the university of michigan, ann arbor engineering research center for reconfigurable manufacturing...

The University of Michigan, Ann Arbor

Engineering Research Center for

Reconfigurable Manufacturing Systems

TA-3 ProjectsIn-Process Metrology

NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan, College of Engineering

TA-3 Presentation pg.2

Motivation of TA-3



Results of TA-3: In Process Metrology

Our results in Metrology are divided into two areas:

1.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.



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



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



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



Reconfigurable Inspection Machine-RIM

Laser probes

Slide system

Engine cylinder headVision system

Same machineNew Configuration



Plant floor testing (2/3 - 2006)

RIM –Technology Transfer

GEMA – Dundee, MI

GM “RIM”- Flint Plant



Inspection of Complex Surfaces

OptimetLaser Probe

Inspected Part

x

yz

OptimetLaser Probe

Inspected Part

x

yz

Stage Controller

Probe 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)

Objective: • To develop a rapid and accurate

reconfigurable optical system for inspecting a part family with sculpture surfaces



Inspection of Complex Surfaces

Linear Motion Stages

Rotary Stage

Inspected Part

Computer

Non-Contact Laser Probe

Blade Inspection Machine (BIM)



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



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)



Full Scale Prototype

Four laser probesFour laser probes

V-8 Engine Inspection SetupV-8 Engine Inspection Setup



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



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



Sight Pipe System

CCD

Sight Pipe Part

Top view of the system

Detected Pores

Bore Image



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



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)

Project #3 - In-line Valve Seat Inspection



Experimental Setup For Valve Seats Measurement

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)

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)



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

Grinding Robot

Blade Inspection Machine (BIM)



Integration of Measurement and Machining

Location Calculator

(Relative to the part)

Correction Action

Robot Part

Sensor

Measuring

Machine

CAD Model

+

-

Motion

Command

Robot Location

Measuring Machine location

Finished Parts

Data Processing

•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



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.

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

670 675 680 685 690 6951700

1750

1800

1850

1900

1950

2000

2050

X

Z 30mm

20 m



Set Up and Master Plate for Calibration

Sample Master Plate

Experimental Set Up

Research tools



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



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.

Slip Ring

Bore Surface

MirrorLensDetector Laser



Rapid Imaging System Set Up

Fiber illumination source

Monitor

Borescope

Rotary table



Questions are Welcomed!

The End



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

the university of michigan, ann arbor engineering research center for reconfigurable manufacturing...

Documents

college of engineering

results of ta

motivation of ta

computer vision algorithms

diameter of pores algorithms

process metrology slide

metrology infrastructure

performance slide