ok.
    • Particle counts below the defined allowed number of particles per size class (=acceptance criterion) are rated as ok.

Opening Standard Templates

It is not possible to change standard templates provided with the TCA software - this is indicated by a small lock icon. To modify it, create a copy and modify the copy.

  1. The Manage Templates mode is selected.
  1. Select the list entry Standards Technical Cleanliness using the Show drop-down list.
  2. The template list shows the provided standard templates.
  3. Right-click the desired template and select Copy & Edit. Alternatively, in the Toolbar, click the Copy & Edit icon:
  4. The step Define Technical Cleanliness Standard opens, see Defining a Standard Template.

Defining a Standard Template

  1. The Standard Template Editor is open.
  1. Open step Define Technical Cleanliness Standard.
  2. The following view is displayed.
  3. Fill in data in the Standard Name field, Method Name field, and Year field.
  4. In the Template is Based on Standard field it is displayed which standard your modified template is based on. This information is displayed in the Report.
  5. The selected template is used in the respective job template for component or oil cleanliness.
  6. The information is used for the template name in the order Standard name (year) method when saving the template.
  7. The information is also used in the Technical Cleanliness Standard Selection tool. This tool is located in the first step of the job template.
  8. The Type is preselected and depends on the application. The following types are available: Component Cleanliness and Oil Cleanliness.
  9. Click Next.
  10. The step Basic Template Settings opens, see Defining Basic Template Settings.

Defining Length and Width Classes (Workbench Area)

Define individual particle length and width size classes in the Center Screen Area if required, and select the desired acceptance criteria in the Workbench Area. The number of displayed columns is dependent on the settings in the workbench area.

In the Image Gallery, all particles are displayed by default from 5 µm length and width onwards. As a Supervisor, you can change the minimum size of the displayed particles in the Region Filter tool in the Region Filter workbench. By default, the Region Filter workbench is set to run silent, see Region Filter.

  1. You have defined the basic template settings.
  1. Open step Define Length Classes.
  2. The following view is displayed.
  3. Define the settings in the workbench area. Define the length or width classes. Select the Classification Parameter, if required.

    You have the following options for length classification:
    - Feret Max
    - Length X
    - Fiber Length
    - ECD
    Default value: Feret Max
    Note that the selection of other classification parameter than the default parameter is only recommended for non-standard based analysis.
    You have the following options for width classification:
    - Feret Min
    - Length Y
    - ECD
    - Max. Inscribed Circle
    Default value: Feret Min
    For more information on Length and Width Classification, see Measurement Parameters for Length and Width Classification.
  4. Activate the Selection.

    You have the following options:
    - Activate Particle Height Measurement to show additional columns in the center area to define the particles of certain size classes to be considered for particle height measurement.
    - Activate EDS Measurement with SEM (Correlative Workflow) for a correlative workflow. If activated, additional columns are shown in the Classes table to define the particles for EM/EDS analysis. For correlative LM/EM-EDS workflow, you operate in Free Mode and need to activate the S&F Find List tool, see Correlative Workflows.
  5. Defined particles for EM/EDS measurement will appear in this list.
  6. In the Operator for Size Classification section, define the handling at the class border limits for the particle size classification.
  7. In the Acceptance Criterion section, activate Allowed Number of Particles for the definition of acceptance criteria based on the allowed maximum particle number per size class.

    You have the following options:
    - Absolute Count (absolute particle number)
    - Normalized (N) (= absolute particle number/component number)
    - Normalized (A) (= absolute particle number/wetted component area)*1000 [cm2]
    - Normalized (V) (= absolute particle number/wetted component volume)*100 [cm3]
  8. Select the Operator for Acceptance Criterion to define the handling at the class border limit for the definition of acceptance criteria.
  9. Select the Allowed Number of Particles.

