Rapid Prototyping Using Three-Dimensional Computer Vision

A method for building model data for CAD and CAM purposes from physical instances using three-dimensional sensor data is presented. These techniques are suitable for Reverse Engineering of industrial parts, and can be used as a design aid as well. The nature of the reverse engineering task is quantitative, and the emphasis is on accurate recovery of the geometry of the part, whereas the object recognition task is qualitative, and aims to recognize similar shapes. The proposed method employs multiple representation to build a CAD model for the part, and to produce useful information for part analysis and process planning. The model building strategy is selected based on the obtained surface and volumetric data descriptions and their quality. A novel, robust non-linear filtering method is presented to attenuate noise from sensor data. Volumetric description is obtained by recovering a superquadric model for the whole data set. A surface characterization process is used to determine the complexity of the underlying surface. A substantial data compression can be obtained by approximating huge amount sensor data by B-spline surfaces. As a result a Boundary Representation model for Alpha-1 solid modeling system is constructed. The model data is represented both in Alpha-1 modeling language and IGES product data exchange format. Experimental results for standard geometric shapes and for sculptured free-form surfaces are presented using both real and synthetic range data

Multiple Representation Approach to Geometric Model Construction From Range Data

A method is presented for constructing geometric design data from noisy 3-D sensor measurements of physical parts. In early processing phase, RLTS regression filters stemming from robust estimation theory are used for separating the desired part of the signal in contaminated sensor data from undesired part. Strategies for producing a complete 3-D data set from partial views are studied. Multiple representations are used in model construction because there is no single representation that would be most appropriate in all situations. In particular, surface triangulation, NURBS, and super-ellipsoids are employed in order to represent efficiently polygonal and irregular shapes, free form surfaces and standard primitive solids. The size of the required control point mesh for spline description is estimated using a surface characterization process. Surfaces of arbitrary topology are modeled using triangulation and trimmed NURBS. A user given tolerance value is driving refinement of the obtained surface model. The resulting model description is a procedural CAD model which can convey structural information in addition to low level geometric primitives. The model is translated to IGES standard product data exchange format to enable data sharing with other processes in concurrent engineering environment. Preliminary results on view registration using simulated data are shown. Examples of model construction using both real and simulated data are also given

Design, test, and evaluation of three active flutter suppression controllers

Three control law design techniques for flutter suppression are presented. Each technique uses multiple control surfaces and/or sensors. The first method uses traditional tools (such as pole/zero loci and Nyquist diagrams) for producing a controller that has minimal complexity and which is sufficiently robust to handle plant uncertainty. The second procedure uses linear combinations of several accelerometer signals and dynamic compensation to synthesize the model rate of the critical mode for feedback to the distributed control surfaces. The third technique starts with a minimum-energy linear quadratic Gaussian controller, iteratively modifies intensity matrices corresponding to input and output noise, and applies controller order reduction to achieve a low-order, robust controller. The resulting designs were implemented digitally and tested subsonically on the active flexible wing wind-tunnel model in the Langley Transonic Dynamics Tunnel. Only the traditional pole/zero loci design was sufficiently robust to errors in the nominal plant to successfully suppress flutter during the test. The traditional pole/zero loci design provided simultaneous suppression of symmetric and antisymmetric flutter with a 24-percent increase in attainable dynamic pressure. Posttest analyses are shown which illustrate the problems encountered with the other laws

Active control of aerothermoelastic effects for a conceptual hypersonic aircraft

Procedures for and results of aeroservothermoelastic studies are described. The objectives of these studies were to develop the necessary procedures for performing an aeroelastic analysis of an aerodynamically heated vehicle and to analyze a configuration in the classical cold state and in a hot state. Major tasks include the development of the structural and aerodynamic models, open loop analyses, design of active control laws for improving dynamic responses and analyses of the closed loop vehicles. The analyses performed focused on flutter speed calculations, short period eigenvalue trends and statistical analyses of the vehicle response to controls and turbulence. Improving the ride quality of the vehicle and raising the flutter boundary of the aerodynamically-heated vehicle up to that of the cold vehicle were the objectives of the control law design investigations

