User Interface for Optical Multi-Sensorial Measurements at Extruded Profiles

Transcription

1 Etruder v User Interface for Optical Multi-Sensorial Measurements at Etruded Profiles Place of Installation A. Weckenmann, J. Bernstein IMEKO XIX WCC 2009, , Lisbon? v 1 Introduction 2 Bi-Sensorial Test Stand 3 Adjustement of the Measurement System 4 Measurements with the User Interface 5 Conclusion and Outlook Source: DIEHL Metall Stiftung & Co. KG, 2009 Gratefully founded by the: Bavarian Research Foundation Chair Quality Management and Manufacturing Metrology Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. mult. Albert Weckenmann

2 Introduction Etruding process - constraints: Enormous heat disposal Shop floor: lubrificant, oide, graphite profile vibrations, movement speeds up to 10 m/s vobject Etruder Brass ( ) Coil Transport rollers Graphit rail Round L- T- Square Heagon QFM, Erlangen, 2009 # 2 (14)

3 Introduction (II) State of the art Light-Section System Shadow System / parallel light rays Empfangsoptik Camera Collimator Receiving Optics Detector Light Source Lichtquelle φ D v P z y concave zones can be measured, measurement uncertainty > 0.1 mm Measurement Object Motor Regulation Measurement Object Oscillator Objectives: 360 measurements measuring concave ca profiles po fast in-line ability uncertainties < 0.1 mm Analysis Electronics Gate Calibration zero set Visualization, Data Output uncertainty 0.01 mm, one distance, concave zones cannot be measured QFM, Erlangen, 2009 # 3 (14)

4 Bi-sensorial test stand Prototype of the Optical Bi-Sensorial Measurement System Performance: Profiles up to 100 mm diameter i distance di t measuring > 200 mm y customized processing software stiff design g from aluminum z Cameras: piels 20 fps (frames per second) adjustable holders rotatable shadow system (360 ) Laserfans: 58 mw, mw 652 nm SPS-Actoric: 2-D movement based: granite plate, 1.3 tons Eperimental set up of the Chair Quality Management and Manufacturing Metrology, QFM, Erlangen, 2009 # 4 (14)

5 Bi-sensorial test stand (II) Eperimental set up Eperimental set up of the Chair Quality Management and Manufacturing Metrology, QFM, Erlangen, 2009 # 5 (14)

6 Bi-sensorial test stand (III) Granite plate Actuating elements Etruding Adjustable Ring Frame Cameras Lasers Shadow system Top view of the optical eperimental set up y Movement of test profile s: in two aes independently z different movements possible easy fiing Side view of the optical eperimental set up QFM, Erlangen, 2009 # 6 (14)

7 Adjustement of the measurement system shadow system Light source (652 nm,10 mw) Parallel light rays Etruding y Adjustement: 360 fleibel very stiff bearing easy fiing Fi mounted ring Rotating ring Receiving unit a 1 Construction a 2 Granite plate a a 1 2 = v = v L L t t a1 ; a2 ; QFM, Erlangen, 2009 # 7 (14)

8 Adjustement Measurements of(ii) the measurement system (II) light section system Camera 2 C y 60 C1 Camera 1 Field of view for Camera 1 at -30 to the object H-Profile (Brass) 50 Recommendations for: ma. depth of field profile s type ma. effective resolution Overlap L 1 /L 2 /L 3 > 10% C3 Camera QFM, Erlangen, 2009 # 8 (14)

9 Measurements with the User Interface light section system - Image processing and co-ordinate transformation observed profile zone automatically etracted t edge piel co-ordinates (> 100 per image) y c c reconstruction camera coordinates y p p transforming to profile s coordinates l p profile z p Triangulation: Δh = Δl 1 ; sinβ (cotα + cot β ) recommended d : α = 90 ; QFM, Erlangen, 2009 # 9 (14)

10 Measurements with the User Interface (II) Calibration of the three light-section systems distortion by perspective, imperfections on the camera chip/lens Camera reference markers on a flat plate (1200 dpi) Stored calibration routine applied T y R t T = y T zt O 1 z 1 1 position in world-coordinates w w w ; position in cameraco-ordinates Internal correction by software to homogeneous results QFM, Erlangen, 2009 # 10 (14)

11 Measurements with the User Interface (III) Automation by the user interface for Calibration of the light-section systems Eample: measured profile with > 300 measuring points in, y Nr. y automated detection of the calibration marks on the plate Calculating the middle of every e calibration at point (center of gravity) QFM, Erlangen, 2009 # 11 (14)

12 Measurements with the User Interface (IV) Visualized Results of the optical bi-sensorial measurement system y in mm form elements for determining characteristics noise and irregulations by reflections, filtered a Maimum lengths corrected by the results of the shadow system w col cam 0 w row cam 0 results in one world- w col cam 1 co-ordinate system: w row cam 1 Three w col pointclouds cam 2 w row cam 2 Data Fusion third dataset most 40 critical by fitting ICP-algorithm with ICP (interative-closest point) 35 deviations ~ 0.02 mm in mm QFM, Erlangen, 2009 # 12 (14)

13 Measurements with the User Interface (V) User interface for analyzing the measurement results Features: Ergonomic to DIN ISO , -17 Diameter, lengths Form, angles cp-, cp k - values Visualization in-line analysis User-Interface of optical Bi-Sensor Measurements QFM, Erlangen, 2009 # 13 (14)

14 Conclusion and Outlook Indicators of the user interface for optical bi-sensor measurements Ergonomic usability of the optical bi-sensor measurement system Recommendations for adjustment and calibration of various profiles Efficient use of the illumination and the observers in angle and distance Grabbing automatically, image processing and measurement of characteristics Fundamentals for fusing the datasets, calibration and synchronization Functional methods for analysis of defined specifications In-line adapted measurement with included visualization and analysis Fields of further research: Data synchronization with a minimum of measurement uncertainty Use of improved filter methods for improved measurement results Real in-line test at the shop floor challenging: dust, heat, vibration and dirt A user guide and interactive help to the measurement procedure QFM, Erlangen, 2009 # 14 (14)

15 Thank you for your attention! Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. mult. Albert Weckenmann Phone: Fa: M.Eng. Johannes Bernstein Phone: In cooperation with: Gratefully funded by: Bavarian Research Foundation Chair Quality Management and Manufacturing Metrology Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. mult. Albert Weckenmann # 17 (17)