    This function is only active, if in the Acceptance Criterion section Allowed Number of Particles is activated. Here, you define the allowed number of particles per type class and for "class all with or without fibers", see Type Classification for Class "All" Tool. You have the following options:
    - Same Limit Value for all Types. Define one limit value for allowed particle numbers independent of the particle type. This limit value is also valid for "class all/with or without fiber". The defined values are the base for the approval rating displayed in the Size Distribution View.
    - Individual Limit Value per Type. Define individual limit values for allowed particle numbers for each particle type. The limit value for allowed particle numbers in "class all/with or without fiber" is equal to the sum of the allowed particle numbers of the particle types. The defined values are the base for approval ratings displayed in the Size Distribution View.
  10. Continue in the Classes table, see Defining Length and Width Classes (Center Screen Area)

Defining Length and Width Classes (Center Screen Area)

The predefined size classes are given by the corresponding standard.

  1. You have defined the settings in the Workbench Area.
  1. Proceed to the Center Screen Area and set your settings. Define individual acceptance criteria by the allowed number of particles per size class. Add limit values for the allowed number of particles per size class, see example below.
  2. The result is displayed in the Size Distribution view, see Class Chart - Length Class Table. The result of the acceptance criteria is displayed in green color indicating particle counts are below the defined limit values; red color means that particle counts are above defined limit values.
  3. Define particle size classes for height measurement of particles. Activate the size classes considered for particle height measurement, e.g., METALLIC SHINY and NON SHINY for component cleanliness standards, or PARTICLE for oil cleanliness standards.
  4. The pre-selected particles are automatically marked in the gallery of the Size Distribution view of the job run. Additionally, you can mark or unmark desired particles manually in the Particle Gallery, see Particle Height Measurement.
  5. Define a selection of particles automatically provided for EM/EDS analysis in a correlative workflow. Execute the TCA workflow as usual. For a correlative LM/EM-EDS workflow continue in Free Mode and load the S&F Find (List) tool to retrieve the particles for subsequent EDS analysis, For more information, see Correlative Workflows
  6. By selection of a certain particle size class all particles belonging to this size class are added automatically to the archived EDS particle selection table.
  7. Modify the particle size classification for the definition of individual company standards.
  8. The red numbers indicate that the entered values are wrong. A tool tip informs you on the error.
  9. To add a new row for defining the next particle size class, click the Add Class button. Add size class values and a name for this size class.
  10. Click Next if you want to modify the size classes for width as well.
  11. The Define Width Classes step is displayed.
  12. Define the particle width classification in the same way as described before.
  13. Click Next.
  14. The step Define Approval Logic is displayed, see Defining the Approval Logic.

Measurement Parameters for Length and Width Classification

The following size classification parameters are available: The default value for length is Feret Max and the default value for the width is Feret Min.

Length X

Indicates the width (size in x-direction) of a bounding box for a region. The box is drawn in parallel to the x and y axis.

  • Formula: Length right - Length left
  • Unit: Unit of the scaling assigned to the image (e.g. μm)

Length Y

Indicates the height (size in y-direction) of a bounding box for a region. The box is drawn in parallel to the x and y axis.

  • Unit: Unit of the scaling assigned to the image (e.g. μm)
  • Formula: Length top - Length bottom

Defining the Approval Logic

The approval logic is based on definable conditions for particle length and width. Length and width are based on the definition of the measurement parameter in the steps Define Length Classes and Define Width Classes. Particles which exceed the defined size limits are colored in red. To filter them, click Filter NOK in the Scatter Plot of the Size Distribution View. All particles lying under the defined size limit are colored in green.

  1. You have selected Particle Size in the Approval Rating, see Defining Basic Template Settings.
  1. Open step Define Approval Logic.
  2. The following view is displayed:
  3. In the FOR TYPE drop down list, select the particle type. Add the condition, e.g., length or width, and use logical operations for defining the allowed size range. You can set further conditions using the + icon.
  4. The displayed particles are indicated by red colored dots in the scatter plot of the Size Distribution view.
  5. If desired, add a second approval definition. Click Add Condition to do so, and add a definition.
  6. Multiple conditions within one row are linked by an AND operator. Further conditions in additional rows are linked by an OR operator.
  7. All conditions are applied automatically and the result is presented in the Scatter Plot of the Size Distribution View.
  8. Click Next.
  9. You have adapted the standard to you needs.
  10. The step Define Cleanliness Codes is displayed and read-only, see Cleanliness/Contamination Classification and Cleanliness/Contamination Codes.

