Engineering Research Center for Reconfigurable Manufacturing Systems

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Engineering Research Center forReconfigurable
Manufacturing Systems
TA-3 Projects In-Process Metrology
The University of Michigan, Ann Arbor
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Motivation of TA-3
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Results of TA-3 In Process Metrology

• Our results in Metrology are divided into two
  areas
• Metrology infrastructure i.e. methodologies and
  algorithms . Each of the listed items is backed
  up with a report or paper.
• 2. Metrology hardware i.e. Machines and devices
  developed for specific applications.

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TA-3 Infrastructure Computer Vision

• Algorithms for precise measurement of complex
  volumes using 3D vision
• Real time vision algorithms for dimensional
  measurements
• Algorithms for precise calculation of the
  diameter of pores
• Algorithms for quantification of small indents on
  autobody panels
• Hardware and algorithms for detecting pores
  inside small diameter bores

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TA-3 Infrastructure Free Form Surface Inspection

• Methodology
• Methodology for fixtureless inspection of free
  form parts
• Algorithms
• Algorithms to support the above methodology
• 3D reconstruction algorithms
• Automatic tracking algorithms

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TA-3 Infrastructure Measurements

• Design concepts and algorithms for the
  reconfigurable inspection machine
• Real time flatness and parallelism measurement
  techniques for prismatic machined parts
• Algorithms to convert non contact probe
  measurements to contact CMM measurements for
  comparison (Virtual ball)
• Laser technology and algorithms to identify
  residual boring marks in real time
• Self calibration algorithms
• Benchmarking study of all available non-contact,
  high-precision measurement technologies
• Laser technology and algorithms for error
  corrections and alignment of machine tools

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Reconfigurable Inspection Machine-RIM
Same machineNew Configuration
Vision system
Engine cylinder head
Laser probes
Slide system
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Plant floor testing (2/3 - 2006)
RIM Technology Transfer
GEMA Dundee, MI
GM RIM- Flint Plant
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Inspection of Complex Surfaces

• Objective
• To develop a rapid and accurate reconfigurable
  optical system for inspecting a part family with
  sculpture surfaces

Probe Controller
Stage Controller

• Accomplishments
• Designed and built a laboratory prototype
  inspection machine for turbine blades.
• Developed algorithms for turbine blade inspection
  and performed automatic inspections.
• Generate interests from non-automotive industry
  (e.g. Aerospace Industry)

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Inspection of Complex Surfaces
Blade Inspection Machine (BIM)
Computer
Inspected Part
Linear Motion Stages
Rotary Stage
Non-Contact Laser Probe
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TA3 Projects
1 Cylinder Bore Inspection Prototype Big 3 - Built (DEMO)
2 Detection of Surface Defects in Small Diameter Cylinders Big 3 requested (DEMO)
3 In-line Valve Seat Inspection Big 3 requested (DEMO)
4 Reconfigurable System for Turbine Blade Finishing NSF W. Robotics
5 Inspection of Auto-body Panels (Redirected to Research Project) For our Post Docs
6 Dimensional Measurement of Bores IOMS/STTR
7 Benchmarking High-precision Non-contact Sensors Y-12 Completed
8 RIM Technology Transfer GEMA -Stopped
9 Automatic Detection of Porosity in Engine Pistons DCX - Stopped
10 Measurement of Combustion Chamber Volume Cognitens -Stopped
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Project 1 - Cylinder Bore Surface Inspection
Prototype

• Goal
• Build a portable machine prototype for bore
  inspection technology (V and L blocks) that meets
  production line rates ( about 20 sec.)
• Deliverables
• The prototype was built and integrated
• The software for data collection and analysis is
  operating and will be improved
• Technology Transfer (to be discussed)

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Full Scale Prototype
Four laser probes
V-8 Engine Inspection Setup
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Future Work

