Implementation of 3D Optical Scanning Technology for Automotive Applications

Reverse engineering (RE) is a powerful tool for generating a CAD model from the 3D scan data of a physical part that lacks documentation or has changed from the original CAD design of the part. The process of digitizing a part and creating a CAD model from 3D scan data is less time consuming and provides greater accuracy than manually measuring the part and designing the part from scratch in CAD. 3D optical scanning technology is one of the measurement methods which have evolved over the last few years and it is used in a wide range of areas from industrial applications to art and cultural heritage. It is also used extensively in the automotive industry for applications such as part inspections, scanning of tools without CAD definition, scanning the casting for definition of the stock (i.e. the amount of material to be removed from the surface of the castings) model for CAM programs and reverse engineering. In this study two scanning experiments of automotive applications are illustrated. The first one examines the processes from scanning to re-manufacturing the damaged sheet metal cutting die, using a 3D scanning technique and the second study compares the scanned point clouds data to 3D CAD data for inspection purposes. Furthermore, the deviations of the part holes are determined by using different lenses and scanning parameters

Finite element analysis of porously punched prosthetic short stem virtually designed for simulative uncemented hip arthroplasty

Background: There is no universal hip implant suitably fills all femoral types, whether prostheses of porous short-stem suitable for Hip Arthroplasty is to be measured scientifically. Methods: Ten specimens of femurs scanned by CT were input onto Mimics to rebuild 3D models; their *stl format dataset were imported into Geomagic-Studio for simulative osteotomy; the generated *.igs dataset were interacted by UG to fit solid models; the prosthesis were obtained by the same way from patients, and bored by punching bears designed by Pro-E virtually; cements between femora and prosthesis were extracted by deleting prosthesis; in HyperMesh, all compartments were assembled onto four artificial joint style as: (a) cemented long-stem prosthesis; (b) porous long-stem prosthesis; (c) cemented short-stem prosthesis; (d) porous short-stem prosthesis. Then, these numerical models of Finite Element Analysis were exported to AnSys for numerical solution. Results: Observed whatever from femur or prosthesis or combinational femora-prostheses, “Kruskal-Wallis” value p > 0.05 demonstrates that displacement of (d) ≈ (a) ≈ (b) ≈ (c) shows nothing different significantly by comparison with 600 N load. If stresses are tested upon prosthesis, (d) ≈ (a) ≈ (b) ≈ (c) is also displayed; if upon femora, (d) ≈ (a) ≈ (b) < (c) is suggested; if upon integral joint, (d) ≈ (a) < (b) < (c) is presented. Conclusions: Mechanically, these four sorts of artificial joint replacement are stabilized in quantity. Cemented short-stem prostheses present the biggest stress, while porous short-stem & cemented long-stem designs are equivalently better than porous long-stem prostheses and alternatives for femoral-head replacement. The preferred design of those two depends on clinical conditions. The cemented long-stem is favorable for inactive elders with osteoporosis, and porously punched cementless short-stem design is suitable for patients with osteoporosis, while the porously punched cementless short-stem is favorable for those with a cement allergy. Clinically, the strength of this study is to enable preoperative strategy to provide acute correction and decrease procedure time

Extraction robuste de primitives géométriques 3D dans un nuage de points et alignement basé sur les primitives

