In-situ 3D contour measurement for laser powder bed fusion based on phase guidance

In-situ layerwise imaging measurement of laser powder bed fusion(LPBF)provides a wealth of forming and defect data which enables monitoring of components quality and powder bed homogeneity.Using high-resolution camera layerwise imaging and image processing algorithms to monitor fusion area and powder bed geometric defects has been studied by many researchers,which successfully monitored the contours of components and evaluated their accuracy.However,research for the methods of in-situ 3D contour measurement or component edge warping identification is rare.In this study,a 3D contour mea-surement method combining gray intensity and phase difference is proposed,and its accuracy is verified by designed experiments.The results show that the high-precision of the 3D contours can be achieved by the constructed energy minimization function.This method can detect the deviations of common ge-ometric features as well as warpage at LPBF component edges,and provides fundamental data for in-situ quality monitoring tools.

An Improved Calibration Method of Grating Projection Measurement System

In the traditional fringe projection profilometry system,the projector and the camera light center are both spatially virtual points.The spatial position relationships specified in the model are not easy to obtain,leading to inaccurate system parameters and affectingmeasurement accuracy.This paper proposes a method for solving the system parameters of the fringe projection profilometry system,and the spatial position of the camera and projector can be adjusted in accordance with the obtained calibration parameters.The steps are as follows:First,in accordance with the conversion relationship of the coordinate system in the calibration process,the calculation formula of the vertical distance from the camera light center to the reference plane and the calculation formula of the distance between the projector and the camera light center are given respectively.Secondly,according to the projector calibration principle,the position of the projector light axis perpendicular to the reference plane is gained by comparing the parallel relationship between the reference plane coordinate system and the projector coordinate system’s Z-axis.Then,in order to fulfill the position restriction that the line between the projector light center and the camera light center must be parallel to the reference plane,the camera’s spatial location is adjusted so that the vertical distance between it and the reference plane tends to that between the projector light center and the reference plane.And finally,the three-dimensional(3D)reconstruction of the target object can be finished using the phase height model’s system parameters once the aforementioned position limitations are put into practice.Experimental results demonstrate that the method improves the measurement accuracy,and verifies that it is effective and available in 3D shape measurement.

3D LDV MEASUREMENTS OF ROTOR BLADE TIP VORTEX IN HOVER

An investigation made on the rotor blade tip vortex through use of a Three Dimensional Laser Doppler Velocimetry(3D LDV) is described. The experiment is conducted with a 2 m in diameter model helicopter rotor. By a series of measurements near blade tip, the velocity field near blade tip is documented, and through which, the tip vortex rollup and development are presented. The radial distribution of instantaneous velocities at various levels above and under the rotor disc is also measured in this investigation. Using this distribution, the influence of the tip vortex from the preceding blade on the follow up blade is discussed.

MULTIPARAMETER MEASUREMENT FOR RACEWAY GROOVE OF BEARING BASED ON 3D RECONSTRUCTION WITH DIGITAL STRUCTURED LIGHT

A fast 3D reconstruction method based on structured light to measure various parameters of the raceway groove is presented. Digital parallel grating stripes distributed with sine density are projected onto the raceway groove by a DLP projector, and distorting of stripes is happened on the raceway. Simultaneously, aided by three-step phase-shifting approach, three images covered by different stripes are obtained by a high-resolution CCD camera at the same location, thus a more accuracy local topography can be obtained. And then the bearing is rotated on a high precision computer controlled rotational stage. Three images are also obtained as the former step at next planned location triggered by the motor. After one cycle, all images information is combined through the mosaics. As a result, the 3D information of raceway groove can be gained. Not only geometric properties but also surface flaws can be extracted by software. A preliminary hardware system has been built, with which some geometric parameters have been extracted from reconstructed local topography.

Accurate 3D geometry measurement for non-cooperative spacecraft with an unfocused light-field camera

This work explores an alternative 3D geometry measurement method for non-cooperative spacecraft guiding navigation and proximity operations.From one snapshot of an unfocused light-field camera, the 3D point cloud of a non-cooperative spacecraft can be calculated from sub-aperture images with the epipolar plane image(EPI) based light-field rendering algorithm.A Chang'e-3 model(7.2 cm×5.6 cm×7.0 cm) is tested to validate the proposed technique.Three measurement distances(1.0 m, 1.2 m, 1.5 m) are considered to simulate different approaching stages.Measuring errors are quantified by comparing the light-field camera data with a high precision commercial laser scanner.The mean error distance for the three cases are 0.837 mm, 0.743 mm, and 0.973 mm respectively, indicating that the method can well reconstruct 3D geometry of a non-cooperative spacecraft with a densely distributed 3D point cloud and is thus promising in space-related missions.

