The quality test is one of the main components of a production process. The main task of the quality test is the
inspection of the relevant geometry parts concerning the predefined tolerance range. To verify, that the relevant
geometry parts can be detected with a measurement uncertainty, which is less than the predefined tolerance
range, multiple measurements of an appropriate reference specimen have to be done. The related time and
money effort is very high and can be reduced using a numerical simulation of the whole measurement process.
The measurement uncertainty can be estimated using a virtual measurement process and Monte-Carlo methods.
Using the combination of the simulation and Monte-Carlo methods, it is, for example, possible, to calculate the
optimal alignment of the workpiece within the measurement volume. Thereby, the optimality criterion can be
defined as a minimum of the measurement uncertainty or as a hollistic measurement.
In addition to the estimation of uncertainties, it is possible to use the virtual measurement system as part
of an assistance system. The assistance system should provide measurement strategies with respect to different
criteria, like the minimisation of the measurement uncertainty. This is the field of research of the subproject B5
of the collaborative research centre 489 (CRC 489), funded by the German Research Foundation (DFG). The
main task is the setup of a virtual multisensor assistance system for the calculation of optimised work piece
adapted measurement strategies.
In this paper the virtual measurement system and process of a shadow projection system will be explained
in detail. Besides the mathematical model, a verification of the simulation and a concept for the estimation of
measurement uncertainties will be given.