Automated Low Cost 3D Scanning
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Automated Low Cost 3D Scanning

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The uses of 3D imaging are extending rapidly to many industries that are leveraging the power of 3D software to greatly enhance their products. While 3D scanning technologies have typically been ...

The uses of 3D imaging are extending rapidly to many industries that are leveraging the power of 3D software to greatly enhance their products. While 3D scanning technologies have typically been available as high-end industrial systems that are expensive and limited to specific objects they can scan, small and medium businesses need an affordable 3D scanning solution they can use in their manufacturing processes.

Thomas Tong from 3D3 Solutions and Nasir Mannan from Connecticut Center for Advanced Technology (CCAT) presented at RAPID 2010 on the topic "Low Cost Automated 3D Scanning".

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Automated Low Cost 3D Scanning Automated Low Cost 3D Scanning Presentation Transcript

  • Automated Low Cost 3D Scanning Nasir Mannan, CCAT Thomas Tong, 3D3 Solutions © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • About CCAT • CCAT-The Connecticut Center for Advanced Technology, Inc. • NCAL-National Center for Aerospace Leadership. • Nonprofit organization that serves as economic development center for excellence for the region, state and nation. • Core programs address military and civilian industrial manufacturing needs. • Collaborating with 3D3 Solutions to develop push button 3D scanning solutions in the aerospace and automotive industries. © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • About 3D3 Solutions • 3D3 Solutions is a research and development company that develops 3D scanning technology. i t h l • Our focus is on flexible white light 3D scanning systems. • Works with companies to develop custom scanning solutions for specific needs such as high resolution, high speed or low cost. g , g p © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Overview/Introduction Current Manufacturing Process • F small and medium sized businesses For ll d di i db i • Common metrology process • Equipment Issue • Bottlenecking Resolution • I t d ti t non-contact measurement Introduction to t t t • Making it easy to use • Making it cost effective • H ldi the accuracy Holding h • Reporting © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Small and Medium Businesses • Suppliers to major OEM companies • Limited on resources and specialized skilled workers • Most produce parts for OEM’s at high rates • Must produce parts to quality standard • Have limited budgets for improvements • Have limited resources to research new technologies © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Equipment for Quality Control As parts come off from manufacturing it goes to quality control. There are two basic pathways for inspection. Coordinate Measuring Machines Hand Gauging Tools © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Common Metrology Process © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Bottlenecking Bottlenecking occurs when parts are manufactured faster than they are being inspected during the quality control process. 3 hours 2 weeks © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Bottlenecking © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Resolution: Non-Contact Measurement Use of 3D scanning to measure parts for quality inspection. © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • White Light 3D Scanning Systems • A projector projects a series of reference patterns onto the scan object. • The scene is captured using 1 or 2 cameras. cameras • 3D scanning software processes the images from the cameras to acquire the data needed to create a q 3D model. • Compared to a laser scanner, it takes a full view of the object instead of using laser beam. i d f i l b • Takes a few seconds to create a single scan. © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Automation • One button O b tt scanning i • 3D scanning generally takes lots of work (depends on the complexity of the scan object) • Goal of technology is to save time effort • Whole object scanning with a single click © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Automating the Pipeline 4. Data Scan 1. Acquire 2. Scan 3. Scan Filtering and Report or Data Alignment Merging Conversion Manufacturing © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Complete Data Acquisition • If the object is small and easily moved: Move the object • If the object is large and difficult to move: Move the scanner © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Multiple Scanners • The Th use of multiple scan heads controlled by one PC f lti l h d t ll d b • Fast 3D data capture © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Data Alignment One scanner • Manual feature alignment • Motion control alignment • Photogrammetric dots Multiple scanners • Geometric object alignment © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Data Cleanup Automated Cleanup • Noise Filters • H l Filli Hole Filling • Scan Merging • Abnormal Triangles • S Smoothing thi one scan (left) vs. multiple scans of an object (right) © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Making it Cost Effective: Data Acquisition Individual I di id l scans need to be highly d b hi hl accurate because downstreaming cannot improve the quality and accuracy of the d f h data. © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Making it Cost Effective: Hardware • Small d S ll and mediums businesses have a limited resources di b i h li i d • Make technology cost effective by using off-the shelf hardware components (ie. projectors, cameras, lenses) © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Making it Cost Effective: Post Processing • Range of mesh editing tools to sample, filter, smooth, enhance, decimate, align, merge, remesh, etc…point clouds and triangulated meshes. li h i l d d i l d h • Reverse Engineering modules allows users to create solid or surface models from scan data. • Inspection modules allows whole deviation 3D measurement for part qualification. © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Holding the Accuracy: Tracking the Positioner The coordinate system of the positioner table needs to be accurate in order for data alignment to be accurate. © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Holding the Accuracy: Target Registration • Align two scans together using features in your scan (ie. spheres). • Recognizes th spheres and captures th center point of th sphere and R i the h d t the t i t f the h d use it for alignment. © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Holding the Accuracy: Global Registration ICP (Iterative Closest P i ) (I i Cl Point): • Associate points by nearest neighbor criteria. • Estimate transformation parameters using a mean square cost function. • Transform the points using the estimated parameters. • Iterate (re-associate the points and so on). • Provides better accuracy. © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Holding the Accuracy: Automation • Use a positioner table with reference spheres for one button scanning. • Then align the data using target registration with global alignment. © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Case Studies: Accuracy Single Camera Scanning and Alignment g g g Simulation Scan - Ideal 46 sec 31 sec © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Case Studies: Accuracy Accuracy Single Camera Scanning and Alignment Indicator scan 1 vs scan 2 scan 2 vs scan 3 scan 3 vs scan 4 Simulation Scan - Ideal © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Causes for Accuracy Distortion Using a single camera: Slight rotation creates mis-alignment of projector and camera coordinate systems. © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Solution: Accuracy Improved Using Two Cameras Improve scan accuracy by using two industrial cameras. © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Case Studies: Accuracy Improved Using Two Cameras Accuracy Two Camera Scanning and Alignment Indicator scan 1 vs scan 2 scan 2 vs scan 3 scan 3 vs scan 4 Simulation Scan - Ideal Case study proves that off-the-shelf hardware can produce accurate results for quality inspection and aerospace at lower cost. © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Reporting Most post-processing software have reporting function for quality inspection. © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Automatic Reporting Acquire Scan Fixture Part Index Part End of Program Target Align Merge Report Automate these steps © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Automation Process 10 min 83 hours h 8.16 hours 8 16 h 8 hour © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Future Plans • Experiment with different optical techniques/reconstruction algorithms to E i t ith diff t ti l t h i / t ti l ith t solve shiny part scanning without coating • Multi scanner setup for faster quality inspection • Large area scanning at high accuracies • Deform mesh alignment – account for movement. • High accuracy single camera calibration © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.
  • Thank you! Nasir Mannan Thomas Tong CCAT 3D3 Solutions nmannan@ccat.us thomastong@3d3solutions.com © 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.