A sensor data fusion-based locating method for large-scale metrology

The measurement of geometric and dimensional variations in the context of large-sized products is a complex operation. One of the most efficient ways to identify deviations is by comparing the nominal object with a digitalisation of the real object through a reverse engineering process. The accurate digitalisation of large geometric models usually requires multiple acquisitions from different acquiring locations; the acquired point clouds must then be correctly aligned in the 3D digital environment. The identification of the exact scanning location is crucial to correctly realign point clouds and generate an accurate 3D CAD model. To achieve this, an acquisition method based on the use of a handling device is proposed that enhances reverse engineering scanning systems and is able to self-locate. The present paper tackles the device’s locating problem by using sensor data fusion based on a Kalman filter. The method was firstsimulated in a MatLAB environment; a prototype was then designed and developed using low-cost hardware. Tests on the sensor data fusion have shown a locating accuracy better than that of each individual sensor. Despite the low-cost hardware, the results are encouraging and open to future improvements

3D indoor topological modelling based on homotopy continuation

Indoor navigation is important for various applications such as disaster management, building modelling and safety analysis. In the last decade, the indoor environment has been a focus of extensive research that includes the development of indoor data acquisition techniques, three-dimensional (3D) data modelling and indoor navigation. 3D indoor navigation modelling requires a valid 3D geometrical model that can be represented as a cell complex: a model without any gap or intersection such that the two cells, a room and corridor, should perfectly touch each other. This research is to develop a method for 3D topological modelling of an indoor navigation network using a geometrical model of an indoor building environment. To reduce the time and cost of the surveying process, a low-cost non-contact range-based surveying technique was used to acquire indoor building data. This technique is rapid as it requires a shorter time than others, but the results show inconsistencies in the horizontal angles for short distances in indoor environments. The rangefinder was calibrated using the least squares adjustment and a polynomial kernel. A method of combined interval analysis and homotopy continuation was developed to model the uncertainty level and minimize error of the non-contact range-based surveying techniques used in an indoor building environment. Finally, a method of 3D indoor topological building modelling was developed as a base for building models which include 3D geometry, topology and semantic information. The developed methods in this research can locate a low-cost, efficient and affordable procedure for developing a disaster management system in the near-future

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

Proceedings of the 5th Baltic Mechatronics Symposium - Espoo April 17, 2020

The Baltic Mechatronics Symposium is annual symposium with the objective to provide a forum for young scientists from Baltic countries to exchange knowledge, experience, results and information in large variety of fields in mechatronics. The symposium was organized in co-operation with Taltech and Aalto University. Due to Coronavirus COVID-19 the symposium was organized as a virtual conference. The content of the proceedings1. Monitoring Cleanliness of Public Transportation with Computer Vision2. Device for Bending and Cutting Coaxial Wires for Cryostat in Quantum Computing3. Inertial Measurement Method and Application for Bowling Performance Metrics4. Mechatronics Escape Room5. Hardware-In-the-Loop Test Setup for Tuning Semi-Active Hydraulic Suspension Systems6. Newtonian Telescope Design for Stand-off Laser Induced Breakdown Spectroscopy7. Simulation and Testing of Temperature Behavior in Flat Type Linear Motor Carrier8. Powder Removal Device for Metal Additive Manufacturing9. Self-Leveling Spreader Beam for Adjusting the Orientation of an Overhead Crane Loa

Calibration and 3D Model Generation for a Low-Cost Structured Light Foot Scanner

The need for custom footwear among the consumers is growing every day. Serious research is being undertaken with regards to the fit and comfort of the footwear. The integration of scanning systems in the footwear and orthotic industries have played a significant role in generating 3D digital representation of the foot for automated measurements from which a custom footwear or an orthosis is manufactured. The cost of such systems is considerably high for many manufacturers due to their expensive components, complex processing algorithms and difficult calibration techniques. This thesis presents a fast and robust calibration technique for a low-cost 3D laser scanner. The calibration technique is based on determining the mathematical relationship that relates the image coordinates to the real world coordinates. The relationship is determined by mapping the known real world coordinates of a reference object to its corresponding image coordinates by multivariate polynomial regression. With the developed mathematical relationship, 3D data points can be obtained from the 2D images of any object placed in the scanner. An image processing script is developed to detect the 2D image points of the laser profile in a series of scan images from 8 cameras. The detected 2D image points are reconstructed into 3D data points based on the mathematical model developed by the calibration process. Following that, the output model is achieved by triangulating the 3D data points as a mesh model with vertices and normals. The data is exported as a computer aided design (CAD) software readable format for viewing and measuring. This method proves to be less complex and the scanner was able to generate 3D models with an accuracy of +/-0.05 cm. The 3D data points from the output model were compared against a reference model scanned by an industrial grade scanner to verify and validate the result. The devised methodology for calibrating the 3D laser scanner can be employed to obtain accurate and reliable 3D data of the foot shape and it has been successfully tested with several participants