Dans ce projet, nous étudions les problèmes de rétro-ingénierie et de contrôle de la qualité qui jouent un rôle important dans la fabrication industrielle. La rétro-ingénierie tente de reconstruire un modèle 3D à partir de nuages de points, qui s’apparente au problème de la reconstruction de la surface 3D. Le contrôle de la qualité est un processus dans lequel la qualité de tous les facteurs impliqués dans la production est abordée. En fait, les systèmes ci-dessus nécessitent beaucoup d’intervention de la part d’un utilisateur expérimenté, résultat souhaité est encore loin soit une automatisation complète du processus. Par conséquent, de nombreux défis doivent encore être abordés pour atteindre ce résultat hautement souhaitable en production automatisée. La première question abordée dans la thèse consiste à extraire les primitives géométriques 3D à partir de nuages de points. Un cadre complet pour extraire plusieurs types de primitives à partir de données 3D est proposé. En particulier, une nouvelle méthode de validation est proposée pour évaluer la qualité des primitives extraites. À la fin, toutes les primitives présentes dans le nuage de points sont extraites avec les points de données associés et leurs paramètres descriptifs. Ces résultats pourraient être utilisés dans diverses applications telles que la reconstruction de scènes on d’édifices, la géométrie constructive et etc. La seconde question traiée dans ce travail porte sur l’alignement de deux ensembles de données 3D à l’aide de primitives géométriques, qui sont considérées comme un nouveau descripteur robuste. L’idée d’utiliser les primitives pour l’alignement arrive à surmonter plusieurs défis rencontrés par les méthodes d’alignement existantes. Ce problème d’alignement est une étape essentielle dans la modélisation 3D, la mise en registre, la récupération de modèles. Enfin, nous proposons également une méthode automatique pour extraire les discontinutés à partir de données 3D d’objets manufacturés. En intégrant ces discontinutés au problème d’alignement, il est possible d’établir automatiquement les correspondances entre primitives en utilisant l’appariement de graphes relationnels avec attributs. Nous avons expérimenté tous les algorithmes proposés sur différents jeux de données synthétiques et réelles. Ces algorithmes ont non seulement réussi à accomplir leur tâches avec succès mais se sont aussi avérés supérieus aux méthodes proposées dans la literature. Les résultats présentés dans le thèse pourraient s’avérér utilises à plusieurs applications.In this research project, we address reverse engineering and quality control problems that play significant roles in industrial manufacturing. Reverse engineering attempts to rebuild a 3D model from the scanned data captured from a object, which is the problem similar to 3D surface reconstruction. Quality control is a process in which the quality of all factors involved in production is monitored and revised. In fact, the above systems currently require significant intervention from experienced users, and are thus still far from being fully automated. Therefore, many challenges still need to be addressed to achieve the desired performance for automated production. The first proposition of this thesis is to extract 3D geometric primitives from point clouds for reverse engineering and surface reconstruction. A complete framework to extract multiple types of primitives from 3D data is proposed. In particular, a novel validation method is also proposed to assess the quality of the extracted primitives. At the end, all primitives present in the point cloud are extracted with their associated data points and descriptive parameters. These results could be used in various applications such as scene and building reconstruction, constructive solid geometry, etc. The second proposition of the thesis is to align two 3D datasets using the extracted geometric primitives, which is introduced as a novel and robust descriptor. The idea of using primitives for alignment is addressed several challenges faced by existing registration methods. This alignment problem is an essential step in 3D modeling, registration and model retrieval. Finally, an automatic method to extract sharp features from 3D data of man-made objects is also proposed. By integrating the extracted sharp features into the alignment framework, it is possible implement automatic assignment of primitive correspondences using attribute relational graph matching. Each primitive is considered as a node of the graph and an attribute relational graph is created to provide a structural and relational description between primitives. We have experimented all the proposed algorithms on different synthetic and real scanned datasets. Our algorithms not only are successful in completing their tasks with good results but also outperform other methods. We believe that the contribution of them could be useful in many applications

Registration using Graphics Processor Unit

Data point set registration is an important operation in coordinate metrology. Registration is the operation by which sampled point clouds are aligned with a CAD model by a 4X4 homogeneous transformation (e.g., rotation and translation). This alignment permits validation of the produced artifact\u27s geometry. State-of-the-art metrology systems are now capable of generating thousands, if not millions, of data points during an inspection operation, resulting in increased computational power to fully utilize these larger data sets. The registration process is an iterative nonlinear optimization operation having an execution time directly related to the number of points processed and CAD model complexity. The objective function to be minimized by this optimization is the sum of the square distances between each point in the point cloud and the closest surface in the CAD model. A brute force approach to registration, which is often used, is to compute the minimum distance between each point and each surface in the CAD model. As point cloud sizes and CAD model complexity increase, this approach becomes intractable and inefficient. Highly efficient numerical and analytical gradient based algorithms exist and their goal is to convergence to an optimal solution in minimum time. This thesis presents a new approach to efficiently perform the registration process by employing readily available computer hardware, the graphical processor unit (GPU). The data point set registration time for the GPU shows a significant improvement (around 15-20 times) over typical CPU performance. Efficient GPU programming decreases the complexity of the steps and improves the rate of convergence of the existing algorithms. The experimental setup reveals the exponential increasing nature of the CPU and the linear performance of the GPU in various aspects of an algorithm. The importance of CPU in the GPU programming is highlighted. The future implementations disclose the possible extensions of a GPU for higher order and complex coordinate metrology algorithms