Superquadric representation of scenes from multi-view range data

Object representation denotes representing three-dimensional (3D) real-world objects with known graphic or mathematic primitives recognizable to computers. This research has numerous applications for object-related tasks in areas including computer vision, computer graphics, reverse engineering, etc. Superquadrics, as volumetric and parametric models, have been selected to be the representation primitives throughout this research. Superquadrics are able to represent a large family of solid shapes by a single equation with only a few parameters. This dissertation addresses superquadric representation of multi-part objects and multiobject scenes. Two issues motivate this research. First, superquadric representation of multipart objects or multi-object scenes has been an unsolved problem due to the complex geometry of objects. Second, superquadrics recovered from single-view range data tend to have low confidence and accuracy due to partially scanned object surfaces caused by inherent occlusions. To address these two problems, this dissertation proposes a multi-view superquadric representation algorithm. By incorporating both part decomposition and multi-view range data, the proposed algorithm is able to not only represent multi-part objects or multi-object scenes, but also achieve high confidence and accuracy of recovered superquadrics. The multi-view superquadric representation algorithm consists of (i) initial superquadric model recovery from single-view range data, (ii) pairwise view registration based on recovered superquadric models, (iii) view integration, (iv) part decomposition, and (v) final superquadric fitting for each decomposed part. Within the multi-view superquadric representation framework, this dissertation proposes a 3D part decomposition algorithm to automatically decompose multi-part objects or multiobject scenes into their constituent single parts consistent with human visual perception. Superquadrics can then be recovered for each decomposed single-part object. The proposed part decomposition algorithm is based on curvature analysis, and includes (i) Gaussian curvature estimation, (ii) boundary labeling, (iii) part growing and labeling, and (iv) post-processing. In addition, this dissertation proposes an extended view registration algorithm based on superquadrics. The proposed view registration algorithm is able to handle deformable superquadrics as well as 3D unstructured data sets. For superquadric fitting, two objective functions primarily used in the literature have been comprehensively investigated with respect to noise, viewpoints, sample resolutions, etc. The objective function proved to have better performance has been used throughout this dissertation. In summary, the three algorithms (contributions) proposed in this dissertation are generic and flexible in the sense of handling triangle meshes, which are standard surface primitives in computer vision and graphics. For each proposed algorithm, the dissertation presents both theory and experimental results. The results demonstrate the efficiency of the algorithms using both synthetic and real range data of a large variety of objects and scenes. In addition, the experimental results include comparisons with previous methods from the literature. Finally, the dissertation concludes with a summary of the contributions to the state of the art in superquadric representation, and presents possible future extensions to this research

Simulation of pore-scale flow using finite element-methods

I present a new finite element (FE) simulation method to simulate pore-scale flow. Within the pore-space, I solve a simplified form of the incompressible Navier-Stoke’s equation, yielding the velocity field in a two-step solution approach. First, Poisson’s equation is solved with homogeneous boundary conditions, and then the pore pressure is computed and the velocity field obtained for no slip conditions at the grain boundaries. From the computed velocity field I estimate the effective permeability of porous media samples characterized by thin section micrographs, micro-CT scans and synthetically generated grain packings. This two-step process is much simpler than solving the full Navier Stokes equation and therefore provides the opportunity to study pore geometries with hundreds of thousands of pores in a computationally more cost effective manner than solving the full Navier-Stoke’s equation. My numerical model is verified with an analytical solution and validated on samples whose permeabilities and porosities had been measured in laboratory experiments (Akanji and Matthai, 2010). Comparisons were also made with Stokes solver, published experimental, approximate and exact permeability data. Starting with a numerically constructed synthetic grain packings, I also investigated the extent to which the details of pore micro-structure affect the hydraulic permeability (Garcia et al., 2009). I then estimate the hydraulic anisotropy of unconsolidated granular packings. With the future aim to simulate multiphase flow within the pore-space, I also compute the radii and derive capillary pressure from the Young-Laplace equation (Akanji and Matthai,2010

AN INTELLIGENT SYSTEM FOR THE DEFECT INSPECTION OF SPECULAR PAINTED CERAMIC TILES

Product visual inspection is still performed manually or semi automatically in most industries from simple ceramic tile grading to complicated automotive body panel paint defect and surface quality inspection. Moreover, specular surfaces present additional challenges to conventional vision systems due to specular reflections, which may mask the true location of objects and lead to incorrect measurements. Some sophisticated optical inspection methods have already been developed for high precision surface defect inspection in recent years. Unfortunately, most of them are highly computational. Systems built on those methods are either inapplicable or costly to achieve real-time inspection. This thesis describes an integrated low-cost intelligent system developed to automatically capture and extract regular defects of the ceramic tiles with uniformly colored specular coatings. The proposed system is implemented on a group of smart cameras using its on-board processing ability to achieve real-time inspection. The results of this study will be used to facilitate the design of a robust, low-cost, closed-loop inspection system for a class of products with smooth specular coatings. The experimental results on real test panels demonstrate the effectiveness and robustness of proposed system

Patch-wise Quadrature of Trimmed Surfaces in Isogeometric Analysis

This work presents an efficient quadrature rule for shell analysis fully integrated in CAD by means of Isogeometric Analysis (IGA). General CAD-models may consist of trimmed parts such as holes, intersections, cut-offs etc. Therefore, IGA should be able to deal with these models in order to fulfil its promise of closing the gap between design and analysis. Trimming operations violate the tensor-product structure of the used Non-Uniform Rational B-spline (NURBS) basis functions and of typical quadrature rules. Existing efficient patch-wise quadrature rules consider actual knot vectors and are determined in 1D. They are extended to further dimensions by means of a tensor-product. Therefore, they are not directly applicable to trimmed structures. The herein proposed method extends patch-wise quadrature rules to trimmed surfaces. Thereby, the number of quadrature points can be signifficantly reduced. Geometrically linear and non-linear benchmarks of plane, plate and shell structures are investigated. The results are compared to a standard trimming procedure and a good performance is observed