Characterization and calibration of multiple 2D laser scanners

This paper presents the comparative evaluation of multiple compact and lightweight 2D laser scanners for their possible backpack based scanning and mapping applications. These scanners include Hokuyo URG-04LX, Slamtec RPLidar A1-M8 and Hokuyo UTM- 30LX-EW scanners. Since the technical datasheets provide general information and limited working details, this research presents a thorough study on the performance of each scanner related explicitly to indoor mapping operations. A series of scanning experiments have been performed for the characterization of each scanner using statistical analysis. During the testing, all the scanning data has been recorded using Robot Operating System (ROS) and then computed in offline processing. In initial tests, each scanner's drift effect on range measurements has been tested and presented in the relevant section of the paper. In continuation, the effect of various scanning distances on measurement accuracy has been evaluated and discussed. Later the impact of various materials typically found in indoor vicinities and their respective properties of color and smoothness have been tested and provided in the paper. Finally, a Kalman Filtering based mathematical formulation has been utilized to calibrate each scanner and to reduce the measuring uncertainties as observed in various tests for each scanner

Optical measurement of shape and deformation fields on challenging surfaces

A multiple-sensor optical shape measurement system (SMS) based on the principle of white-light fringe projection has been developed and commercialised by Loughborough University and Phase Vision Ltd for over 10 years. The use of the temporal phase unwrapping technique allows precise and dense shape measurements of complex surfaces; and the photogrammetry-based calibration technique offers the ability to calibrate multiple sensors simultaneously in order to achieve 360° measurement coverage. Nevertheless, to enhance the applicability of the SMS in industrial environments, further developments are needed (i) to improve the calibration speed for quicker deployment, (ii) to broaden the application range from shape measurement to deformation field measurement, and (iii) to tackle practically-challenging surfaces of which specular components may disrupt the acquired data and result in spurious measurements. The calibration process typically requires manual positioning of an artefact (i.e., reference object) at many locations within the view of the sensors. This is not only timeconsuming but also complicated for an operator with average knowledge of metrology. This thesis introduces an automated artefact positioning system which enables automatic and optimised distribution of the artefacts, automatic prediction of their whereabouts to increase the artefact detection speed and robustness, and thereby greater overall calibration performance. This thesis also describes a novel technique that integrates the digital image correlation (DIC) technique into the present fringe projection SMS for the purpose of simultaneous shape and deformation field measurement. This combined technique offers three key advantages: (a) the ability to deal with geometrical discontinuities which are commonly present on mechanical surfaces and currently challenging to most deformation measurement methods, (b) the ability to measure 3D displacement fields with a basic single-camera single-projector SMS with no additional hardware components, and (c) the simple implementation on a multiple-sensor hardware platform to achieve complete coverage of large-scale and complex samples, with the resulting displacement fields automatically lying in a single global coordinate system. A displacement measurement iii accuracy of ≅1/12,000 of the measurement volume, which is comparable to that of an industry-standard DIC system, has been achieved. The applications of this novel technique to several structural tests of aircraft wing panels on-site at the research centre of Airbus UK in Filton are also presented. Mechanical components with shiny surface finish and complex geometry may introduce another challenge to present fringe projection techniques. In certain circumstances, multiple reflections of the projected fringes on an object surface may cause ambiguity in the phase estimation process and result in incorrect coordinate measurements. This thesis presents a new technique which adopts a Fourier domain ranging (FDR) method to correctly identifying multiple phase signals and enables unambiguous triangulation for a measured coordinate. Experiments of the new FDR technique on various types of surfaces have shown promising results as compared to the traditional phase unwrapping techniques

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