Dedicated Software Algorithms for 3D Clouds of Points

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1 Dedicated Software Algorithms for 3D Clouds of Points

2 Introduction AQSENSE develops and commercializes 3D image acquisition and processing technologies that allow high speed in-line 100% production inspection, for the Machine Vision Industry. In addition to the SAL3D library, AQSENSE also offers consultancy services and special developments related to 3D projects

3 Where are we? Parc Científic i Tecnològic de la UdG Girona (Catalonia - Spain)

4 AQSENSE: Products and Services SAL3D: The Shape Analysis Library Custom Products and Consultancy services (specially for OEM and System Integrators

5 Presentation Outline Part I: SAL3D PCM The ZMap as a FLAT representation of a COP Part II: SAL3D Tools Overview Accurate Light Stripe Detection Easy and Fast Profiles Merging Metric Calibration for Linear and Angular Scanning Measuring Geometric Primitives Ultra-Fast Alignment for Pose Determination and Dimensional Control Importing Models from CAD Designs Integrating Multiple 3D Views into a Single Mesh Area computational tool Part III: Applications Examples Automatic 3D measurement using Match3D and Sherlock Pipe Diameter measurement

6 PART I SAL3D Point Cloud Manager (PCM)

7 Point Cloud Manager (PCM) Tool for management for 3D data: COPs and ZMaps COP: Organized container for 3D data coming from different sources: Laser triangulation Time-of-flight Structured Light Stereo vision

8 PCM: Zmap, the flat representation of the COP data Orthogonal projection onto the Z plane A A COP COP is is an an organized organized set set of of 3D 3D points, points, expressed expressed in in X, X, Y Y and and ZZ coordinates. coordinates. It's It's like like aa set set of of 33 images images of of floating point numbers, floating point numbers, representing representing the the X, X, Y Y and and ZZ sets sets of of coordinates coordinates A A ZMap ZMap is is the the projection projection of of aa COP COP onto onto the the Z=0 Z=0 plane. plane. Its horizontal and vertical Its horizontal and vertical coordinates coordinates are are proportional proportional to to the the actual actual X X and and Y Y coordinates coordinates of of the the COP, COP, while while its its contents contents are are the the ZZ coordinate coordinate values. values.

9 PCM: Zmap, the flat representation of the COP data Zmap data allows 3D measurements using common 2D tools SAL3D contains examples to how to export 3D data to standard 2D libraries ( Halcon, MIL and OpenCV). Zmap factors allow the conversion from pixel data to metric data: Length Diameter Area and volume of defects etc.

10 8bits Small Z range 8bits High Z range High Z range Importance of 3D processing

11 PART II SAL3D Tools Overview

12 SAL3D Tools Overview

13 SAL3D Tools Overview

14 Accurate Light Stripe Detection Grey level representation Determination of the maximum value position up to 1/64th of a pixel A single point is obtained for each line across the laser stripe. This point is obtained at subpixel accuracy at a maximum of 1/64 pixel. Lab tests revealed 5 microns in Z, with a FOV of 130mm.

15 Range Map as the accumulation of laser profiles

16 Accurate Light Stripe Detection Light stripe detection COG 8x to 10x better detection accuracy. (3 orthogonal distance measurements of a plane reconstructed object) Better detection allows smaller details to be visible. Peak Detector

17 SAL3D Tools Overview

18 MERGER Tool: Easy and Fast Profiles Merging A This area is not visible by camera A ADD MORE CAMERAS B

19 SAL3D Tools Overview

20 Metric Calibration for Linear and Angular scanning Linear Scanning RANGEMAP Angular Scanning CLOUD OF POINTS (COP)

21 Metric Calibration for Linear and Angular scanning Multi-camera system for large high resolution Single camera system for large low resolution Special Multi-camera system for 360º view scanning

22 Metric Calibration for Linear and Angular scanning SCANNING A TILTED CYLINDER DIRECT 3D REPRESENTATION RANGEMAP RANGEMAP 3D REPRESENTATION AFTER METRIC CALIBRATION A A rangemap rangemap can can create create an an illusion illusion of of 3D. 3D. Not Not only only metric metric coordinates coordinates are are missing, missing, but but perspective perspective distortion distortion makes makes the the shape shape completely completely different different from from what what itit really really is. is.