Fast Profilometry of 360° Spinning 3D Measurement

A technique of fast 360° spinning 3D measurement is realized.A laser diode used as light source produces 0.5 mm wide slit which is projected onto the surface of an object via a groupe of optical lenses.A CCD camera can grab the reflect curve line and its video output is processed by special hardware circuitries.Then the surface height value which the slit directs to will be directly obtained.The spinning table turns one degree each time and totally 360° 3D information acquisition need only 15 s.The result and conclusion are presented.

A conoscopic holography-based 3D measurement system for analyzing defects in steel plate surface

A conoscopic holography-based 3D measurement system for analyzing the defects on the surface of steel plates was introduced in this paper. The hardware, which is automated through software, performs sampling of the steel plate surface. Through the software interface,point-cloud data of the steel plate surface are obtained and reconstructed to form a 3D image of the steel plate surface. The software allows automatic analysis of steel plate surface detects through identification of the bulges and depressions. In addition, the software can also automatically calculate the defect information ,such as the deepest point, volume, opening area, opening length, and so on, thereby determining the defect size. The results determined by this 3D measurement system were found to be in good agreement with the actual values.

High Speed Laser 3D Measurement System

Using the method of line structure light produced by a laser diode,three dimensional profile measurement is deeply researched.A hardware circuit developed is used to get the center position of light section for the improvement of the measurement speed.A double CCD compensation technology is used to improve the measurement precision. An easy and effective calibration method of the least squares to fit the parameter of system structure is used to get the relative coordinate relationship of objects and images of light section in the directions of height and axis. Sensor scanning segment by segment and layer by layer makes the measurement range expand greatly.

A Flexible Calibration Method of Laser Light-Sectioning System for Online 3D Measurement

A flexible calibration method based on a front-coated flat mirror is proposed for a laser light-sectioning three-dimensional(3D)measurement system. Since the calibration target and its mirror image are spatially separated and can be recorded in an image by a camera,the proposed method requires only a single composite image that contains a non-planar checkerboard pattern,a laser strip projected on the target and their mirror images to complete the calibration of the camera and the laser plane in one step. Levenberg-Marquardt(LM)algorithm is used to optimize the system parameters,and the measurement accuracy and speed are improved to enable online 3D inspection. Static and dynamic online 3D measurements are carried out on a cup and a triple stepped shaft,respectively,to validate the proposed method. The shaft has two steps with the depth of(0.5±0.01)mm and(2±0.01)mm to be measured online when the shaft is rotated and translated at the same time. The measurement results can be output at a frequency of 7 to 11 readings per second with standard deviations of 0.040 mm and 0.051 mm. The experimental results verify the effectiveness and flexibility of the proposed method.

THEORETICAL ANALYSIS OF COORDINATES MEASUREMENT BY FLEXIBLE 3D MEASURING SYSTEM

The system mathematical model of flexible 3D measuring system is built by theoretical analysis, and the theoretical formula for measuring space point coordinate is also derived. Frog-jumping based coordinate transform method is put forward in order to solve measuring problem for large size parts. The frog-jumping method is discussed, and the coordinate transform mathematical model is method of the space point coordinate compared to original value, and an advanced method is provided, Form the space point coordinate transform formula can derive the calculation measuring method for measuring large size parts.

3D Depth Measurement for Holoscopic 3D Imaging System

Holoscopic 3D imaging is a true 3D imaging system mimics fly’s eye technique to acquire a true 3D optical model of a real scene. To reconstruct the 3D image computationally, an efficient implementation of an Auto-Feature-Edge (AFE) descriptor algorithm is required that provides an individual feature detector for integration of 3D information to locate objects in the scene. The AFE descriptor plays a key role in simplifying the detection of both edge-based and region-based objects. The detector is based on a Multi-Quantize Adaptive Local Histogram Analysis (MQALHA) algorithm. This is distinctive for each Feature-Edge (FE) block i.e. the large contrast changes (gradients) in FE are easier to localise. The novelty of this work lies in generating a free-noise 3D-Map (3DM) according to a correlation analysis of region contours. This automatically combines the exploitation of the available depth estimation technique with edge-based feature shape recognition technique. The application area consists of two varied domains, which prove the efficiency and robustness of the approach: a) extracting a set of setting feature-edges, for both tracking and mapping process for 3D depthmap estimation, and b) separation and recognition of focus objects in the scene. Experimental results show that the proposed 3DM technique is performed efficiently compared to the state-of-the-art algorithms.