• Technology transfer of prototype system
• Optimization of parallel detection at the ERC
• Study detection of rough hone or boring stages
  marks
• Evaluate the possibility of measuring dimensional
  properties of the bore

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Project 2 - Inspection of Surface Defects in
Small Diameter Bores

• Goal
• Surface defects detection (mainly porosity) in
  small diameter holes
• Deliverables
• Stage 1 (Completed)
• Literature review
• Problem analysis
• Concepts suggestion
• Stage 2 (To be completed12/07)
• Proof of concept
• Stage 3 (To be discussed)
• Build a prototype

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Sight Pipe System
Detected Pores
CCD
Sight Pipe
Part
Bore Image
Top view of the system
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Next Steps

• Optimize the pore detection algorithms
• Improve the mounting structure of the sight pipe
  system
• Increase the optical magnification to get higher
  resolution
• Upgrade the CCD and DAQ device for higher speed
• Continue the Mini CCD study
• Decide about building a demonstrator

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Project 3 - In-line Valve Seat Inspection

• Goal
• Develop an accurate technique for in-line
  measurements of valve seat properties
• Profile (in Progress)
• Geometry (Roundness Run out to be evaluated)
• Deliverables
• Literature review (done)
• Alternatives evaluation (done)
• Concept development (in progress)
• Build a demonstrator (ME 450)
• Build a prototype (To be discussed)

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Experimental Setup For Valve Seats Measurement

• Critical Dimensional and Geometric Features
• Seat Angle (with respect to valve guide)
• Seat Length
• Roundness of critical seat
• Run-out of critical seat (with respect to valve
  guide)

• Current Setup
• 2-axis Aerotech motion stage system
• Optimet Conoprobe single point laser range
  sensor
• Setup Improvements
• Addition of 3rd axis system for multiple cross
  sections
• Portable demonstrator (ME450 senior design
  class)

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Project 4 -Reconfigurable System for Turbine
Blade Finishing
The Goal To develop a closed-loop system for
Turbine Blades Finishing that includes defects
detection, machining and inspection
Blade Inspection Machine (BIM)
Grinding Robot
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Integration of Measurement and Machining

• Closed loop integration of measurement and
  machining
• Inspection machine detects and measures defects
  on turbine blade
• Defect coordinates fed to the automatic robot for
  machining
• Robot machines the defects
• Inspection machine validates machining

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Project 5 - Inspection of Auto-body Panels (New
Title Measurement of Small Curvatures)

• MOTIVATION
• Automated detection of defects on auto body
  stamped panels
• OBJECTIVES
• Development of technologies and methods for
  reliable, automatic surface curvature measurement
• DELIVERABLES
• Sound analytical understanding and proof of
  concept
• Implement the method for measuring dents on sheet
  metal parts

• ACCOMPLISHMENTS
• Surface defects quantitative characterization
• Appropriate technology is currently identified
  for surface defect analysis and a prototype was
  designed and is built.

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Set Up and Master Plate for Calibration
Research tools
Experimental Set Up
Sample Master Plate
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Project 6 - Dimensional Measurement of Bores

• Goals
• Evaluate probe technology for dimensional
  measurement of cylinder bores combined with NCU
  inspection capability
• Develop rapid imaging system to inspect defect of
  interest inside the bore.
• Time frame for the project 2-years

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Dimension Sensing Probe

• Scatter from surface is imaged onto detector by
  lens.
• Image position changes with distance from probe
  to surface.
• Detector is position sensitive.

Bore Surface
Slip Ring
Mirror
Lens
Detector
Laser
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Rapid Imaging System Set Up
Borescope
Rotary table
Monitor
Fiber illumination source
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The End
Questions are Welcomed!
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Automatic Porosity Detection on Engine Pistons

• Goal
• Automatic porosity detection on engine pistons
• Deliverables
• Building a prototype for image acquisition of
  cylindrical surfaces
• Developing an algorithm for the auto-alignment of
  masks and templates
• Algorithms for automated porosity detection