Computer aided inspection procedures to support smart manufacturing of injection moulded components

This work presents Reverse Engineering and Computer Aided technologies to improve the inspection of injection moulded electro-mechanical parts. Through a strong integration and automation of these methods, tolerance analysis, acquisition tool-path optimization and data management are performed. The core of the procedure concerns the automation of the data measure originally developed through voxel-based segmentation. This paper discusses the overall framework and its integration made according to Smart Manufacturing requirements. The experimental set-up, now in operative conditions at ABB SACE, is composed of a laser scanner installed on a CMM machine able to measure components with lengths in the range of 5÷250 mm, (b) a tool path optimization procedure and (c) a data management both developed as CAD-based applications

Digitization Methods of Grinding Pins for Technological Process Planning

The paper presents different techniques for digitizing grinding pins and discusses the use of digitalized pins and the results of measurements in technological process planning (TPP), focusing on the challenges of the digital era. It describes the potential of different measuring devices, taking into account the digitization of a real tool shape into virtual 2D and 3D models. The following methods for measuring grinding pins are presented in the study: contact and non-contact coordinate measurements – performed on coordinate measuring machines (CMM); optical measurements on microscopes (i.e. focus-variation technique); optical measurements using tool presetters; optical measurements with measuring arm; laser micrometer measurements; and laser triangulation sensor measurements. Moreover, the use of testers which are applied in contour measurements is analyzed. On the basis of the presented methods, taking into account their possibilities and limitations, we discuss how the obtained digital data can be used in the planning of technological processes.publishedVersio

Defining scanning trajectory for on-machine inspection using a laser-plane scanner

International audienceScan path planning for on-machine inspection in a 5-axis machine tool is still a challenge to measure part geometry in a minimum amount of time with a given scanning quality. Indeed, as the laser-plane scanner takes the place of the cutting tool, the time allocated to measurement must be reduced, but not at detrimental of the quality. In this direction, this paper proposes a method for scan path planning in a 5-axis machine tool with the control of scanning overlap. This method is an adaptation of a method dedicated to a robot that has proved its efficiency for part inspection

Texture wear analysis in textile floor coverings by using depth information

Considerable industrial and academic interest is addressed to automate the quality inspection of textile floor coverings, mostly using intensity images. Recently, the use of depth information has been explored to better capture the 3D structure of the surface. In this paper, we present a comparison of features extracted from three texture analysis techniques. The evaluation is based on how well the algorithms allow a good linear ranking and a good discriminance of consecutive wear labels. The results show that the use of Local Binary Patterns techniques result in a better ranking of the wear labels as well as in a higher amount of discrimination between features related to consecutive degrees of wear

A Novel Approach for 3D Part Inspection Using Laser-plane Sensors

AbstractThe paper deals with the relevance of using laser-plane sensors in 3D part inspection. First, based on the evaluation of the measuring system capacities, a digitizing strategy permits to obtain a set of points with a sufficient quality as regards geometrical specifications. Despite the optimized strategy, the digitizing noise associated to the sensor alters data quality, and may affect the estimation of the surface defects (form deviation for instance is strongly affected by digitizing noise). An original filtering method is proposed to remove digitizing noise before the evaluation of the specifications

Three-dimensional scanning as a means of archiving sculptures

Thesis (M. Tech. Design technology) -- Central University of Technology, Free State, 2011This dissertation outlines a procedural scanning process using the portable ZCorporation ZScanner® 700 and provides an overview of the developments surrounding 3D scanning technologies; specifically their application for archiving Cultural Heritage sites and projects. The procedural scanning process is structured around the identification of 3D data recording variables applicable to the digital archiving of an art museum’s collection of sculptures. The outlining of a procedural 3D scanning environment supports the developing technology of 3D digital archiving in view of artefact preservation and interactive digital accessibility. Presented in this paper are several case studies that record 3D scanning variables such as texture, scale, surface detail, light and data conversion applicable to varied sculptural surfaces and form. Emphasis is placed on the procedural documentation and the anomalies associated with the physical object, equipment used, and the scanning environment. In support of the above, the Cultural Heritage projects that are analyzed prove that 3D portable scanning could provide digital longevity and access to previously inaccessible arenas for a diverse range of digital data archiving infrastructures. The development of 3D data acquisition via scanning, CAD modelling and 2D to 3D data file conversion technologies as well as the aesthetic effect and standards of digital archiving in terms of the artwork – viewer relationship and international practices or criterions of 3D digitizing are analysed. These projects indicate the significant use of optical 3D scanning techniques and their employ on renowned historical artefacts thus emphasizing their importance, safety and effectiveness. The aim with this research is to establish that the innovation and future implications of 3D scanning could be instrumental to future technological advancement in an interdisciplinary capacity to further data capture and processing in various Cultural Heritage diagnostic applications