An Experimental System Development for Head Posture Estimation Based on 3-D Images Measurement

Although automobile is an indispensable vehicle to modern life, it also serves as a social problem with a big traffic accident. Among the reasons of traffic accidents, careless driving accounts for the largest part. So in order to avoid the careless driving, a system which can measure the posture of a driver and warns driver to drive carefully in the case of looking aside is necessary. Although the image measurement method is used broadly, there is a problem on which measurement accuracy is influenced by environment light, makeup of the driver, etc. in the general method based on the two-dimensional image. Therefore, in this study, we propose an image measurement method to obtain the head posture of driver. First we use three-dimensional measurement method which based on the infrared pattern projection to get 3-D information of head, and then we calculate the angle for faces. In this paper, we explain the composition method of an experiment system, and the results of head posture measurement experiment.

New Approach for 3D Shape Measurement Based on Color-Coded Fringe and Neural Network

A new 3D surface contouring and ranging system based on digital fringe projection and phase shifting technique is presented. Using the phase-shift technique, points cloud with high spatial resolution and limited accuracy can be generated. Stereo-pair images obtained from two cameras can be used to compute 3D world coordinates of a point using traditional active triangulation approach, yet the camera calibration is crucial. Neural network is a well-known approach to approximate a nonlinear system without an explicit physical model, in this work it is used to train the stereo vision application system to calculating 3D world coordinates such that the camera calibration can be bypassed. The training set for neural network consists of a variety of stereo-pair images and the corresponding 3D world coordinates. The picture elements correspondence problem is solved by using projected color-coded fringes with different orientations. Color imbalance is completely eliminated by the new color-coded method. Once the high accuracy correspondence of 2D images with 3D points is acquired, high precision 3D points cloud can be recognized by the well trained net. The obvious advantage of this approach is that high spatial resolution can be obtained by the phase-shifting technique and high accuracy 3D object point coordinates are achieved by the well trained net which is independent of the camera model works for any type of camera. Some experiments verified the performance of the method.

A light field measurement system through PSF estimation by a morphology-based method

Light field imaging technology can obtain three-dimensional(3D)information of a test surface in a single exposure.Traditional light field reconstruction algorithms not only take a long time to trace back to the original image,but also require the exact parameters of the light field system,such as the position and posture of a microlens array(MLA),which will cause errors in the reconstructed image if these parameters cannot be precisely obtained.This paper proposes a reconstruction algorithm for light field imaging based on the point spread function(PSF),which does not require prior knowledge of the system.The accurate PSF derivation process of a light field system is presented,and modeling and simulation were conducted to obtain the relationship between the spatial distribution characteristics and the PSF of the light field system.A morphology-based method is proposed to analyze the overlapping area of the subimages of light field images to identify the accurate spatial location of the MLA used in the system,which is thereafter used to accurately refocus light field imaging.A light field system is built to verify the algorithm’s effectiveness.Experimental results show that the measurement accuracy is increased over 41.0%compared with the traditional method by measuring a step standard.The accuracy of parameters is also improved through a microstructure measurement with a peak-to-valley value of 25.4%and root mean square value of 23.5%improvement.This further validates that the algorithm can effectively improve the refocusing efficiency and the accuracy of the light field imaging results with the superiority of refocusing light field imaging without prior knowledge of the system.The proposed method provides a new solution for fast and accurate 3D measurement based on a light field.

Multi-objective strategy to optimize dithering technique for high-quality three-dimensional shape measurement

Dithering optimization techniques can be divided into the phase-optimized technique and the intensity-optimized technique. The problem with the former is the poor sensitivity to various defocusing amounts, and the problem with the latter is that it cannot enhance phase quality directly nor efficiently. In this paper, we present a multi-objective optimization framework for three-dimensional(3D) measurement by utilizing binary defocusing technique. Moreover, a binary patch optimization technique is used to solve the time-consuming issue of genetic algorithm. It is demonstrated that the presented technique consistently obtains significant phase performance improvement under various defocusing amounts.

