Evaluation of Gap and Flush Inspection Algorithms in a Portable Laser Line Triangulation System Through Measurement System Analysis (MSA)

The shift toward Industry 5.0 places human-centred and digitally integrated metrology at the core of modern manufacturing, particularly in the automotive sector, where portable Laser Line Triangulation (LLT) systems must combine accuracy with operator usability. This study addresses the challenge of operator-induced variability by evaluating how algorithmic strategies and mechanical support features jointly influence the performance of a portable LLT device derived from the G3F sensor. A comprehensive Measurement System Analysis was performed to compare three feature extraction algorithms—GC, FIR, and Steger—and to assess the effect of a masking device designed to improve mechanical alignment during manual measurements. The results highlight distinct algorithm-dependent behaviours in terms of repeatability, reproducibility, and computational efficiency. More sophisticated algorithms demonstrate improved sensitivity and feature localisation under controlled conditions, whereas simpler gradient-based strategies provide more stable performance and shorter processing times when measurement conditions deviate from the ideal. These differences indicate a trade-off between algorithmic complexity and operational robustness that is particularly relevant for portable, operator-assisted metrology. The presence of mechanical alignment aids was found to contribute to improved measurement consistency across all algorithms. Overall, the findings highlight the need for an integrated co-design of algorithms, calibration procedures, and ergonomic aids to enhance repeatability and support operator-friendly LLT systems aligned with Industry 5.0 principles.