93 research outputs found

    Three-Dimensional Shape Measurements of Specular Objects Using Phase-Measuring Deflectometry

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    The fast development in the fields of integrated circuits, photovoltaics, the automobile industry, advanced manufacturing, and astronomy have led to the importance and necessity of quickly and accurately obtaining three-dimensional (3D) shape data of specular surfaces for quality control and function evaluation. Owing to the advantages of a large dynamic range, non-contact operation, full-field and fast acquisition, high accuracy, and automatic data processing, phase-measuring deflectometry (PMD, also called fringe reflection profilometry) has been widely studied and applied in many fields. Phase information coded in the reflected fringe patterns relates to the local slope and height of the measured specular objects. The 3D shape is obtained by integrating the local gradient data or directly calculating the depth data from the phase information. We present a review of the relevant techniques regarding classical PMD. The improved PMD technique is then used to measure specular objects having discontinuous and/or isolated surfaces. Some influential factors on the measured results are presented. The challenges and future research directions are discussed to further advance PMD techniques. Finally, the application fields of PMD are briefly introduce

    A gaussian process-based multi-sensor metrology system for precision measurement of freeform surfaces

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    Nowadays, precision freeform surfaces play an important role since they have superior performance and indispensable functionalities. Due to their geometrical complexity, high form accuracy and low surface roughness, precision freeform surfaces introduce a lot of research challenges in precision manufacturing and measurement processes. This is particularly true when the measurement is performed on traditional off-line single-sensor instruments such as white light interferometers (WLIs) and coordinate measuring machines (CMMs) whose measurement abilities are limited. For a single-sensor instrument, the measurement range and measurement resolution always need to strike a balance since the two terms appear to be contradictory. Moreover, when the workpiece is extremely large and error compensation procedure is needed to correct the form error of the workpiece, it is necessary to perform the measurement on machining facilities since repositioning error is unacceptable. However, off-line based measurement instruments cannot fulfil the in-situ measurement requirement. To address the above issues, this research firstly established a generic Gaussian process data modelling and image registration-based stitching method for the measurement of precision freeform surfaces based on traditional single-sensor surface measurement instruments using multiple measurement methods. With the proposed method, a dataset with a large measurement range and high resolution can be obtained. The proposed stitching method provides a turn-key solution for high dynamic range measurement using single-sensor instruments with a multiple measurement method. For multi-sensor instruments such as multi-sensor coordinate measuring machines (CMMs), this study proposes a Gaussian process-based data modelling and maximum likelihood data fusion method for the measurement of freeform surfaces for multi-sensor CMMs. The method utilizes an optical sensor such as laser sensor and a touch trigger probe mounted on the multi-sensor coordinate measuring machine for the measurement of freeform surfaces, and the measurement data are modelled using the Gaussian process modelling method. The combination of different kinds of sensors balances the measurement efficiency and accuracy since most optical sensors have a fast measurement speed and high density but low accuracy while contact sensors have an accurate measurement result but low efficiency. The measurement datasets from the laser sensor and touch trigger probe were fused with a maximum likelihood method so as to reduce the overall measurement uncertainty. To address the in-situ measurement issue, this thesis proposes an autonomous multi-sensor in-situ metrology system for high dynamic range measurement of freeform surfaces for precision machine tools. The system utilizes a laser scanner and a motion sensor together with a designed trajectory so as to perform in-situ measurement on the machining facilities. The proposed system is independent of the machining facilities which makes it extendable to a wide range of industrial applications. Based on the theory developed for the autonomous multi-sensor in-situ metrology system, a homogeneous multi-sensor in-situ measurement metrology system was developed equipped with a laser line sensor and laser point sensor. The laser line sensor provides high lateral resolution data while the laser point sensor gives accurate data. The measurement data from these two kinds of sensors are fused to obtain a more accurate result without losing the high lateral resolution. The present study has very large potential applications in industry. The successful development of the Gaussian process and image registration-based stitching method provides an important means for high dynamic range measurement, while the Gaussian process-based data modelling and maximum likelihood-based data fusion method establishes a generic measurement strategy for multi-sensor coordinate measuring machines so as to improve the measurement accuracy for precision freeform surfaces. The proposed in-situ multi-sensor high dynamic range measurement method and hence the homogeneous multi-sensor in-situ metrology system enable the measurement ability of machine tools so as to improve the efficiency and accuracy of the precision manufacture of complex freeform surfaces. The outcome of the research contributes significantly to the measurement science and technology, especially in the field of multi-sensor measurement and in-situ measurement of precision freeform surfaces