Cleanliness/Contamination Classification

For each of the supported standards the corresponding cleanliness/contamination classes are shown and cannot be modified. Cleanliness/contamination classes allocate normalized particle numbers into cleanliness/contamination level. For more information on the supported standards, see Introduction to Standards.

1

Size Classes

Displays the cleanliness/contamination level corresponding to normalized particle counts. Only valid for A, V.

2

Class Table Usage

Identical Class Table for all Particle Size Classes: Applies one cleanliness code classification table to all particle size classes;

Individual Class Tables for each Particle Size Class: Applies one individual cleanliness code classification table per particle size class, i.e. each particle size class has its own cleanliness classification table.

3

Operator for Cleanliness Classes

Defines the handling of the class border limits.

4

Cleanliness Code Notation

Options for displaying the cleanliness/contamination classification in the condensed one-line notation with class names or without class names.

Example:
CCC=1/2/3/4 or CCC=A1/B2/C3/D4.

The latter example shows a notation in which the letter represents a certain particle size class and the number stands for the corresponding cleanliness/contamination level, indicating the detected and normalized number of particles which belong to this particle size class.

Views for Inspection

Size Distribution View

The Size Distribution view displays the particle results for the selected standard. You can filter the results by approval status, particle type or particle size class.

In the Image Gallery, all particles are displayed from 5 µm length and width onwards. As a Supervisor, you can change the minimum size of the displayed particles in the Region Filter tool in the Region Filter workbench. By default, the Region Filter workbench is set to run silent, see Region Filter.

For individually created job templates it is recommended to display only standards with the same smallest particle size in the Standard Selection tool and adapted the Region Filter tool accordingly.

1

Class Chart

Displays the number of particles sorted in size classes and particle types according to their size in µm. You can filter by particle type and by approval status. Further tables are available to inform you about the test results in respect of length and width classes.

See

2

Scatter Plot

Displays the particle values for length versus width. You can filter by particle type and by approval status. See Scatter Plot.

3

Particle Button bar

Filters artifacts or particles by type. You can view all particles clicking the All button. See Particle Button Bar and Filtering Particles.

4

Image Gallery

Displays all detected particles. Default: Minimized view. The Mid-Sized view shows the particle images with an enlarged zoom level. See TCA Image Gallery.

Class Chart - Diagram

This diagram displays the particle size distribution and the approval status by particle type. The capital letters at the x-axis are representative for the particle size classes according to ISO 16232 and VDA 19.1.

The bars are either displayed in green or red color corresponding to the approval status OK or NOK. The coloring and the corresponding approval status are dependent on the acceptance criteria as defined in the Standard Template. If no approval is defined, the bars are represented in gray color.

Click the Filter NOK Button to show only those particles in the Image Gallery that exceed the limits as defined by the acceptance criteria.

Click one or more bar(s) in the diagram to filter the Image Gallery accordingly.

Class Chart - Width Class Table

This table displays the particle size distribution by particle type. The default width classification parameter is Feret Min.

The displayed particle size classification table shows the following information:

  • The absolute and/or normalized particle counts, according to the selection in the Displayed Normalization tool.
  • The allowed number of particles as defined in the standard template.
  • The corresponding cleanliness level as defined in the standard.
  • The approval result (OK/NOK).

The table is saved to the archive and is shown in the report.

Note that there is no interaction with the Image Gallery.

Scatter Plot

This diagram displays the distribution of particles in relation to their length and width.

Each particle is indicated by a measuring point and is either displayed in green or red color corresponding to the approval status OK or NOK. The coloring and the corresponding approval status is dependent on the acceptance criteria as defined in the standard template.

If no acceptance criteria are defined, the measuring points are displayed in gray color.

Click Filter NOK to show those particles in the Image Gallery that exceed the limits as defined by the acceptance criteria. From the Type drop-down list, select a certain particle type in the scatter plot to filter the particle gallery accordingly.

