Dynamic 3D Analysis

Deformation Analysis on Components and Assemblies

Dynamic 3D Analysis

The optimization of modern product development demands accurate and reliable measurement equipment delivering user independent measure-ment results with high accuracy and repeatability. A better understanding of the dynamic component behavior allows an efficient component deve-lopment reducing the required iteration cycles.

Dynamic 3D motion and deformation analysis

PONTOS is an optical mobile measurement system, which accurately determines the 3D coordinates of object points over time. In contrast to con-ventional displacement measuring systems, the PONTOS system reduces the measuring procedure to a fraction of the time. In addition, the under- standing of the measuring results is visually supported by an animated representation.

PONTOS replaces conventional displacement measuring systems and accelerometers. Indepen-dent of the structures to be measured, displace-ments and deformations are captured rapidly in a non-contact manner.

Results

Measuring with high absolute accuracy and the ability to capture unlimited measuring points simultaneously PONTOS is the perfect tool to measure and evaluate

• 3D coordinates• 3D motion and deformation• 3D velocity• 3D acceleration• 6 degree of freedom (6DoF) measures

Universal measurement solution

Where the use of common measurement devices is time-consuming, cost intensive or even impossible PONTOS is easily applicable for

• Complex 3D motion analysis • Relative 3D motion analysis • The determination of components deformation and vibration behavior • The measurement of hot components and surfaces (> 1000°C)

Image processing for dynamic 3D measurements

PONTOS evaluates images from high-resolution or high-speed cameras of any test object under load. A precise mathematical calibration model of the sensor setup is derived utilizing adjustment compu-tations to determine 3D camera positions and lens distortion parameters.

Using the exact mathematical model of the sensor setup and triangulation routines 3D coordinates are derived from corresponding points in all images. Subtracting these 3D coordinates at all points in time high-accurate X, Y and Z displacement values are calculated. Based on calculated 3D displace-ment values 3D velocity and 3D acceleration results are provided automatically. PONTOS provides the measurement results as

• 3D point clouds

• Vector displacements

• Overlay Images and Videos

• Free definable ASCII exports

• User-defined result reports

Automotive

The product development in the automotive sector is today driven by shorter development cycles and the reduction of costs to be competitive on the markets.

In modern automobiles various components are being developed and improved with high demands on function, safety and life time stability.

All components must undergo testing procedures to be certified for series production, such as:

• Thermal or mechanical deformation behavior• Vibration and noise response• Creep and aging processes• Crash behavior

PONTOS supports the understanding of static and dynamic component behavior and assists root cause analysis, e. g. disturbing noises, vibrations and complex motions. Thus delivering valuable feedback for component improvements.

PONTOS is the right tool for various applications for automotive testing, e. g:

• Door-, hood- and hatch-slam tests• Engine- and gearbox behavior• Manifold and decoupling element testing• Wind tunnel testing• Crash analysis• Pedestrian safety analysis• Stiffness analysis

Dynamic 3D Analysis

Aerospace

The development and manufacturing of a modern flight vehicle is an extremely complex process and demands careful balance and compromise between technical abilities, design, available technologies and costs.

Consequently, in aerospace development different technologies and engineering disciplines are consolidated, such as aerodynamics, propulsion, materials science, structural design and manu-facturing.

During developments component and structural testing is an important task in terms of evaluating stability and proving safety.

PONTOS is used in aircraft engineering and testing for component analysis, such as:

• Wing and flap deflection measurement• Barrel pressure testing• Vibration analysis• Structural testing

Biomechanics

Nowadays the development of biomechanical products does not differ much from other development workflows as known in the automotive or aerospace industry. Numerical simulation approaches as well as the determination of material parameters and the study of the response of human systems are integral parts of biomechanical research.

PONTOS enables the determination of 3D-motion and 3D-deformation under load of

• Bones and soft tissues • Implants • Osteosynthesis • Orthoses • Micro motion at fracture gaps

Research and Development

Numerical methods are today used to describe components and structural response in all research areas during the development and testing phase. An important role in the optimization of such numerical models is the validation with experimental setups.

