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AICON 3D Systems GmbH
Biberweg 30 C
D-38114 Braunschweig
Germany
http://www.aicon3d.com
Industrial Photogrammetry
Dr.-Ing. Carl-Thomas Schneider
Hanover, October 13th, 2012
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Industrial Photogrammetry
• 3D object measurement by means of images
• Photogrammetry is as old as photography
• Aerial and architectural photogrammetry
• Industrial applications since early 1980‘s
• Wide range of applications in
industry since the mid 1990‘s
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Industrial Photogrammetry
• High mobility – low transportation weight
• Quick results on site
• Independent from object size
• Low investment
• High accuracy
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Industrial Photogrammetry
Components of a Photogrammetry System
High resolution digital
camera
Scale bar
Targets
Processing Software
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Functional principle
1 2
3
4 5
X
Z
Y
For three dimensional object points …
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1 2
3
4 5
X
Z
Y
… the system calculates precisely 3D coordinates …
Functional principle
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1 2
3
5
X
Z
Y 4
… using high resolution measuring images.
Functional principle
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Work flow
Step 1: signalization of the object with targets
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Step 2: signalization of the object with adaptors
Work flow
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Step 3: placement of coded targets, reference cross
und reference scale bars
coded targets
reference cross
reference
scale bars
Work flow
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Step 4: Photographing the object from
different directions
Work flow
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Work flow
Step 4: Photographing the object from
different directions
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Work flow
Step 4: Photographing the object from
different directions
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Work flow
Step 4: Photographing the object from
different directions
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Work flow
Step 4: Photographing the object from
different directions
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Work flow
Step 4: Photographing the object from
different directions
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Step 5: processing of the digital measuring images with
the analysis computer
W-Lan
transfer
Work flow
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Step 6: 3D data analysis and result presentation
Work flow
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Industrial Photogrammetry
Accuracy of a Photogrammetry Systems
• ± 15µm per meter object size
• ± 0.1mm for a passenger car
• Standard: VDI 2634
-0,060
-0,050
-0,040
-0,030
-0,020
-0,010
0,000
0,010
0,020
0,030
0,040
0,050
0,060
0 200 400 600 800 1000 1200 1400 1600 1800 2000
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Industrial Photogrammetry
• Wind Energy
• Nuclear Research
• Tunnel Surveying
• Subsea Applications
• Deformation Analyses
Fields of Application
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Inspection of Rotor Hub
Object Signalisation
Industrial Applications
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Industrial Applications
Inspection of Rotor Hub
Tooling for Flange and Thread Signalisation
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Inspection of Rotor Hub
Image Acquisition
Industrial Applications
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Postprocessing
Industrial Applications
Inspection of Rotor Hub
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Feature Laser Tracker DPAInspect Deviation
Diam Cyl EA 325,066 325,045 0,021
Diam Cyl EC 325,064 325,122 -0,058
Dist D - Origin 2190,160 2190,094 0,066
Dist CA - Ref A 1109,919 1109,888 0,031
Dist CB - Ref A 1109,842 1109,858 -0,016
Dist CC - Ref A 1110,003 1109,952 0,051
Dist CA - D 1080,238 1080,205 0,033
Dist CB - D 1080,292 1080,236 0,056
Dist CC - D 1080,185 1080,142 0,043
Comparison of Results with Laser Tracker
Industrial Applications
Inspection of Rotor Hub
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Industrial Applications
• Inspection of Rotor Hub
• Control of Rotor Blade
• Flatness Test of Base Flange
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Industrial Applications
Control of Rotor Blade
Length: 40m
Diametre : 3,5m
Weight : appr. 3 to
Customer :
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Industrial Applications
Control of Rotor Blade
Inspection of Master Model,
leading edge, trailing edge and profiles
3700 object points, overall accuracy 0.5 mm
350 images taken
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Industrial Applications
Control of Rotor Blade
CAD Comparison of Master Model
leading edge, trailing edge
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Industrial Applications
Control of Rotor Blade
Cad Comparison of Master Model
