Industrial Photogrammetry For Applications In Automotive And Aerospace .
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 Bösemann AICON 3D Systems GmbH Biberweg 30C D-38114 Braunschweig Germany werner.boesemann@hexagon.com 56th Photogrammetric Week 2 22/08/2017
About AICON Founded in 1990 as a spin off from 3 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 22/08/2017
INDUSTRIAL PHOTOGRAMMETRY FOR APPLICATIONS IN AUTOMOTIVE AND AEROSPACE INDUSTRY Introduction Requirements Technologies and Systems Application Examples Conclusion 4 22/08/2017
The impact of Industry 4.0 on industrial metrology Source: WZL Aachen 5 22/08/2017
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 6 22/08/2017
The impact of Industry 4.0 on industrial metrology Idustry 4.0 Source: WZL Aachen 7 22/08/2017
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 8 22/08/2017
Photogrammetry: Resolution, Frequency and Duration Resolution high: surfaces Duration long term: days, months, years low: single points, 6DOF Frequency short term: n sec low: 1 Hz 9 22/08/2017 high: 500 Hz Frequency
Instrument Positioning 10 22/08/2017
INDUSTRIAL PHOTOGRAMMETRY FOR APPLICATIONS IN AUTOMOTIVE AND AEROSPACE INDUSTRY Introduction Requirements Technologies and Systems Application Examples Conclusion 11 22/08/2017
Requirements: Inspection GD&T features of a simple part 12 22/08/2017 CAD comparison
Requirements: Tight part and feature tolerances surface tolerance 0.2 mm 10% allowance for measurement - 0.02 mm accuracy required - /- 0.01 mm 13 22/08/2017
Requirements: Traceability and certification 14 22/08/2017
Requirements: Understanding the application talk and listen to your customer the customer needs solutions photogrammetry is just a tool learn to speak his language 15 22/08/2017
INDUSTRIAL PHOTOGRAMMETRY FOR APPLICATIONS IN AUTOMOTIVE AND AEROSPACE INDUSTRY Introduction Requirements Technologies and Systems Application Examples Conclusion 16 22/08/2017
Photogrammetry solutions Photogrammetry solutions Photogrammetry (Single points, Adapter, Features) Multicamera solutions for multipoint positioning and tracked probe White light scanner (point clouds) 17 22/08/2017
Photogrammetry solutions Photogrammetry solutions 18 22/08/2017 Photogrammetry (Single points, Adapter, Features) AICON GSI Gom Multicamera solutions for multipoint positioning and tracked probe AICON Creaform GSI Metronor White light scanner (point clouds) AICON (Breuckmann) Gom Zeiss (Steinbichler)
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 19 22/08/2017
Fixed multi camera solutions Probing Tracking Targetting Dynamic referencing Easy use 20 22/08/2017
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 of cameras No reference targets at object necessary Alignment to object coordinate system by adapters or probe measurements 21 22/08/2017
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 22 22/08/2017
Image acquisition with combined GrayCode /Phase Shift Technique (measuring time approx. one second) Analysis of Sequence Calculation of 3D coordinates GrayCode 23 22/08/2017 Phase map Fringe contrast 3D data (STL)
Resolution Impact 24 22/08/2017
StereoScan neo – multi color projection 25 22/08/2017
StereoScan neo – Back-Projection 26 CAD comparison Shape defects Geometry elements Legends Marking / Labeling 22/08/2017
INDUSTRIAL PHOTOGRAMMETRY FOR APPLICATIONS IN AUTOMOTIVE AND AEROSPACE INDUSTRY Introduction Requirements Technologies and Systems Application Examples Conclusion 27 22/08/2017
Testing: Deformation and load tests on a helicopter cabin Task 28 3D deformation measurement of a complete helicopter cabin (L appr. 10m) Measurement within a high force actuator test rig (load simulation, hard landing, ) 22/08/2017
Process Improvements in Aero Applications by Integration of Camera Technology Deformation and load tests on a helicopter cabin 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 29 22/08/2017
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 online tracking in full 3D 4 pairs of online cameras mounted on camera beams Reference points taken by offline photogrammetry – global reference frame 30 22/08/2017
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 online 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 31 22/08/2017
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 online 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 32 22/08/2017
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 online 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 33 22/08/2017
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 34 22/08/2017
Process Improvements in Aero Applications by Integration of Camera Technology Deformation and load tests on a helicopter cabin 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 35 22/08/2017
Testing: Deformation of an aircraft door during change of cabin pressure Solution Camera system which allows multiple point online 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) 36 22/08/2017
MAA: Adjustment and final inspection of aircraft doors Task 37 Adjustment of passenger door locks in production Final inspection of more than 250 features Reduction of total time for adjustment and measurement 22/08/2017
Airbus Helicopters Germany 38 22/08/2017
Applications 3D Scanner: Automated inspection of turbine blades Robot-based quality control System configuration according to individual customer requests 39 22/08/2017
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) 40 22/08/2017
3D Arena in design studios 41 22/08/2017
Dynamic solutions: Motion Analysis WheelWatch WheelWatch is a non-contact high speed monitoring systems for wheel motion / engine motion analysis on a moving vehicle or in a test station 42 22/08/2017
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 43 22/08/2017
Our approach to Industry 4.0 44 22/08/2017
Conclusion 45 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 22/08/2017
Thank you! www.aicon3d.com 46 22/08/2017
White light scanner (point clouds) Photogrammetry solutions. 18 22/08/2017 Photogrammetry solutions Photogrammetry (Single points, Adapter, Features) . White-Light Scanner (Structured light) Very high accuracy (down to some µm) Highest resolution Scalable for different volumes (mm to several m)
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Photogrammetry is a cost efficient surveying method for mapping large areas. Photogrammetry may be safer than other surveying methods. It is safer to take photographs of a dangerous area than to place surveyors in harms way. Photogrammetry provides the ability to map areas inaccessible to field crews.
photogrammetry. He developed the analytical solutions to space resection, orientation, intersection, rectification, and control extension using direction cosines. Church, a professor at Syracuse University and one of the founding members of the American Society of Photogrammetry, is referred to as the "American Father of Photogrammetry".
Photogrammetry has been previously validated as an effective technology for documenting both damaged vehicles and scenes [1,2,3,4,5,6,7,8,9,10,11,12]. Modern photogrammetry uses the same photogrammetric principles, but requires less user input and delivers more data points in its solution. Photogrammetry software is capable
Unity Photogrammetry Workflow 3 1. Overview 1.1. Introduction What is photogrammetry? Photogrammetry is the process of authoring a digital asset using multiple photos of the original real-
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