Automated Inspection for a Manufacturing Process

1
Automated Inspection for a Manufacturing Process

• Group Members
• Ali Awdi (ME/MEM)
• Jeff Euen (MEM)Donald Gwizdat (MEM)Shailan Lala
  (CMPE)Haley Meader (MEM)Alejandro Wille
  (CSE/EE)
• Advisors
• John Ayers
• Zbigniew Bzymek
• Manuel Nunez
• Sikorsky Aircraft

2
Possible Solutions

• Photogrammetry
• A camera takes pictures of the part from several
  angles
• Pictures are reconstructed into a 3d image
• Image can then be compared to actual part
• Molding
• Image negative is created in a mold
• The negative is placed on top of the piece
• A backlight shows the holes between mold and part
• Shadow Figures
• An image is projected onto a photosensitive
  screen
• Measurements are done by computer on the screen

3
Possible Solutions

• 3D Laser scanning
• A laser scans each surface of a piece
• The piece is then reconstructed in a CAD program
  by hand
• Pieces up to 25m can be scanned
• 3D Digitization
• Multiple scanning instruments are used to scan a
  3D image of an object
• The image is then transmitted to a CAD program
• Pieces the size of a human body can be scanned

4
Drawbacks

• Photogrammetry
• Accuracy is less than with lasers
• Pictures are
• Molding
• The human factor is not removed
• Very time consuming process
• Accuracy of negative must be maintained
• Shadow Figures
• Coherent light must be used
• Border reflections create gray scales at borders
  rather than smooth cutoff
• Size limitation
• Accuracy is difficult to obtain

5
3D Laser scanning

• MENSI
• Founded in Paris, France in 1987
• Develop and market 3D laser scanning technology
  and 3D modeling software
• Used by BOEING, NASA, TECHNIP, EDF, SHELL

6
3D Laser scanning

• S Series Laser scanner
• Hardware
• 0.25mm Accuracy
• 320 x 46 Field of Vision
• 0.8m 25m Range
• 25m Depth of Field
• 100 Points/Second
• Class 3 Laser
• Software
• Realworks
• Quick output
• Creates a wire frame from point clouds

7
3D Digitization

• Cyberware
• Founded in Monterey, California in December of
  1982
• Manufactures rapid 3D digitizing scanners
• Cyberware has sold digitizers to customers in 27
  countries

8
3D Digitization

• Whole body color 3D scanner, Model WB4
• Hardware
• Four scanning instruments are mounted on two
  vertical towers
• The WB4 scans a cylindrical volume 2 meters (79")
  high with a diameter of 1.2 meters (47")
• Size
• Width 3.60m (144)
• Height 2.92m (117)
• Depth 3.00m (120)
• Weight 450Kg (992 lbs)
• Software
• CyDirWB, Decimate, and CyScan