Filtering the image gallery by scatter plot or by particle bar, they update one another.

Particle Button Bar

In the Particle Button Bar, you filter artifacts and particles per type to synchronize the Image Gallery in parallel. You can view all particles by clicking the All button.

If you filter the Image Gallery via the bar diagram or the scatter plot, a description of the applied filter(s) is shown above the Image Gallery. You can use the filter description to remove applied filters selectively.

Particle types for component cleanliness

  • Metallic-shiny (M)
  • Non-shiny (N)
  • Fiber (F)
  • Artifacts (A)

Particle types for oil cleanliness

  • Particle (P)
  • Fiber (F)
  • Artifacts (A)

Parameter

Description

Show Annotations

Surrounds and displays the shape of the particle with a red line.

Show Scaling

Displays the size of the particle based on the scaling factor.

Drop-down menu

Changes the sorting in the image gallery by particle length, width, area and ID. The default sorting order is descending for size: length, area, width, and ascending for the particle ID.

Filtering Particles

In the Size Distribution view, various methods are available for filtering particles to enable rapid particle inspection.

Filtering by particle size class

  1. You are in the Size Distribution view.
  1. Click on one or more bar(s) in the Class Chart diagram tab.
  2. The images displayed in the Image Gallery are filtered according to the selected data.
  1. The filter buttons in the Particle Button bar above the Image Gallery are replaced by the filter description, e.g. Class Chart Filter: B Non-shiny.

Filtering by acceptance criteria

You can obtain a rapid overview on potentially critical particles by filtering over the approval status NOK.

  1. You have defined acceptance criteria in the Standard Template to display OK or NOK in the Size Distribution view. For more information, see Standard Template Editor.
  2. You are in the Size Distribution view.
  1. In the Class Chart diagram, click on the toggle button to switch between the approval status NOK or OK.
  2. The Class Chart diagram and the Image Gallery are adapted.
  3. The filter buttons in the Particle Button bar above the Image Gallery are replaced by the filter description, e.g. NOK Filter active.
  4. In the Scatter Plot, click the toggle button to switch between OK and NOK.
  5. The Scatter Plot and the Image Gallery are updated.
  6. The filter buttons in the Particle Button Bar above the Image Gallery are replaced by the filter description, e.g. NOK Filter Active.

Filtering by particle type

You can filter your results by particle types.

  1. You are in the Size Distribution view.
  1. In the Particle Button bar above the Image Gallery, click the particle type button you want to filter the Image Gallery by.
  2. The Image Gallery and the Class Chart diagram are adapted.

Editing Particle Analysis Results in the Particle Edit View

You can display sections of the original tile images instead of a thumbnail image in 2D view and edit them. In case the quality of the result is not satisfactory because for instance adjacent particles touch each other, you edit the analysis result. In the Image Gallery, you use the arrow key to scroll through the particle images, to update the Edit View.

The Edit View is available with or without the option to inspect and retrieve particles in live mode, see Configuring the TCA Job Template by Switching the Active Branch.

If your color camera is Axiocam 705c, the default setting for live speed should be changed.

  1. In the Extended Camera tool > Mode section > Live Speed drop down list, select High Res.

    See Extended Camera Tool.
  2. The live zoom factor for Axiocam 705c and Axiocam 705pol is aligned.
  1. You are in the Size Distribution view.
  1. In the Image Gallery, hover the mouse over the picture frame of a gallery image.
  2. The Opens the Particle Edit View icon in the upper right side of the picture frame is displayed.
  3. Click the icon.
  4. The Edit View appears and the tile image section with the selected particle is displayed in the left window of the center area. The Live mode is displayed in the right window of the center area and shows the selected particle centered. The Edit View with camera in Live mode is the default setting.
    Use the particle gallery at the bottom to navigate between the particles and inspect them in the live mode of the two cameras. With the Axiocam 705 pol you can switch between the different polarization orientations. With the color camera you get additional color information of the selected particle.


