Optical Microscopy for High-Resolution IPMC Displacement Measurement.

This study presents an integrated, low-cost system for measuring extremely small displacements in Ionic Polymer-Metal Composite (IPMC) actuators operating in aqueous environments. A custom optical setup was developed, combining a glass tank, a tubular microscope with a 10× achromatic objective, a digital USB camera and uniform LED backlighting, enabling side-view imaging of the actuator with high contrast. The microscopy system achieves a spatial sampling of 0.536 μm/pixel on the horizontal axis and 0.518 μm/pixel on the vertical axis, while lens distortion is limited to a maximum edge deviation of +0.015 μm/pixel (≈+2.8%), ensuring consistent geometric magnification across the field of view. On the image-processing side, a predictive grid-based tracking algorithm is introduced to localize the free tip of the IPMC. The method combines edge detection, Harris corners and a constant-length geometric constraint with an adaptive search over selected grid cells. On 1920 × 1080-pixel frames, the proposed algorithm achieves a mean processing time of about 10 ms per frame and a frame-level detection accuracy of approximately 99% (98.3-99.4% depending on the allowed search radius) for actuation frequencies below 2 Hz, enabling real-time monitoring at 30 fps. In parallel, dedicated electronic circuitry for supply and load monitoring provides overvoltage, undervoltage, open-circuit and short-circuit detection in 100 injected fault events, all faults were detected and no spurious triggers over 3 h of nominal operation. The proposed microscopy and tracking framework offer a compact, reproducible and high-resolution alternative to laser-based or Digital Image Correlation techniques for IPMC displacement characterization and can be extended to other micro-displacement sensing applications in submerged or challenging environments.