Utilizing the PONTOS measurement system during development phases helps to better understand components behavior and significantly improves the

• Amount of iteration cycles • Development time • Development costs

Advantages

With the portable PONTOS measuring system there is no longer a need to setup complex measuring equipment. Small to large component tests can be performed with the same measure-ment device for the analysis of 3D-coordinates, 3D-motion and deformation as well as velocity and acceleration.

PONTOS is the ideal tool in component deve-lopment without influencing any components behavior.

• Non-contact measurement• Unlimited number of ultra-light measurement targets• Mobile sensor• Independent of environmental measuring conditions• Easy workflow & quick setup times• Fast evaluation• Measurement of small to large objects with one sensor head• Time and cost saving

Complete workflow in one software application

The entire measuring, evaluation and documen-tation process is carried out within the integrated PONTOS Software. The full potential of the availa-ble hardware is used to capture and evaluate the measuring area efficiently and with high accuracy.

The mobile PONTOS sensor is positioned in front of the measuring object and an unlimited number of lightweight, self ad-hesive measurement markers are applied.

• Mobile measurement system

• Easy and fast preparation times

• Unlimited measurement points

• No cables or references frames on object

1. Preparation

PONTOS dynamically records images from the test object during loading and automatically collects analog data from external measuring devices.

• Measurement independent of environmental conditions; sun light, climate chambers, wind tunnels, …

• Fast image acquisition

• Non contact measurement

• Easy integration in existing test environments

The result and reporting engine auto-matically displays all available measu-rement results including

• 3D visualization

• Diagrams

• Images

• Movies

• Standard and user-defined export

The measurement results, including 3D coordinates and displacements, are instantly processed and calculated after the test is completed.

• CAD import and alignment

• 3D coordinate transformation

• Rigid body motion compensation

• Displacement and deformation analysis

• 6 degree of freedom analysis

2. Measurement 3. Evaluation 4. Results and Reporting

GOM provides a complete solution with the PONTOS system for measuring, evaluation and reporting.

• Optimized workflows – time saving• User friendly – one training session• One support contact

GOM completely develops the PONTOS hardware and software in house. The software is designed to run the sensor and controller, to process all measurements, to automatically compute result data and to perform necessary post-processing.

PONTOS is an industrial grade solution providing all necessary functionalities even for complex research tasks. PONTOS can easily be integrated in stan-dard process chains through versatile import and export capabilities. All common CAD data formats are directly supported and used for coordinate transformations and deviation calculations.

• Native: Catia v4/v5, UG, ProE• General: IGES, STL, VDA, STEP

To close the process loop, all result data are exported in standard or free definable formats. All workflows are available for automated use with a record and play pro-cedure. New analysis models can easily be implemented by the operator and added to the standard evaluation as PONTOS offers a scripting interface.

Turn Key Solution

Sensor, image processing computer, software, accessories in one complete package Including all measuring and inspection software Complete integration in existing test environments Intensive training and support.

Complete Measuring Solution

development engineer to perform his own problem-oriented analysis and thus freeing up measuring capacities.

All necessary functionalities are part of the PONTOS Viewer:

• Creating further analyses• User defined legends• Handling CAD data for visualizations• Creating and exporting measuring reports and videos

The powerful, integrated PONTOS Software guides the operator through the complete measurement and evaluation process, providing support for setting up new measuring tasks and evaluating measurement results.The PONTOS software is used to run the sensor head, to process the 3D point cloud and to edit and post-process the result data. The simple graphical user interface helps support today‘s de-manding tasks in material and component testing

The free PONTOS Viewer allows for easily inter-changing of 3D measuring results and reports. Instead of working with printed tables and 2D reports, the PONTOS Viewer supports the interac-tion between colleagues and customers with 3D visualizations of coordinates, displacements, accelerations and velocities. With the PONTOS Viewer, GOM provides not only a free viewing tool for complete PONTOS projects but also a free working tool which allows the