    Smart optical coordinate and surface metrology

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    Manufacturing has recently experienced increased adoption of optimised and fast solutions for checking product quality during fabrication, allowing for manufacturing times and costs to be significantly reduced. Due to the integration of machine learning algorithms, advanced sensors and faster processing systems, smart instruments can autonomously plan measurement pipelines, perform decisional tasks and trigger correctional actions as required. In this paper, we summarise the state of the art in smart optical metrology, covering the latest advances in integrated intelligent solutions in optical coordinate and surface metrology, respectively for the measurement of part geometry and surface texture. Within this field, we include the use of a priori knowledge and implementation of machine learning algorithms for measurement planning optimisation. We also cover the development of multi-sensor and multi-view instrument configurations to speed up the measurement process, as well as the design of novel feedback tools for measurement quality evaluation

    Integrated tactile-optical coordinate measurement for the reverse engineering of complex geometry

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    Complex design specifications and tighter tolerances are increasingly required in modern engineering applications, either for functional or aesthetic demands. Multiple sensors are therefore exploited to achieve both holistic measurement information and improved reliability or reduced uncertainty of measurement data. Multi-sensor integration systems can combine data from several information sources (sensors) into a common representational format in order that the measurement evaluation can benefit from all available sensor information and data. This means a multi-sensor system is able to provide more efficient solutions and better performances than a single sensor based system. This thesis develops a compensation approach for reverse engineering applications based on the hybrid tactile-optical multi-sensor system. In the multi-sensor integration system, each individual sensor should be configured to its optimum for satisfactory measurement results. All the data measured from different equipment have to be precisely integrated into a common coordinate system. To solve this problem, this thesis proposes an accurate and flexible method to unify the coordinates of optical and tactile sensors for reverse engineering. A sphere-plate artefact with nine spheres is created and a set of routines are developed for data integration of a multi-sensor system. Experimental results prove that this novel centroid approach is more accurate than the traditional method. Thus, data sampled by different measuring devices, irrespective of their location can be accurately unified. This thesis describes a competitive integration for reverse engineering applications where the point cloud data scanned by the fast optical sensor is compensated and corrected by the slower, but more accurate tactile probe measurement to improve its overall accuracy. A new competitive approach for rapid and accurate reverse engineering of geometric features from multi-sensor systems based on a geometric algebra approach is proposed and a set of programs based on the MATLAB platform has been generated for the verification of the proposed method. After data fusion, the measurement efficiency is improved 90% in comparison to the tactile method and the accuracy of the reconstructed geometric model is improved from 45 micrometres to 7 micrometres in comparison to the optical method, which are validated by case study

    Integrated Quality Control of Precision Assemblies using Computed Tomography

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    Metrological characterization of 3D imaging systems: progress report on standards developments

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    A significant issue for companies or organizations integrating non-contact three-dimensional (3D) imaging systems into their production pipeline is deciding in which technology to invest. Quality non-contact 3D imaging systems typically involve a significant investment when considering the cost of equipment, training, software, and maintenance contracts over the functional lifetime of a given system or systems notwithstanding the requirements of the global nature of manufacturing activities. Numerous methods have been published to “help” users navigate the many products and specifications claims about “quality”. Moreover, the “best” system for one application may not be ideally suited for another application. The lack of publically-available characterization methods from trusted sources for certain areas of 3D imaging make it difficult for a typical user to select a system based on information written on a specification sheet alone. An internationally-recognized standard is a vehicle that allows better communication between users and manufacturers. It is in this context that we present a progress report on standards developments to date in the diverse, but finite, world of non-contact 3D imaging systems from the nanometre to the 100 m range

