Development of new techniques for high-speed and high-accuracy industrial part metrology**

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Parts metrology is critical for quality control in the manufacturing industry, and its market capacity reached US$465 billion in 2016. Automotive part manufacturers-including KIRCHHOFF Automotive, one of the two supporting organizations for this project-have dramatically raised their part quality control standards to stay competitive. The geometry of every part must be accurately measured to ensure correct dimensions and perfect fit with increasingly tight tolerances. State-of-the-art 3D measurement systems (e.g., Gocator scanners from our other supporting organization, LMI Technologies) have been applied and tested on parts manufactured by KIRCHHOFF Automotive. Unfortunately, these measurement techniques and systems are slow (~5 frames per second, fps). For large parts (e.g., 2-meter-long cross car beams), it takes more than 90 seconds to inspect ~100 features (i.e., dimensions of edges, holes, presence of the clippers, etc.) with commercial 3D scanners and image processing software. Furthermore, these measurement systems also have poor accuracy for parts with significant variations in reflectance, large curvatures, and large depths. The automotive industry and the broader manufacturing industry demand new technologies for high-speed and high-accuracy 3D shape part metrology.****This project aims to develop new techniques and an instrument prototype for 3D measurement of industrial parts with better performance than existing 3D part metrology systems. This project has three specific objectives: (1) to develop a new hardware/scanner prototype for generating adaptively varied curved patterns and project structured light with varying intensities; (2) to develop new phase-based measurement techniques for part inspection/metrology; and (3) to evaluate the performance of the system by performing measurements on industrial parts with a high speed (>50 fps vs. 5 fps in state-of-the-art), and high accuracy (2% vs. 15% in state-of-the-art for parts with large curvatures and significant reflectance variations).