Powerful Software for Measurement and Evaluation

[ms]

Head - X-DisplacementHead - Y-DisplacementHead - Z-Displacement

[mm]

[mm]

Sensor Controller Technical Data

Analog Input

Channels

Digital Resolution

Voltage Range

Sampling Frequency

8

16 bit

-10 V to +10 V

up to 100 kHz

Analog Output

Channels

Digital Resolution

Voltage Range

Sampling Frequency

4

12 bit

0 V to +10 V

up to 500 Hz

Dimensions

Weight

Operating Temperature

445 x 44 x 370 mm³

2.8 kg

5 – 40°

Trigger

Event List Based Triggering

pre / direct / post

points in time, analog values, external signals

Power for

Communication / Data Transfer

cameras, illumination, positioning pointers

gigabit ethernet (TCP/IP)

PONTOS Technical Data

Additional sensor configurations available on request.

up to 15 Hz (29 Hz)

2448 x 2050 px

Frame Rate

Camera Resolution

up to 5 kHz (1 MHz)

up to 1024 x 1024 px

up to 168 Hz (1334 Hz)

2400 x 1728 px

up to 58 Hz (464 Hz)

4000 x 3000 px

up to 500 Hz (4000 Hz)

1280 x 1024 px

Measuring Area

Accuracy

Specimen Temperature

cm² up to > m²

depending on measuring area up to 0.001 mm

typ. -100°C up to +1500°C

5MConfiguration 4M 12M HS High Speed

Camera Base

Laserpointer

Flash Illumination

fixed/variable

3 or 1

-

•

fixed/variable

3 or 1

•

•

fixed/variable

3 or 1

•

•

fixed/variable

3 or 1

•

•

variable

-

-

•

High-End 19“PC

Notebook

Control Device

•

•

Sensor Controller

•

-

Sensor Controller

•

-

Sensor Controller

•

-

Sensor Controller

•

•

optional

Sensor Dimensions (mm³)

Weight

typ. 700 x 200 x 140

5 kg

typ. 700 x 200 x 140

7 kg

typ. 700 x 200 x 140

7 kg

typ. 700 x 200 x 140

7 kg

Ring Buffer

GOM customers (extract)

