INDUSTRIAL PHOTOGRAMMETRY FOR APPLICATIONS IN AUTOMOTIVE AND - - PowerPoint PPT Presentation

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INDUSTRIAL PHOTOGRAMMETRY FOR APPLICATIONS IN AUTOMOTIVE AND - - PowerPoint PPT Presentation

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INDUSTRIAL PHOTOGRAMMETRY FOR APPLICATIONS IN AUTOMOTIVE AND AEROSPACE INDUSTRY 56th Photogrammetric Week 1 22/08/2017 INDUSTRIAL PHOTOGRAMMETRY FOR APPLICATIONS IN AUTOMOTIVE AND AEROSPACE INDUSTRY Werner Bsemann AICON 3D Systems GmbH

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INDUSTRIAL PHOTOGRAMMETRY FOR APPLICATIONS IN AUTOMOTIVE AND AEROSPACE INDUSTRY

56th Photogrammetric Week

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INDUSTRIAL PHOTOGRAMMETRY FOR APPLICATIONS IN AUTOMOTIVE AND AEROSPACE INDUSTRY

Werner Bösemann AICON 3D Systems GmbH Biberweg 30C D-38114 Braunschweig Germany werner.boesemann@hexagon.com 56th Photogrammetric Week

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About AICON

  • Founded in 1990 as a spin off from

Volkswagen R&D and the Technical University Braunschweig by Dr.-Ing. Carl-Thomas Schneider and Dr.-Ing. Werner Bösemann

  • Purchase of Breuckmann GmbH

2012

  • Merged 2015
  • More than 140 employees
  • Since April 1, 2016 part of

HEXAGON Manufacturing Intelligence

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Introduction Requirements Technologies and Systems Application Examples Conclusion

INDUSTRIAL PHOTOGRAMMETRY FOR APPLICATIONS IN AUTOMOTIVE AND AEROSPACE INDUSTRY

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The impact of Industry 4.0 on industrial metrology

Source: WZL Aachen

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The impact of Industry 4.0 on industrial metrology

  • Individualisation of products
  • Flexible Manufacturing
  • Combining virtual and real worlds
  • Interfacing to production

Source: WZL Aachen

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The impact of Industry 4.0 on industrial metrology

Idustry 4.0 Source: WZL Aachen

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The impact of Industry 4.0 on industrial metrology

The role of metrology changes:

  • Final inspection becomes less important
  • Feedback loop to production
  • In-, at- and near-line installations growing fast
  • MAA (Measurement assisted assembly)

Here photogrammetry offers:

  • Scalable and flexible solutions
  • Fast and precise multipoint measurements
  • Dynamic and real-time output
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Photogrammetry: Resolution, Frequency and Duration

Duration Frequency

long term: days, months, years

short term: < n sec low: < 1 Hz high: > 500 Hz

low: single points, 6DOF high: surfaces

Resolution Frequency

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Instrument Positioning

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Introduction Requirements Technologies and Systems Application Examples Conclusion

INDUSTRIAL PHOTOGRAMMETRY FOR APPLICATIONS IN AUTOMOTIVE AND AEROSPACE INDUSTRY

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Requirements: Inspection

GD&T features of a simple part CAD comparison

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Requirements: Tight part and feature tolerances

surface tolerance 0.2 mm 10% allowance for measurement

  • > 0.02 mm accuracy required
  • > +/- 0.01 mm
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Requirements: Traceability and certification

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Requirements: Understanding the application

talk and listen to your customer the customer needs solutions photogrammetry is just a tool learn to speak his language

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Introduction Requirements Technologies and Systems Application Examples Conclusion

INDUSTRIAL PHOTOGRAMMETRY FOR APPLICATIONS IN AUTOMOTIVE AND AEROSPACE INDUSTRY

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Photogrammetry solutions

Photogrammetry (Single points, Adapter, Features) Multicamera solutions for multipoint positioning and tracked probe White light scanner (point clouds)

Photogrammetry solutions

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Photogrammetry solutions

Photogrammetry (Single points, Adapter, Features) Multicamera solutions for multipoint positioning and tracked probe White light scanner (point clouds)

Photogrammetry solutions

AICON GSI Gom AICON Creaform GSI Metronor AICON (Breuckmann) Gom Zeiss (Steinbichler)

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Handheld single camera – Targeting

  • Customer benefits
  • Extremely mobile
  • Perfect for rough environment
  • Unlimited measuring volume
  • Multi purpose
  • Applications
  • Part inspection
  • Deformation analysis
  • Set up of reference meshes
  • CAD comparison
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Fixed multi camera solutions

  • Probing
  • Tracking
  • Targetting
  • Dynamic referencing
  • Easy use
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Flexible multi camera solutions

  • MoveInspect camera-array to cover

large measurement volumes

  • Tracking / Scanning / Probing in the

whole measurement area

  • Reference targets for position control
  • f cameras
  • No reference targets at object

necessary

  • Alignment to object coordinate system

by adapters or probe measurements

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White-Light Scanner (Structured light)

  • Very high accuracy (down to some µm)
  • Highest resolution
  • Scalable for different volumes (mm to several m)
  • Automation (turn-tilt or robot)
  • Mobile application
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GrayCode Phase map Fringe contrast

