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

零部件计量对制造业的质量控制至关重要，2016年其市场容量达到4650亿美元。汽车零部件制造商，包括KIRCHHOFF汽车公司，该项目的两个支持组织之一，已经大大提高了他们的零部件质量控制标准，以保持竞争力。必须精确测量每个零件的几何形状，以确保尺寸正确，并与日益严格的公差完美配合。最先进的3D测量系统（例如，来自我们其他支持组织LMI Technologies的Gocator扫描仪）已应用于KIRCHHOFF Automotive制造的零件上并进行了测试。不幸的是，这些测量技术和系统是缓慢的（~5帧每秒，fps）。对于大型部件（例如2米长的汽车横梁），使用商用3D扫描仪和图像处理软件检查约100个特征（即边缘、孔的尺寸、剪子的存在等）需要90多秒。此外，这些测量系统对于反射率、大曲率和大深度变化较大的部件精度也很差。汽车工业和更广泛的制造业需要高速、高精度的3D形状零件计量新技术。该项目旨在开发新技术和仪器原型，用于工业零件的3D测量，其性能优于现有的3D零件测量系统。该项目有三个具体目标：(1)开发一种新的硬件/扫描仪原型，用于产生自适应变化的曲线图案和不同强度的项目结构光；(2)为零件检验/计量开发新的基于相位的测量技术；(3)通过对工业零件进行高速（50帧/秒对5帧/秒）和高精度（对于具有大曲率和显著反射变化的零件，2%对15%）的测量来评估系统的性能。

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).