A wireless sensor network-based approach to large-scale dimensional metrology

In many branches of industry, dimensional measurements have become an important part of the production cycle, in order to check product compliance with specifications. This task is not trivial especially when dealing with largescale dimensional measurements: the bigger the measurement dimensions are, the harder is to achieve high accuracies. Nowadays, the problem can be handled using many metrological systems, based on different technologies (e.g. optical, mechanical, electromagnetic). Each of these systems is more or less adequate, depending upon measuring conditions, user's experience and skill, or other factors such as time, cost, accuracy and portability. This article focuses on a new possible approach to large-scale dimensional metrology based on wireless sensor networks. Advantages and drawbacks of such approach are analysed and deeply discussed. Then, the article briefly presents a recent prototype system - the Mobile Spatial Coordinate-Measuring System (MScMS-II) - which has been developed at the Industrial Metrology and Quality Laboratory of DISPEA - Politecnico di Torino. The system seems to be suitable for performing dimensional measurements of large-size objects (sizes on the order of several meters). Owing to its distributed nature, the system - based on a wireless network of optical devices - is portable, fully scalable with respect to dimensions and shapes and easily adaptable to different working environments. Preliminary results of experimental tests, aimed at evaluating system performance as well as research perspectives for further improvements, are discusse

MScMS-II: an innovative IR-based indoor coordinate measuring system for large-scale metrology applications

According to the current great interest concerning large-scale metrology applications in many different fields of manufacturing industry, technologies and techniques for dimensional measurement have recently shown a substantial improvement. Ease-of-use, logistic and economic issues, as well as metrological performance are assuming a more and more important role among system requirements. This paper describes the architecture and the working principles of a novel infrared (IR) optical-based system, designed to perform low-cost and easy indoor coordinate measurements of large-size objects. The system consists of a distributed network-based layout, whose modularity allows fitting differently sized and shaped working volumes by adequately increasing the number of sensing units. Differently from existing spatially distributed metrological instruments, the remote sensor devices are intended to provide embedded data elaboration capabilities, in order to share the overall computational load. The overall system functionalities, including distributed layout configuration, network self-calibration, 3D point localization, and measurement data elaboration, are discussed. A preliminary metrological characterization of system performance, based on experimental testing, is also presente

Analysing uncertainty contributions in dimensional measurements of large-size objects by ultrasound sensors

According to the ever-increasing interest in metrological systems for dimensional measurements of large-size objects in a wide range of industrial sectors, several solutions based on different technologies, working principles, architectures and functionalities have been recently designed. Among these, a distributed flexible system based on a network of low-cost ultrasound (US) sensors - the Mobile Spatial coordinate Measuring System (MScMS) - has been developed. This article presents a possible approach to assess the system uncertainty referring to the measured point coordinates in the 3D space, focusing on the sources of measurement uncertainty and the related propagation la

Corrective algorithms for measurement improvement in MScMS-II (Mobile Spatial coordinate Measurement System)

This paper presents a set of algorithms for the correction of measurement errors of a prototype system designed for Large Scale Dimensional Metrology (LSDM) applications. The system, developed in the Quality and Industrial Metrology Laboratory of Politecnico di Torino, is based on the principles of photogrammetry and consists of a set of cameras wirelessly connected to a central unit able to track the position of a portable contact probe. Due to its architecture the system is affected by several systematic error sources. This paper addresses some of them: the distortion of the lenses, the dimension of the probe tip and the kinematic of the probe. By means of the implementation of appropriate mathematical correction models, the overall system performance is significantly improved as shown by the conducted test

Study and Characterization of a Camera-based Distributed System for Large-Volume Dimensional Metrology Applications

Large-Volume Dimensional Metrology (LVDM) deals with dimensional inspection of large objects with dimensions in the order of tens up to hundreds of meters. Typical large volume dimensional metrology applications concern the assembly/disassembly phase of large objects, referring to industrial engineering. Based on different technologies and measurement principles, a wealth of LVDM systems have been proposed and developed in the literature, just to name a few, e.g., optical based systems such as laser tracker, laser radar, and mechanical based systems such as gantry CMM and multi-joints artificial arm CMM, and so on. Basically, the main existing LVDM systems can be divided into two categories, i.e. centralized systems and distributed systems, according to the scheme of hardware configuration. By definition, a centralized system is a stand-alone unit which works independently to provide measurements of a spatial point, while a distributed system, is defined as a system that consists of a series of sensors which work cooperatively to provide measurements of a spatial point, and usually individual sensor cannot measure the coordinates separately. Some representative distributed systems in the literature are iGPS, MScMS-II, and etc. The current trend of LVDM systems seem to orient towards distributed systems, and actually, distributed systems demonstrate many advantages that distinguish themselves from conventional centralized systems

The Mobile Spatial coordinate Measuring System II (MScMS-II):system description and preliminary assessmentof the measurement uncertainty

According to the increasing interest in metrological systems for the dimensional measurements of large-size objects in a wide range of industrial sectors, several solutions based on different technologies, working principles, architectures, and functionalities have recently been developed. Among all, the most flexible and easily transportable solutions are those that have aroused most interest and have found greater success. In order to address the needs of Large-Scale Metrology (LSM) applications, a distributed flexible system based on a network of low-cost InfraRed (IR) sensors – the Mobile Spatial coordinate Measuring System II (MScMS-II) – has been developed at the Industrial Quality and Metrology Laboratory of Politecnico di Torino. This paper presents a preliminary uncertainty assessment of the system referring to the measured point coordinates in the 3D space, focusing on the sources of measurement uncertainty and the related propagation laws. A preliminary metrological characterization of MScMS-II architecture, experimentally evaluated through a system prototype, is also presented and discussed

Review of industrial temperature measurement technologies and research priorities for the thermal characterisation of the factories of the future

As the largest source of dimensional measurement uncertainty, addressing the challenges of thermal variation is vital to ensure product and equipment integrity in the factories of the future. While it is possible to closely control room temperature, this is often not practical or economical to realise in all cases where inspection is required. This article reviews recent progress and trends in seven key commercially available industrial temperature measurement sensor technologies primarily in the range of 0 °C–50 °C for invasive, semi-invasive and non-invasive measurement. These sensors will ultimately be used to measure and model thermal variation in the assembly, test and integration environment. The intended applications for these technologies are presented alongside some consideration of measurement uncertainty requirements with regard to the thermal expansion of common materials. Research priorities are identified and discussed for each of the technologies as well as temperature measurement at large. Future developments are briefly discussed to provide some insight into which direction the development and application of temperature measurement technologies are likely to head

Verification of the indoor GPS system, by comparison with calibrated coordinates and by angular reference

This paper details work carried out to verify the dimensional measurement performance of the Indoor GPS (iGPS) system; a network of Rotary-Laser Automatic Theodolites (R-LATs). Initially tests were carried out to determine the angular uncertainties on an individual R-LAT transmitter-receiver pair. A method is presented of determining the uncertainty of dimensional measurement for a three dimensional coordinate measurement machine. An experimental procedure was developed to compare three dimensional coordinate measurements with calibrated reference points. The reference standard used to calibrate these reference points was a fringe counting interferometer with the multilateration technique employed to establish three dimensional coordinates. This is an extension of the established technique of comparing measured lengths with calibrated lengths. The method was found to be practical and able to establish that the expanded uncertainty of the basic iGPS system was approximately 1 mm at a 95% confidence level. Further tests carried out on a highly optimized version of the iGPS system have shown that the coordinate uncertainty can be reduced to 0.25 mm at a 95% confidence level