Rapid 2010 Presentation - Automated Low Cost 3D Scanning

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.
About 3D3 Solutions
• 3D3 Solutions is a research and development company that develops 3D

scanning
i technology.
t h l
• Our focus is on flexible white light 3D scanning systems.
• Works with companies to develop custom scanning solutions for specific
g resolution,, high
needs such as high g speed
p or low cost.
Overview/Introduction
Current Manufacturing Process

• For
F smallll and
d medium
di sized
i d businesses
b i
• Common metrology process
• Equipment
Issue
• Bottlenecking
Resolution
• Introduction
I t d ti tto non-contact t t measurementt
• Making it easy to use
• Making it cost effective
• Holding
H ldi the h accuracy
• Reporting
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
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
Common Metrology Process
Bottlenecking
Bottlenecking occurs when

parts are manufactured
faster than they are being
inspected during the quality
control process.
3 hours
2 weeks
Bottlenecking
Resolution: Non-Contact Measurement
Use of 3D scanning to measure parts for quality inspection.
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
q the data needed to create a
3D model.
• Compared to a laser scanner, it
takes a full view of the object
i
instead
d off using
i laser
l beam.
b
• Takes a few seconds to create a
single scan.
Automation
• One b
O button
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
Automating the Pipeline
4. Data
Scan 1. Acquire 2. Scan 3. Scan
Filtering and Report or
Data Alignment Merging
Conversion Manufacturing
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
Multiple Scanners
• The use off multiple

Th lti l scan heads
h d controlled
t ll d by
b one PC
• Fast 3D data capture
Data Alignment
One scanner
• Manual feature alignment
• Motion control alignment
• Photogrammetric dots
Multiple scanners
• Geometric object alignment
Data Cleanup
Automated Cleanup
• Noise Filters
• Hole
H l Filling
Filli
• Scan Merging
• Abnormal Triangles
• Smoothing
S thi
one scan (left) vs. multiple scans of an object (right)
Making it Cost Effective: Data Acquisition
IIndividual
di id l scans need d to be
b highly
hi hl
accurate because downstreaming
cannot improve the quality and
accuracy off the
h ddata.
Making it Cost Effective: Hardware
• Small
S ll and
d mediums
di businesses
b i have
h a limited
li i d resources
• Make technology cost effective by using off-the shelf hardware
components (ie. projectors, cameras, lenses)
Making it Cost Effective: Post Processing
• Range of mesh editing tools to sample, filter, smooth, enhance, decimate,

align,
li merge, remesh,
h etc…point
i clouds
l d and d triangulated
i l d meshes.
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.
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.
Holding the Accuracy: Target Registration
• Align two scans together using features in your scan (ie. spheres).
• R
Recognizes
i th spheres
the h and
d captures
t th center
the t point
i t off th
the sphere
h and
d
use it for alignment.
Holding the Accuracy: Global Registration
ICP (Iterative
(I i Closest
Cl P
Point):
i )
• 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.
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.
Case Studies: Accuracy
Single
g Camera Scanning
g and Alignment
g Simulation Scan - Ideal
46 sec 31 sec
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
Causes for Accuracy Distortion
Using a single camera:

Slight rotation creates mis-alignment of
projector and camera coordinate systems.
Solution: Accuracy Improved Using Two Cameras
Improve scan accuracy by using

two industrial cameras.
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.
Reporting
Most post-processing software have

reporting function for quality inspection.
Automatic Reporting
Acquire Scan
Fixture Part Index Part End of Program Target Align Merge Report
Automate these steps
Automation Process
10 min
83 hours
h 8 16 hours
8.16 h
8 hour
Future Plans
• Experiment
E i t with
ith different
diff t optical
ti l techniques/reconstruction
t h i / t ti algorithms
l ith to
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
Thank you!
Nasir Mannan Thomas Tong

CCAT 3D3 Solutions
nmannan@ccat.us thomastong@3d3solutions.com

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Automated Low Cost 3D Scanning

Nasir Mannan, CCAT

• CCAT-The Connecticut Center for Advanced Technology, Inc.

• 3D3 Solutions is a research and development company that develops 3D

Current Manufacturing Process

• Suppliers to major OEM companies

As parts come off from manufacturing it goes to quality control.

Coordinate Measuring Machines Hand Gauging Tools

Bottlenecking occurs when

Use of 3D scanning to measure parts for quality inspection.

• A projector projects a series of

• If the object is small and easily moved: Move the object

• The use off multiple

one scan (left) vs. multiple scans of an object (right)

• Range of mesh editing tools to sample, filter, smooth, enhance, decimate,

The coordinate system of the positioner table needs to be accurate in order

scan 1 vs scan 2 scan 2 vs scan 3 scan 3 vs scan 4

Simulation Scan - Ideal

Using a single camera:

Improve scan accuracy by using

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

Most post-processing software have

Automate these steps

• Multi scanner setup for faster quality inspection

• Large area scanning at high accuracies

• Deform mesh alignment – account for movement.

• High accuracy single camera calibration

Nasir Mannan Thomas Tong

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