23 Metric Calibration for Linear and Angular scanning The robot scans the part using one of its angular articulations. Using the accurate positioning of the robot, multiple scans can be overlapped and integrated with SAL3D Integrator Tool

24 SAL3D Tools Overview

25 Lens Calibration Tool: Add on for metric calibrations Lens Calibration dm (distortion model) RangeMap (pattern) Metric Config (including lens correction) Metric Calibration (*)Static, linear or angular Pattern points RangeMap SAL3D PCM COP With a single step, we obtain a COP (without distortion) from a distorted Rangemap

26 SAL3D Tools Overview

27 Geometric Tool The tool to allow you to made 2D measurements on planes not parallel to the 3D sensor. Zmap from the acquired COP Zmap after plane fitting and correction on the acquired COP

28 Geometric Tool The tool to allow you to made 2D measurements on planes not parallel to the 3D sensor. Zmap oriented to the big valve Zmap oriented to the small valve

29 Geometric Tool This tool also allows planarity measurements and sphere fitting.

30 Ultra-Fast Alignment for Pose Determination and Dimensional Control of all Parts Produced Parts Pose Determination for picking operations Dimensional correctness inspection Surface inspection Quantification of tolerances in 3D, for complex, a-priory unknown scanned surfaces

31 SAL3D Tools Overview

32 Ultra-Fast Alignment for Pose Determination and Dimensional Control of all Parts Produced COP of Golden Model COP of a Part to check Alignment is necesary before comparison Part aligned to the model Match3D Match3D determines determines aa part's part's pose, pose, relative relative to to aa known known model model of of it, it, in in aa small small fraction fraction of of aa second. second. After After alignment alignment of of both both COPs COPs itit is is possible possible to to generate generate the the disparity disparity map. map. The The computed computed movement movement can can be be also also used used in in positioning positioning applications. applications. Versions: Versions: Match3D Match3D and and Match3D Match3D with with Coarse. Coarse. Metric disparity map

33 Match3D: Benefits DISPARITY MAP SAL3D can compute the difference between two Clouds Of Points, generating a disparity map. It's a floating point value image which directly conveys 3D metric localized information on the difference between model and part. Allow to compare clouds of points for shape and surface inspection Both alignment and comparison requires less that a second for 1million points Match3D can be use for align the data for further 2D analysis Alignment results can also be used in reverse engineering projects. Cross-section of a shape deviation Differences (or distances) in mm between the model and the scanned surface

34 SAL3D Tools Overview

35 Importing Models from CAD Designs CAD CAD Designs Designs in in IGES IGES or or STL STL formats formats can can be be imported imported to to SAL3D SAL3D COPs COPs for for being being used used in in Match3D Match3D Applications Applications

36 SAL3D Tools Overview

37 Integrating Multiple 3D Views into a Single Mesh Single mesh after integration Multiple views aligned and overlapped A Mesh can be stored as a.ply or.stl file with a simple function call. Reverse Engineering, Rapid Prototyping, Archeology, etc...

38 SAL3D Tools Overview

39 Area Computation Tool Applications Area with respects to a reference line Area of a closed profile Volume measure Density checking: With the help of the Area Tool the volume of an object is obtained. Then, knowing its weight, the density can be easily calculated Slicing: When automatically slicing food to be packed, neither extra material is desired nor can fewer product be given to the user. Computing the piece volume allows a precise cut with the exact weight.

40 PART III Application Examples

41 Peak applications Surface/shape inspection Food industry Presence/Absence

42 Metric applications: Pipe Diameter Measurement Tools: Metric calibration, PCM, and Peak Detector Metric calibration parameters RADIUS estimation X2+Y2=R2 Object to be measured 3D coordinates Laser Projection Peak detection (2.5D) 3D reconstruction and circle fitting

43 Metric applications (Volumetric) Tools: Metric calibration, PCM, Area Tool and Peak Detector Determination of the online volume of the Coconuts shells for automatic classification

44 Incremental volume computation Tools: Metric calibration, Peak Detector, PCM, Area tool Determination of volume of complex shapes combining information of multiple cameras

45 Metric applications (Measurement in different planes) After metric calibration (removing the perspective distortion), it is possible to make metric measurements in all the object, not only in a single plane (as in simple 2D calibration)

46 Match3D applications (Quality control) Tools: Metric calibration, Peak Detector, PCM, Match3D BMW protrotype: Quality control of stamped parts PSA protrotype: Quality control of car engine blocks (foundry)

47 Match3D ( Automatic 3D measurement using Match3D and 2Dtools Tools: Metric calibration, Peak Detector, PCM, Match3D Set-up on reference model Measuring without alignment Measuring after Match alignment

48 Match3D (reverse engineering)

49 Some examples

50 SUMMARY SAL3D as a C++ Standard Library or integrated in other interfaces (CVB,...) SAL3D technology is proven and present in different industries such as Food, Dental, Metal,... SAL3D technologies cover a very wide range of 3D MV applications. Ease of Use, Robustness, Accuracy and Speed are the four pillars of AQSENSE's Technologies, embedded in SAL3D. Possibility to export to 2D libraries (CVB, MIL, Halcon, OpenCV, Sherlock, etc.) to get 3D measurements using 2D tools

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