  6. If you open the Edit View without camera Live mode, the following view is displayed.
  7. The selected particle is displayed with a green frame.
  8. With the Edit Regions tool, edit the selected particle. For more information, see Interactive Segmentation.
    You have the following options:
    - Draw button: Adds the area drawn as a new object which extends an existing object.
    - Erase button: Removes the area drawn from an existing object.
    - Cut button: Splits an object into multiple objects along the line drawn.
    - Connect button: If the area drawn overlaps an existing object, the area and object are joined into a single object.
    - Remove button: Removes the selected object.
    Note: Keep the middle mouse button pressed and drag the mouse to move the image in the view.
  9. For Component Cleanliness workflows: Under Choose Camera, you can select between the Axiocam 705pol and a color camera (Axiocam 705c or Axiocam 305c). The color camera is useful to identify the origin of certain particle classes (colored fibers, different metals and plastics) and to add color images to the report.
  10. For Component Cleanliness workflows: Under Software AF, click Find Focus to start the autofocus search to determine the optimal focus.
    Under Exposure Time, click Auto to apply the exposure time automatically or click Manual, the set the exposure time manually by means of the slider or the spin box.
  11. For Component Cleanliness workflows with Axiocam 705pol: Under Camera Control: Under Live Polarization, select the desired polarization orientation channel (0°, 45°, 90°, 135°).
  12. For Component Cleanliness workflows with a color camera, under White Balance you can adjust the white balance. You have the following options:
    - Auto: Selects the reference point for the white balance correction automatically and adjusts the hue of all other pixels accordingly.
    - Pick: Enables you to specify the reference point for white balance correction manually. The hue of all other pixels is adjusted accordingly.
    - Reset: Resets any other color changes and sets the white balance to 6500 K.
  13. For Component Cleanliness workflows with a color camera, under Offset Correction, you can correct the offset between the two cameras. By default, the option Use Offset Correction is activated.
    Select the camera on which the offset occurs and press Determine Offset. In Live View, select a particle and click on it. The stage moves to the particle and the offset is corrected for all images. See Correcting Camera Offset.
  14. For Component Cleanliness (loaded image): To see better if a very dark metallic particle is metallic shiny or not, with the Configured Polarization Channels switch, you can switch between different polarization orientations. The pre-configured channels of the image are displayed.
  15. Click Apply Changes to save after all desired revision steps are finalized. Note that editing of particles requires a confirmation by Apply of Changes before particle types can be changed in the Edit View.
  16. The edited particle is displayed with the applied revisions steps.
  17. To save and leave the Edit View, click OK.
  18. The segmentation annotation is updated and the revised particle shown in the Image Gallery of the Size Distribution view.
  19. The particle results, classification data and statistics are updated accordingly.
  20. The revised particle gets a new Particle ID, which is represented by the largest number in the Particle Result table.

Particle Selection for EDS Analysis

For EDS analysis you preselect particles, and the coordinates of these particles are saved for later EM/EDS analysis after execution of the correlative LM job template. The EDS particle selection list is loaded in Free Mode via the S&F Find (List) tool in ZEN core, to continue the correlative workflow with the EM.

See Concept of S&F with TCA

You have the following options for particle selection:

  • Automatically configured in the Standard Template Editor, see Defining Length and Width Classes (Workbench Area).
  • Additionally, within the workflow: In the Size Distribution (Live) view, you can manually mark or unmark desired particles in the Particle Gallery.

If desired you can use both selection methods in combination or only one of them. Independent of the used selection method, all particle coordinates are saved into one file.

Marking Particles for EDS Analysis Automatically

  1. Select Standard Template Editor > Define Class step > activate Enable EDS Selection.
  2. An additional column for particles per size class to be marked for EM/EDS measurement is displayed.
  3. The automated selection of particles for EDS analysis is activated.
  4. By default the coordinates of the particles are stored to the archive in the file Particle Selection EDS.
  5. As option the particle coordinates are exported in addition to a predefined file path on your computer, see EDX File Export Tool.
  6. Add the modified standard template to the correlative LM job template.