Report of profile measurement
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Industrial Applications
• Inspection of Rotor Hub
• Control of Rotor Blade
• Flatness Test of Base Flange
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Industrial Applications
Flatness Test of Base Flange
Base Flange Inspection
during Setup of a Wind Mill
for Power Generation
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Industrial Applications
Flatness Test of Base Flange
Signalisation of Base Flange on site
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Industrial Applications
Flatness Test of Base Flange
Presentation of Results
Deformation (enlarged)
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Industrial Photogrammetry
• Wind Energy
• Nuclear Research
• Tunnel Surveying
• Subsea Applications
• Deformation Analyses
Fields of Application
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CERN - European Organization for Nuclear Research
Applications in Nuclear Science
Schematic set up of the
Large Hydron Collider (LHC)
15 m
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Applications in Nuclear Science
Inspection of Muon Barrel
Object: “Muon Barrel”
Diameter: 15m
Accuracy: 0.5 mm
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Applications in Nuclear Science
Inspection of Muon Barrel
Object: “Muon Barrel”
Diameter: 15m
Accuracy: 0.5 mm
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Applications in Nuclear Science
Inspection of Muon Barrel
Object: “Muon Barrel”
Diameter: 15m
Accuracy: 0.5 mm
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Industrial Photogrammetry
• Wind Energy
• Nuclear Research
• Tunnel Surveying
• Subsea Applications
• Deformation Analyses
Fields of Application
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Tunnel Survey Applications
Convergency Measurments
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Tunnel Survey Applications
Convergency Measurement Malmö Tunnel (Subway)
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Tunnel Survey Applications
Convergency Measurement 4th Elbe Tunnel
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Industrial Photogrammetry
• Wind Energy
• Nuclear Research
• Tunnel Surveying
• Subsea Applications
• Deformation Analyses
Fields of Application
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Industrial Photogrammetry
Subsea Applications
Unmanned subsea robot Digital camera in pressure resistant
housing mounted on manipulator
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Industrial Photogrammetry
Subsea Applications
Exchange of components under water
• Monitoring of current situation
• Measurement volume 50m x 30m
• 500 images
• Accuracy +/- 20mm
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Industrial Photogrammetry
Subsea Applications
Exchange of components under water
• Monitoring of current situation
• Measurement volume 50m x 30m
• 500 images
• Accuracy +/- 20mm
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Industrial Photogrammetry
Subsea Applications
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Industrial Photogrammetry
• Wind Energy
• Nuclear Research
• Tunnel Surveying
• Subsea Applications
• Deformation Analyses
Fields of Application
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Industrial Photogrammetry
Deformation Inspection in an Environmental Chamber at 180°C
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Industrial Photogrammetry
Image acquisition by a fire fighter
Deformation Inspection in an Environmental Chamber at 180°C
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Industrial Photogrammetry
Graphic display of results
Deformation Inspection in an Environmental Chamber at 180°C
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Structural Testing of the NH90 Helicopter
NH 90 Cabine
NH 90 in test rig
Aerospace Applications
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Structural Testing of the NH90 Helicopter
NH 90 Cabine
NH 90 in test rig
Aerospace Applications
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Structural Testing of the NH90 Helicopter
Structural testing
Inducement of forces
to the helicopter to
simulate take off,
flight and landing
Rotor mount
Landing gear
Aerospace Applications
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Structural Testing of the NH90 Helicopter
Photogrammetric
Measurement
Targeting of the outer
shell with coded and
uncoded retro-
reflective targets
Aerospace Applications
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Structural Testing of the NH90 Helicopter
5200 points
320 images
Deformation Vectors
Aerospace Applications
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Industrial Photogrammetry
What are the advantages of industrial application ?
• Fully automated processing from image
acquisition to report generation
• Repeating tasks can be automated using makros
• Low transport volume for highest mobility
What are the major benefits ?
• Fast results for decision making on site
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http://www.aicon3d.com
Industrial Photogrammetry