3B Scientific • Aardmann Features • ABB • ACTech • Adidas • AEG

• Air Force Research Labs • Airbus • Alcan • Alcoa • Alfa Laval •

Alstom • Altay Scientific • Apache Footwear • Arcelor • Aselsan •

Asics • ASUS • Audi • Auto Parts Malaysia • Autodie International

• Automotive Lighting • Autopal • Avtovaz • Balda • Bang & Oluf-

sen • BAM • BASF • Batz • Bayer • Bentley • Bertone • Bertrandt •

Blaupunkt • BMW • Boeing • Bombardier • Bosch • Bplas • Braun

• Bridgestone • Bundeskriminalamt • Busch Jäger • Canon • Car-

coustics • Carsun • Casio • Caterpillar • Cessna • Cherry Automoti-

ve • Chicago Mold • China Steel • Ching Luh Shoes • Chrom Alloy

• Chrysler • Continental • Corning • DAAZ • Daihatsu Motor •

Daimler • Delloyd • Delphi • DLR • Dodge • Dräxlmaier • DuPont

• ETH Zürich • E.ON • EADS • EDAG • Ecco • Elasis • ELBAR SULZER

• Electrolux • Embraco • ENDO manufacturing • Ensam • EPFL

Lausanne • ESA • Eurocopter • Ever Tech Plastic • EXXON • FAA

• Fachhochschule Nordwestschweiz • Faurecia • FES • Fiat • First

Automobile Group • FisherPrice • Flextronics Plastics Technology •

FOI • Ford • Forschungszentrum Karlsruhe • Foxconn • Fraunhofer

• Fuji • GE Energy • General Motors • Georg Fischer • Gillette •

Gintic • GKSS Geestacht • Goodrich • Goodyear • Gorbynov Avi-

ation • Greenpoint • HANKOOK • Hansen Transmissions • Head

Tyrolia • Heck + Becker • Hella Leuchtensysteme • Hidrostal • Hilti

• Hitachi Taga • Honda • Honeywell • Howmet • Hydro • Hyundai

• IAV • IBM • IMA Dresden • Imperial College • IMPO • Institute

of Forensic Medicine Berne • International Automotive Research

Centre • Intier Automotive • Istanbul Technical University • Isu-

zu • Italdesign-Giugiaro • IUC • IVM • Jaguar • JAXA • Jhi Soon

Auto Metal • John Deere • Johnson Controls • Kautex Textron •

Kewpump • Kia • Kitech • Krämer + Grebe • KTH • KU Leuven •

Land Rover • Läpple • Laurence Livermore National Laboratories

• Lego • LG Electronics • Liebherr • Lockheed Martin • Los Alamos

Laboratories • LUK • Luxottica • Magna • Magneti Marelli • Mah-

le • Mann + Hummel • Matador • Matrici • Mattel • Max Plank

Institute • McLaren • Metalbages • Michelin • Microsoft • Miele •

Mitsubishi • Modenas • Montupet • Motorola • MTU • Nagasaki

Industrial Research Center • NASA • Nautor • Naval Research Lab

• NAZA • Nemak • Nike • Nissan • Nokia • Nolato • Northrop

Grumman Systems • Nothelfer • Nottingham University • Nypro

• OLHO Technik • Olympus • ONERA • Otto Fuchs • PCC Leoben •

PCI • Peguform • Phiaro Corp. • Philips • Pierburg Kolbenschmidt

• Pietro Rosa • Pilkington Automotive • Pininfarina • Playworks •

Poong Won Che Hwa • Porsche • Pratt & Whitney • PSA • PURAST

• Queen Mary College • Reebok • Renault • RIM • Robbe & Ber-

king • RollsRoyce • RWTH Aachen • Saipa • Salzgitter • Samsung

• Sandia National Lab • Sanyo • Saturn • Sea Ray Boats • Seat •

Shell • Shenyang Aircraft Research Institute • Siemens • Skoda

• SKS Coachbuilders • Snecma • Solar Turbines • Solvay • Sony •

SonyEricsson • Standard Profile • Stihl • Stola • Subaru • Sun Mi-

crosystems • Suzuki • Tata Motors • Tata Steel • Temsa • Thomas-

sen • Thule • ThyssenKrupp • Tianjin Motor Dies • Tokai Rubber

Industries • Topia • Toyota • Triumph • TRW • TU Delft • TU Dres-

den • TU Eindhoven • TU Graz • TU München • Tubitak Marmara

Research Center • Turbine Services • Tyco • Uni Erlangen LFT • Uni

Padova • Uni Stuttgart • US Army Research Lab • Valeo • VDO •

Vertu • Villeroy+Boch • Voest Alpine Stahl • Voith Siemens • Volke

• Volkswagen • Volvo • Vulcan Air • VZLÚ • WAGO • Walt Disney

• Warwick University • Whirlpool • Yamaha • Yulon • ZF Sachs

GOM - Optical MeasuringTechniques

GOM is a global industrial manufacturer that develops and produces revolutionary optical measurement solutions and technologies for 3D coordinate measurement and deformation analysis. GOM‘s measuring systems are based on digital image processing and are used in pro-duct development, quality assurance, material and component testing.

Optical measuring technology and full-field surface measurement systems have become a standard tool within virtually all industries. The data from GOM‘s measurement systems are an invaluable tool for quality control in modern product development and production process chains.

Non-contact optical measuring systems for all measurement tasks

In addition to PONTOS, GOM also offers:

• ATOS: industrial 3D scanning technology• TRITOP: optical 3D coordinate measuring

machine• ARAMIS: optical 3D deformation analysis of

materials and components • ARGUS: optical forming analysis for sheet

metal forming processes

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