研究目的
To develop an automatic and accurate 3D shape measurement system for online inspection of thermal objects, addressing challenges from high temperature and complex online environments.
研究成果
The system successfully performs online 3D inspection of thermal axles with improved efficiency and accuracy. It demonstrates potential for trend analysis and provides solutions for similar applications, though further improvements in accuracy assessment and flexibility are needed.
研究不足
The view integration method is less flexible and needs to be performed separately for different plans and when environmental temperature changes. There is a need for improved means of estimating absolute accuracy and long-term quantitative assessment of robotic repeatability in thermal states.
1:Experimental Design and Method Selection:
The system integrates a fringe projection-based 3D scanner with an industrial robot. Methods include a double filter set and intelligent temperature control for heat resistance, time-division-multiplexing trigger for faster data transmission, improved multi-frequency phase-shifting method to reduce pattern count, view integration method for data alignment based on robot repeatability, and a robust ICP-based registration algorithm for noise-insensitive data alignment.
2:Sample Selection and Data Sources:
Thermal axles from a forging production line are used as samples. Data are acquired using the 3D scanner and cameras.
3:List of Experimental Equipment and Materials:
Industrial grayscale cameras, high lumen blue light digital micromirror device projector, microcontroller for synchronization, industrial robot, cooling system with air pump, heat exchanger, semiconductor thermoelectric cooling device, IR cut filter, blue light filter, reflective material, coordinate measuring machine (HEXAGON GLOBAL CLASSIC SR 07.10.07), portable photogrammetry camera, AutoScan software, Geomagic Control X software.
4:07), portable photogrammetry camera, AutoScan software, Geomagic Control X software. Experimental Procedures and Operational Workflow:
4. Experimental Procedures and Operational Workflow: The robot moves the sensor to scheduled positions; at each position, the sensor projects patterns and captures images; data are processed to generate point clouds; alignment and registration are performed using the proposed methods; key dimensions are extracted and compared to design models.
5:Data Analysis Methods:
Statistical analysis of nearest neighbor distances for adaptive thresholding in ICP, SVD method for solving rotation and translation matrices, and comparison with design models for dimension extraction.
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industrial grayscale cameras
Capture images for 3D measurement
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high lumen blue light digital micromirror device projector
Project fringe patterns for 3D scanning
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microcontroller
Synchronize projector and cameras
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industrial robot
Move the sensor to different positions
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air pump
Circulate air in the cooling system
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heat exchanger
Cool pumped air to room temperature
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semiconductor thermoelectric cooling device
Further cool the air
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IR cut filter
Block infrared light
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blue light filter
Block red light and allow blue light
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coordinate measuring machine
GLOBAL CLASSIC SR 07.10.07
HEXAGON
Provide true values for accuracy validation
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portable photogrammetry camera
Generate accurate points array for calibration
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AutoScan software
Wuhan Vision 3D Technology Ltd.
Generate point cloud data and perform alignment
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Geomagic Control X software
Extract dimensions and generate reports
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