engineering research center for reconfigurable manufacturing systems
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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
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.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.
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.4
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 SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.5
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 SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.6
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 SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.7
Reconfigurable Inspection Machine-RIM
Laser probes
Slide system
Engine cylinder headVision system
Same machineNew Configuration
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.8
Plant floor testing (2/3 - 2006)
RIM –Technology Transfer
GEMA – Dundee, MI
GM “RIM”- Flint Plant
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.9
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
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.10
Inspection of Complex Surfaces
Linear Motion Stages
Rotary Stage
Inspected Part
Computer
Non-Contact Laser Probe
Blade Inspection Machine (BIM)
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.11
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 SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.12
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 SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.13
Full Scale Prototype
Four laser probesFour laser probes
V-8 Engine Inspection SetupV-8 Engine Inspection Setup
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.14
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 SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.15
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 SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.16
Sight Pipe System
CCD
Sight Pipe Part
Top view of the system
Detected Pores
Bore Image
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.17
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 SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.18
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
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.19
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)
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.20
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)
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.21
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
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.22
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
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.23
Set Up and Master Plate for Calibration
Sample Master Plate
Experimental Set Up
Research tools
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.24
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 SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.25
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
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.26
Rapid Imaging System Set Up
Fiber illumination source
Monitor
Borescope
Rotary table
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.27
Questions are Welcomed!
The End
NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan, College of Engineering
TA-3 Presentation pg.28
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
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