Engineering Research Center for
Reconfigurable Manufacturing Systems
TA-3 Projects
In-Process Metrology
The University of Michigan, Ann Arbor
Motivation of TA-3
Build a world-class center of expertise for the research and development
of rapid non-contact inspection methods.
Conduct R&D motivated by industry inspection needs.
Create educational tools in inspection and metrology.
Bridge between end-users and equipment/solutions suppliers. (Evaluate
specs and performance)
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
TA-3 Presentation
pg.2
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.
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
TA-3 Presentation
pg.3
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
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
TA-3 Presentation
pg.4
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
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
TA-3 Presentation
pg.5
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
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
TA-3 Presentation
pg.6
Reconfigurable Inspection Machine-RIM
Same machine
New Configuration
Engine cylinder head
Vision
system
Laser
probes
Slide system
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
TA-3 Presentation
pg.7
RIM –Technology Transfer
GEMA – Dundee, MI
GM “RIM”- Flint Plant
Plant floor testing (2/3 - 2006)
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
TA-3 Presentation
pg.8
Inspection of Complex Surfaces
Objective:
• To develop a rapid and accurate
reconfigurable optical system for inspecting
a part family with sculpture surfaces
Inspected Part
Probe
Controller
Stage Controller

z
x
y
Optimet
Laser Probe
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)
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
TA-3 Presentation
pg.9
Inspection of Complex Surfaces
Blade Inspection Machine (BIM)
Computer
Inspected
Part
Linear
Motion
Stages
Rotary
Stage
Non-Contact
Laser Probe
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
TA-3 Presentation
pg.10
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
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
TA-3 Presentation
pg.11
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)
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
TA-3 Presentation
pg.12
Full Scale Prototype
Four laser probes
V-8 Engine Inspection Setup
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
TA-3 Presentation
pg.13
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
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
TA-3 Presentation
pg.14
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
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
TA-3 Presentation
pg.15
Sight Pipe System
Detected Pores
CCD
Sight Pipe
Part
Bore Image
Top view of the system
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
TA-3 Presentation
pg.16
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
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
TA-3 Presentation
pg.17
Project #3 - In-line Valve Seat Inspection
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)
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
TA-3 Presentation
pg.18
Experimental Setup For Valve Seats Measurement
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)
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)
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
TA-3 Presentation
pg.19
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
Blade Inspection Machine
(BIM)
Grinding
Robot
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
TA-3 Presentation
pg.20
Integration of Measurement and Machining
Location
Calculator
Measuring Machine location
Robot Location
(Relative to the
part)
Command
+
CAD
Model
-
Correction
Action
Data
Processing
Part
Robot
Finished
Parts
Sensor
Measuring
Motion
Machine
•
•
•
•
•
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
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
TA-3 Presentation
pg.21
Project #5 - Inspection of Auto-body Panels
(New Title: Measurement of Small Curvatures)
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
2050
2000
1950
1900
Z
ACCOMPLISHMENTS
•Surface defects quantitative characterization
• Appropriate technology is currently identified for surface
defect analysis and a prototype was designed and is built.
30mm
1850
20 m
1800
NSF Engineering Research Center for Reconfigurable Manufacturing
1750 Systems
University of Michigan, College of Engineering
1700
670
675
TA-3 Presentation
pg.22
680
X
685
690
695
Set Up and Master Plate for Calibration
Research tools
Experimental Set Up
Sample Master Plate
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
TA-3 Presentation
pg.23
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
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
TA-3 Presentation
pg.24
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.
Bore Surface
Slip Ring
Detector
Lens
Mirror
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
Laser
TA-3 Presentation
pg.25
Rapid Imaging System Set Up
Borescope
Rotary table
Monitor
Fiber illumination source
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
TA-3 Presentation
pg.26
The End
Questions are Welcomed!
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
TA-3 Presentation
pg.27
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
NSF Engineering Research Center for Reconfigurable Manufacturing Systems
University of Michigan, College of Engineering
TA-3 Presentation
pg.28