Marking Particles for EDS Analysis Manually

Even though you have configured the automatically marking of particles for EDS analysis, you can add desired particles or remove them from the EDS particle selection list.

  1. You have selected a correlative LM job template.
  2. You are in Size Distribution (Live) view.
  1. In the Image Gallery, in the desired image, click Mark for EDS
    .
  2. By default the coordinates of the particles are stored to the archive in the file Particle Selection EDS.csv.
  3. As option the particle coordinates are exported in addition to a predefined file path on your computer, see EDX File Export Tool.
  4. To unselect the particle for EDS measurement, click Mark for EDS a second time.

Particle Height Measurement

For measuring the height of particles, you select the particles and perform interactive measurement in the Particle Height Measurement view. The marked particles are saved in a table and stored in the archive. The report displays the three largest particles per type independent of the particle selection for height measurement. If a height measurement was conducted for these particles, the report shows the values for particle height in addition to length and width.

You have the following options for particle selection:

  • In advance: By configuration in the Standard Template Editor.
  • Additionally, within the workflow: In the Size Distribution (Live) view, you can manually mark or unmark desired particles in the Particle Gallery.
  • If desired, you can use both selection methods in combination or only one of them. Independent of the used selection method all particles are saved into one file.

Marking Particles for Height Measurement Manually

Even though you have configured the automatical marking of particles for height measurement, you can add desired particles or remove them from the height measurement selection list.

  1. You are in Size Distribution (Live) view.
  1. In the Image Gallery, in the desired image, click
    .
  1. The particle is selected for height measurement. A second mouse click on this icon removes this particle from the height measurement selection list.

Particle Document

As an Operator, after running the job, you want to inspect the saved results of the Size Distribution view. This view is similar to the Size Distribution view, but without the acquisition and particle revision functionality.

Inspecting Results

  1. You have run a TCA job and saved it to the archive.
  2. You are in Browse Results mode.
  1. Select the Inspection-View-Document in the format .PADB and click .
  2. A view very similar to the Size Distribution view is displayed. The tools display statistical and approval information. You can use all filter functions.
  3. In the Image Gallery, select a particle and click the icon in the top right corner.
  4. The Inspection View view opens.
  5. In the Image Gallery, select the particle you want to inspect.
  6. The particle is centered in the view.
  7. You can zoom in and out to inspect the particle.
  8. When you have finished the inspection, click Close.

Interactive Particle Height Measurement View

The Interactive Particle Height Measurement view displays the particles that are intended for height measurement. In the Interactive Height Measurement workbench, in this view, you perform the height measurement.

Correcting Camera Offset

When using a TCA job template on a system with two cameras (AxioCam 705POL and a color camera, e.g. AxioCam 305c), there might be an offset between those cameras.

Example: Offset between AxioCam 705POL and color camera
Example: Offset between AxioCam 705POL and color camera

You check and correct the camera offset in the Edit View.

Note that you perform the offset correction on one particle and then the stage movement is corrected accordingly to the new coordinates for all particles. This applies only to the currently running job template. If you start the job template once more, you again need to correct the camera offset, because the offset settings are not saved.

  1. You are running a TCA job template in dual camera mode.
  2. You have acquired particle images.
  1. Go to the workflow step Size Distribution (Live), and in the Edit View check whether there is an offset between the two cameras.
  2. Here, you have the option to correct the offset. The Use Offset Correction checkbox is activated by default.
  3. Under Select Camera, select the color camera, and under Offset Correction, press Determine Offset.
  4. The Offset Correction mode is activated. The cursor changes to a cross.
  5. In Live View, click in the center of the particle whose stage coordinates you want to correct.
  6. The stage moves to the particle. The offset in displayed in µ in the Offset Correction control .
  7. If you are not satisfied with the result, click Reset

    and select the same particle again, or choose a more suitable one. Carry out the offset correction again.
  1. You have corrected the camera offset of the color camera. In the Position List with EDF workbench and in the Interactive Height Measurement workbench you can continue with your work with the stage set precisely. The new coordinates are also used here if you activate the color camera.