Analysis of Sequence

Image acquisition with combined GrayCode /Phase Shift Technique (measuring time approx. one second)

Calculation of 3D coordinates

3D data (STL)

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Resolution Impact

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StereoScan neo – multi color projection

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StereoScan neo – Back-Projection

  • CAD comparison
  • Shape defects
  • Geometry elements
  • Legends
  • Marking / Labeling
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Introduction Requirements Technologies and Systems Application Examples Conclusion

INDUSTRIAL PHOTOGRAMMETRY FOR APPLICATIONS IN AUTOMOTIVE AND AEROSPACE INDUSTRY

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Testing: Deformation and load tests on a helicopter cabin

Task

  • 3D deformation measurement of a

complete helicopter cabin (L appr. 10m)

  • Measurement within a high force actuator

test rig (load simulation, hard landing,…)

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Challenge

  • Reducing setup time
  • Providing higher point density than actual

string gauges

  • Allow large deformation without data loss
  • Providing 3D data instead of 1D
  • Test until breakage causes risk for

measurement system

  • Data in one global coordinate reference

frame (helicopter system)

  • Synchronization with actuator system

Process Improvements in Aero Applications by Integration of Camera Technology

Deformation and load tests on a helicopter cabin

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Solution

  • Camera system which allows multiple point
  • nline tracking in full 3D
  • 4 pairs of online cameras mounted on

camera beams

  • Reference points taken by offline

photogrammetry – global reference frame Process Improvements in Aero Applications by Integration of Camera Technology

Deformation and load tests on a helicopter cabin

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Process Improvements in Aero Applications by Integration of Camera Technology

Deformation and load tests on a helicopter cabin

Solution

  • Camera system which allows multiple point
  • nline tracking in full 3D
  • 4 pairs of online cameras mounted on

camera beams

  • Reference points taken by offline

photogrammetry – global reference frame

  • Calibration of all cameras in a single

reference frame

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Process Improvements in Aero Applications by Integration of Camera Technology

Deformation and load tests on a helicopter cabin

Solution

  • Camera system which allows multiple point
  • nline tracking in full 3D
  • 4 pairs of online cameras mounted on

camera beams

  • Reference points taken by offline

photogrammetry – global reference frame

  • Calibration of all cameras in a single

reference frame

  • Measurement with 5 Hz while load is

applied

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Process Improvements in Aero Applications by Integration of Camera Technology

Deformation and load tests on a helicopter cabin

Solution

  • Camera system which allows multiple point
  • nline tracking in full 3D
  • 4 pairs of online cameras mounted on

camera beams

  • Reference points taken by offline

photogrammetry – global reference frame

  • Calibration of all cameras in a single

reference frame

  • Measurement with up to 5 Hz while load is

applied

  • Measurement until breakage
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Process Improvements in Aero Applications by Integration of Camera Technology

Deformation and load tests on a helicopter cabin

Configuration

  • No. of cameras

8 (4 x 2 camera pairs) Resolution / Focal length 5 MPixel / 8mm Volume

  • ca. 10 x 4m² per side

Frequency External trigger and 5Hz Tests against string gauges showed equal results

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Process Improvements in Aero Applications by Integration of Camera Technology Advantages

  • Reduced setup time from a couple days to

a few hours

  • No need for huge support structure for

string gauges

  • Full 3D data (coordinate system

consistency)

  • Synchronization with other sensors (force,

strain)

  • Larger deformation without data loss

compared to string gauges

  • Extendability for more area / details

Deformation and load tests on a helicopter cabin

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Testing: Deformation of an aircraft door during change of cabin pressure

Solution

  • Camera system which allows multiple point
  • nline tracking in full 3D
  • Reference points taken by offline

photogrammetry – global reference frame

  • 4 online cameras are mounted on camera

beams

  • Image capturing with multiple Hz
  • Real time output of the displacement as 3D

vectors in a post-processing software (Spatial Analyzer)

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MAA: Adjustment and final inspection of aircraft doors

Task

  • Adjustment of passenger door locks in

production

  • Final inspection of more than 250 features
  • Reduction of total time for adjustment and

measurement

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Airbus Helicopters Germany

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Applications 3D Scanner: Automated inspection of turbine blades

  • Robot-based quality control
  • System configuration according to

individual customer requests

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Design Studio Applications

  • Tracking / Scanning / Probing

in the whole measurement area

  • Tracking of measurement

systems (e. g. scanners) or tools

  • High accuracy (up to 0.2mm)
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3D Arena in design studios

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WheelWatch is a non-contact high speed monitoring systems for wheel motion / engine motion analysis on a moving vehicle or in a test station

WheelWatch

Dynamic solutions: Motion Analysis

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TubeInspect: Efficient Quality Assurance for Tube Manufacturing

  • Optical tube inspection system
  • Control loop with bending

machines

  • Reverse engineering and

inspection of sample tubes

  • Automatic 100 % inspection

in a robot cell

  • Total replacement of mechanical

gauges

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Our approach to Industry 4.0

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Conclusion

  • Industrial photogrammetry is widely used and accepted
  • Highest flexibility and mobility
  • High accuracy potential
  • Fast onsite measurements
  • Scanners and fixed camera solutions widely used
  • Other applications still rare but accepted
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www.aicon3d.com

Thank you!