Measurement and Compensation of Deviations of Real Tooth Surface of Spiral Bevel Gear

This paper presents a method for measurement of deviation of the real gear tooth surface from the theoretical one with a coordinate measurement machine and compensation of repeatable parts. By investigation of characteristics of distortion of the gear tooth surface along the circle direction, the deviation is derived from distortion, and the definition of deviation with the geometrical invariability is proposed. Then the approach for determination of the location and orientation of the gear with respect to the coordinate measurement machine and the measurement way are developed. The deviation is represented with a difference surface, and an algorithm for derivation of parameters of global form deviations from the discrete points has been provided. Finally, the compensation approach is discussed.

Application of Three-dimensional Body Measurement System

The configuration principles and functions of the non-contact three-dimensional （3D） body measurement system （BMS） developed by the Textile/Clothing Technology Corporation （[TC]^2） are described in this paper. The advantages of this new system, compared with traditional contact body measurement instruments （ Martin instruments ） are discussed by selecting 40 female undergraduates of Donghna University as the scan objects. In the experiments both the Martin instruments and [TC]^2 BMS were used respectively. According to the data of different position （Bust Circumference, Full Waist, Full Hips, Bust Height, Front Waist Height and Back Waist Height） obtained from both of the methods we can get the correlation coefficient which is close to 1, indicating that the results of both methods have comparability. Finally some suggestions for the further applications of the non-contact BMS in the apparel development of China are given.

Measurements and Terminology of Different Measure Methods

Body measuring is very important for garment sizing and pattern making. In this paper, we study the difference of the landmarks between the traditional method and 3D scanner and we also select the 19 circumference measurements,29 height and length measurements, 18 breadth and depth measurements and 3 other measurements, which are quite important in fashion body measuring, to compare the terminology of them in these two measuring method. 3D scanners seem better than the traditional method on these aspects, which are the number of measurements, speed,privacy and data accuracy, but they are limited on measuring posture. And there is no uniform standard for the scanners and the definitions of the measurements in the scanners are diversified.

Robot Vision System for Coordinate Measurement of Feature Points on Large Scale Automobile Part

In this paper,we present a robot vision based system for coordinate measurement of feature points on large scale automobile parts.Our system consists of an industrial 6-DOF robot mounted with a CCD camera and a PC.The system controls the robot into the area of feature points.The images of measuring feature points are acquired by the camera mounted on the robot.3D positions of the feature points are obtained from a model based pose estimation that applies to the images.The measured positions of all feature points are then transformed to the reference coordinate of feature points whose positions are obtained from the coordinate measuring machine（CMM）.Finally,the point-to-point distances between the measured feature points and the reference feature points are calculated and reported.The results show that the root mean square error（RMSE） of measure values obtained by our system is less than 0.5 mm.Our system is adequate for automobile assembly and can perform faster than conventional methods.

Multi-Schlieren CT Measurements of Supersonic Microjets from Circular and Square Micro Nozzles

Instantaneous three-dimensional (3D) density distributions of a shock-cell structure of perfectly and imperfectly expanded supersonic microjets escaping into an ambient space are measured. For the 3D observation of supersonic microjets, non-scanning 3D computerized tomography (CT) technique using a 20-directional quantitative schlieren optical system with flashlight source is employed for simultaneous schlieren photography. The 3D density distributions data of the microjets are obtained by 3D-CT reconstruction of the projection’s images using maximum likelihood-expectation maximization. Axisymmetric convergent-divergent (Laval) circular and square micro nozzles with operating nozzle pressure ratio 5.0, 4.5, 4.0, 3.67, and 3.5 have been studied. This study examines perfectly expanded, overexpanded, and underexpanded supersonic microjets issued from micro nozzles with fully expanded jet Mach numbers Mj ranging from 1.47 - 1.71, where the design Mach number is Md = 1.5. A complex phenomenon for free square microjets called axis switching is clearly observed with two types “upright” and “diagonal” of “cross-shaped”. The initial axis-switching is 45° within the first shock-cell range. In addition, from the symmetry and diagonal views of square microjets for the first shock-cells, two different patterns of shock waves are viewed. The shock-cell spacing and supersonic core length for all nozzle pressure ratios are investigated and reported.