Feature-based hybrid inspection planning for complex mechanical parts

Globalization and emerging new powers in the manufacturing world are among many challenges, major manufacturing enterprises are facing. This resulted in increased alternatives to satisfy customers\u27 growing needs regarding products\u27 aesthetic and functional requirements. Complexity of part design and engineering specifications to satisfy such needs often require a better use of advanced and more accurate tools to achieve good quality. Inspection is a crucial manufacturing function that should be further improved to cope with such challenges. Intelligent planning for inspection of parts with complex geometric shapes and free form surfaces using contact or non-contact devices is still a major challenge. Research in segmentation and localization techniques should also enable inspection systems to utilize modern measurement technologies capable of collecting huge number of measured points. Advanced digitization tools can be classified as contact or non-contact sensors. The purpose of this thesis is to develop a hybrid inspection planning system that benefits from the advantages of both techniques. Moreover, the minimization of deviation of measured part from the original CAD model is not the only characteristic that should be considered when implementing the localization process in order to accept or reject the part; geometric tolerances must also be considered. A segmentation technique that deals directly with the individual points is a necessary step in the developed inspection system, where the output is the actual measured points, not a tessellated model as commonly implemented by current segmentation tools. The contribution of this work is three folds. First, a knowledge-based system was developed for selecting the most suitable sensor using an inspection-specific features taxonomy in form of a 3D Matrix where each cell includes the corresponding knowledge rules and generate inspection tasks. A Travel Salesperson Problem (TSP) has been applied for sequencing these hybrid inspection tasks. A novel region-based segmentation algorithm was developed which deals directly with the measured point cloud and generates sub-point clouds, each of which represents a feature to be inspected and includes the original measured points. Finally, a new tolerance-based localization algorithm was developed to verify the functional requirements and was applied and tested using form tolerance specifications. This research enhances the existing inspection planning systems for complex mechanical parts with a hybrid inspection planning model. The main benefits of the developed segmentation and tolerance-based localization algorithms are the improvement of inspection decisions in order not to reject good parts that would have otherwise been rejected due to misleading results from currently available localization techniques. The better and more accurate inspection decisions achieved will lead to less scrap, which, in turn, will reduce the product cost and improve the company potential in the market

Low-Cost Prototype to Automate the 3D Digitization of Pieces: An Application Example and Comparison

This work is aimed at describing the design of a mechanical and programmable 3D capturing system to be used by either 3D scanner or DSLR camera through photogrammetry. Both methods are widely used in diverse areas, from engineering, architecture or archaeology, up to the field of medicine; but they also entail certain disadvantages, such as the high costs of certain equipment, such as scanners with some precision, and the need to resort to specialized operatives, among others. The purpose of this design is to create a robust, precise and cost-effective system that improves the limitations of the present equipment on the market, such as robotic arms or rotary tables. For this reason, a preliminary study has been conducted to analyse the needs of improvement, later, we have focused on the 3D design and prototyping. For its construction, there have been used the FDM additive technology and structural components that are easy to find in the market. With regards to electronic components, basic electronics and Arduino-based 3D printers firmware have been selected. For system testing, the capture equipment consists of a Spider Artec 3D Scanner and a Nikon 5100 SLR Camera. Finally, 3D models have been developed by comparing the 3D meshes obtained by the two methods, obtaining satisfactory results

State-of-The-Art and Applications of 3D Imaging Sensors in Industry, Cultural Heritage, Medicine, and Criminal Investigation

3D imaging sensors for the acquisition of three dimensional (3D) shapes have created, in recent years, a considerable degree of interest for a number of applications. The miniaturization and integration of the optical and electronic components used to build them have played a crucial role in the achievement of compactness, robustness and flexibility of the sensors. Today, several 3D sensors are available on the market, even in combination with other sensors in a “sensor fusion” approach. An importance equal to that of physical miniaturization has the portability of the measurements, via suitable interfaces, into software environments designed for their elaboration, e.g., CAD-CAM systems, virtual renders, and rapid prototyping tools. In this paper, following an overview of the state-of-art of 3D imaging sensors, a number of significant examples of their use are presented, with particular reference to industry, heritage, medicine, and criminal investigation applications