    The development and application of an original 3D laser scanning: a precise and nondestructive structural measurements system

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    Recently, a number of non-destructive testings equipment (NDTs) which can partially replace human-conducted onsite inspections has been implemented for detecting modern civil architectural structures. However, the situation of implementing 3D laser scanning measurement technology worldwide is not optimistic: several inconvenient flaws is troubling users (e.g., heavy, costly, hard to move, hard to inspect and etc.). Therefore, a new equipment to fix those problems is urgently demanded. This paper aims to thoroughly analyze the issue and then develop a feasible. A 3D laser scanning system composed of high precision elevating platform and small 2D laser ranging sensor is designed. Manufacture Process of 3D laser scanning system is describes in detail. Based on the bending fatigue loading test, the scanning designed efficiency and feasibility had been proved by comparing and analyzing traditional measurement results. The designed 3D laser scanning system can quickly capture the information of micro-damage and depth of the structure. Its detecting performance is better than the traditional methods. To overcome the challenges of the 3D laser scanning on-site measurement technology, this article proposed the manufacture process of the 3D scanning system with a high precision, miniaturization and lightweight

    Coordinate Metrology by Traceable Computed Tomography

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    Towards the Fabrication Strategies for Intelligent Wire Arc Additive Manufacturing of Wire Structures from CAD Input to Finished Product

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    With the increasing demand for freedom of part design in the industry, additive manufacturing (AM) has become a vital fabrication process for manufacturing metallic workpieces with high geometrical complexity. Among all metal additive manufacturing technologies, wire arc additive manufacturing (WAAM), which uses gas metal arc welding (GMAW), is gaining popularity for rapid prototyping of sizeable metallic workpieces due to its high deposition rate, low processing conditions limit, and environmental friendliness. In recent years, WAAM has been developed synergistically with industrial robotic systems or CNC machining centers, enabling multi-axis free-form deposition in 3D space. On this basis, the current research of WAAM has gradually focused on fabricating strut-based wire structures to enhance its capability of producing low-fidelity workpieces with high spatial complexity. As a typical wire structure, the large-size free-form lattice structure, featuring lightweight, superior energy absorption, and a high strength-weight ratio, has received extensive attention in developing its WAAM fabrication process. However, there is currently no sophisticated WAAM system commercially available in the industry to implement an automated fabrication process of wire or lattice structures. The challenges faced in depositing wire structures include the lack of methods to effectively identify individual struts in wire structures, 3D slicing algorithms for the whole wire structures, and path planning algorithms to establish reasonable deposition paths for these generated discrete sliced layers. Moreover, the welded area of the struts within the wire structure is relatively small, so the strut forming is more sensitive and more easily affected by the interlayer temperature. Therefore, the control and prediction of strut formation during the fabricating process is still another industry challenge. Simultaneously, there is also an urgent need to improve the processing efficiency of these structures while ensuring the reliability of their forming result

    Frontiers in Ultra-Precision Machining

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    Ultra-precision machining is a multi-disciplinary research area that is an important branch of manufacturing technology. It targets achieving ultra-precision form or surface roughness accuracy, forming the backbone and support of today’s innovative technology industries in aerospace, semiconductors, optics, telecommunications, energy, etc. The increasing demand for components with ultra-precision accuracy has stimulated the development of ultra-precision machining technology in recent decades. Accordingly, this Special Issue includes reviews and regular research papers on the frontiers of ultra-precision machining and will serve as a platform for the communication of the latest development and innovations of ultra-precision machining technologies
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