Saving Job Results

When you have finished your analysis, you save your job results to the archive. In the Browse Results mode, you have an overview over your jobs and documents. Here, you can export documents you cannot open in ZEN core, e. g. MS Excel files.

  1. In the Report workbench, click Exit Loop.
  2. The next view is displayed.
  3. Click Save and Close.
  4. The job and the corresponding documents containing the results are saved to the archive.

Saving Tables

Note that the decimals in tables are saved with full accuracy. But they are displayed according to your settings under Maintenance >General Options > Data Tables > Data Table > Decimal Places. By default, the decimals are clipped and not rounded.

If you export a table as MS Excel file to your local PC, you can change the settings within MS Excel when formatting the cell. You can rise the decimals, for example in case you want to reproduce the classification of a particle in Technical Cleanliness Analysis.

Documentation

Creating EDF Images for the Report

You can acquire EDF (Extended Depth of Focus) images of the largest particle per type for your report. This is only possible, if you are in a workflow with image acquisition. If you work with loaded images, the images of the Particle Gallery are displayed in the report.

In the Position List with EDF workbench, in the position list, the corresponding particle coordinates are saved by default. These are provided from the size distribution results and are used to acquire the EDF images.

  1. You have defined the number of EDF images you want to display in the report, see the Particle Gallery (Report) tool in the Standard Specific Settings workbench, see Particle Gallery (Report) (Components/Oil/Lubricants) Tool.
    Note that you cannot change these settings in the Position List with EDF workbench.
  2. You have defined individual settings for your microscope hardware and camera in the Position List with EDF workbench, in the Light Path Editing tool, see Light Path Editing Tool. This configuration is applied automatically before the EDF acquisition starts.
  1. Run the workflow.
  2. The EDF image is automatically acquired in the Position List with EDF workbench, in the EDF (motorized focus) tool.
  3. The EDF images are displayed in the particle gallery of the report. For your information, the particle length, width and area are shown below the corresponding particle image; for fibers, in addition the fiber length.

Data Results

You can view the analysis results in automatically generated results, for example tables. You can check the following results in Browse Results in the Result Documents area.

For opening tables, see Opening Selected Results in the Viewer.

Legend for the placeholders:

  • <Loop No>: Indicates the loop iteration in which the specimen analysis was performed. For a single sample, the loop number is 1, for multi samples, the numbering is incremented: loop no. = n.

Applied Parameters

This table informs you about the acquisition parameters of microscope and camera and additional parameters to reproduce the analysis result.

Particle Revision Table

This table informs you about particle revision steps (change of type, combine, cut, edit) that you have made in the Size Distribution view, see Changing Particle Type.

Results Statistics Table

This table informs you about the values of the Statistical Analysis in the Size Distribution view, see Statistical Analysis Tool.

Classification Table Particle Length <Standard> <Image no.>

This table informs you about the particle size distribution based on the selected length classification parameter displayed in the Size Distribution view in the Length Class Table, see Class Chart - Length Class Table.

Classification Table Particle Width <Standard> <Image no.>

This table informs you about the particle size distribution based on the selected width classification parameter) displayed in the Size Distribution view in the Width Class Table, see Class Chart - Width Class Table.

Calculation Table Illig Value <Standard> <Image no.>

This table shows the calculation of the Illig value, see Understanding the Illig Method. It is also displayed in the TCA report for component cleanliness analysis.

ParticleDocument <Image no.>

This document opens an inspection view identical to the Size Distribution view to inspect particles, see Inspecting Results. Here, you cannot modify the results.

ParticleTable_Specimen <Image no.>

This table informs you about each individual particle with all relevant measurement results.

<xy>-Loop-<Image no.>

This image includes the analysis results considering particle revision results.

ZEISS Form Technical Cleanliness-<No.>

This form displays the TCA input form, see Form Workbench.

TCA Report <No.>

This report displays general and global information as well as the presentation of the results, see Reports.

Equivalent Particle Area Table <Standard name> - <No.>

This table shows the calculation results of the equivalent total particle area, if activated in the job template, see Equivalent Particle Area (Components) Tool.

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