Design model generation for reverse engineering using multi-sensors

Reverse engineering is the process of creating a design model and a manufacturing database for an existing part or prototype. The applications of reverse engineering are in redesigning of existing partstools or prototype parts where the CAD model of the part is not available. Reverse engineering, for the most part, is performed as an interactive process where the designer identifies the surface features from digitized data and then models the surfaces accordingly. This paper presents the algorithms and implementation results for a reverse engineering system which is intended to automatically create CAD representations of part prototypes. An integrated sensory system combining contact and non-contact sensors has been developed to digitize parts surfaces. The sensory system fuses data from machine vision and a coordinate measuring machine (CMM) in order to automatically digitize the part surface. Machine vision is used to capture the orthographic views of the part. The images of these orthographic views are processed and vectorized to create five views of the part in the form of an engineering drawing. The system utilizes the generated orthographic projections to automatically drive the CMM to capture a grid of point coordinates from the part surface. The CMM digitization process is guided by the segmentation provided from the orthographic views. The segmented data from the part surface is input to the surface modeling module of the system where parametric surfaces are fitted through the digitized points. The surfaces are then extended and intersected using the Hermite approximation method to develop the 3-D CAD model of the part. Accuracy and automation is achieved by combining global shape information obtained from part images with the accurate point data acquired by a CMM. Algorithms for surface segmentation, part digitization, surface extension, and surface intersection modeling are described in this paper.     

Automatic segmentation and approximation of digitized data for reverse engineering

Reverse engineering is the process of developing a computer-aided design (CAD) model and a manufacturing database for an existing object. This process is used in CAD modelling of part prototypes, in designing moulds and in automated inspection of parts with a complex surface. This paper reports on the automatic segmentation and approximation of three-dimensional digitized points for reverse engineering. Based on an innovation that uses the properties of a non-uniform rational B-spline (NURBS) or B-spline and makes ordered digitized points be control points directly to construct a NURBS or B-spline surface, which takes less computation time than traditional algorithms in calculating surface normals and curvatures at digitized points, an algorithm was developed for automatic segmentation and NURBS surfaces fitting for digitized points.     

Automatic segmentation of digitized data for reverse engineering applications

Reverse engineering is the process of developing a Computer Aided Design (CAD)model and a manufacturing database for an existing part. This process is used in CAD modeling of part prototypes, in designing molds, and in automated inspection of parts with complex surfaces. The work reported in this paper is on the automatic segmentation of 3-Dimensional (3-D) digitized data captured by a laser scanner or a Coordinate Measuring Machine (CMM) for reverse engineering applications. Automatic surface segmentation of digitized data is achieved using a combination of region and edge based approaches. It is assumed that the part surface contains planar as well as curved surfaces that are embedded in a base surface. The part surface should be visible to a single scanning probe (21/2D object). Neural network algorithms are developed for surface segmentation and edge detection. A back propagation network is used to segment part surfaces into surface primitives which are homogenous in their intrinsic differential geometric properties. The method is based on the computation of Gaussian and mean curvatures of the surface. They are obtained by locally approximating the object surface using quadratic polynomials. The Gaussian and mean curvatures are used as input to the neural network which outputs an initial region-based segmentation in the form of a curvature sign map. An edge based segmentation is also performed using the partial derivatives of depth values. Here, the output of the Laplacian operator and the unit surface normal are computed and used as input to a Self-Organized Mapping (SOM) network. This network is used to find the edge points on the digitized data. The combination of the region based and the edge based approaches, segment the data into primitive surface regions. The uniqueness of our approach is in automatic calculation of the threshold level for segmentation, and on the adaptability of the method to various noise levels in the digitized data. The developed algorithms and sample results are described in the paper     

Collision-free path planning for coordinate measurement machine probe

This paper focuses on the method of collision-free path of the coordinate measurement machine (CMM). In terms of the collision-free path, the cut face method is used to plan the displaced tracking along the boundary loop. In addition, the 'maximum angle between tangential vectors method' and the heuristic algorithm designated by the displacement characteristic among the feature faces are used to reduce the number of intermediary points. This can also reduce the distance of the displacement. The turning of the probe aims at the contact with the workpiece surface in the normal direction. If the contact position in the normal vector direction is impossible, the probe angle closest to the normal direction is adopted. The normal direction contact with the workpiece can, on the one hand, achieve better measuring position and, on the other hand, accompany with the cut face method and thus make a collision-free path possible.     

Automated accessibility analysis and measurement clustering for CMMs

The aim of inspection planning tasks is to ensure the generation of efficient operation for coordinate measurement machines (CMMs). This paper presents a methodology to automatically define the accessibility domain of measurement points and then group them into a set of clusters. The methodology uses the computer-aided design (CAD) model of the workpiece and tolerance information as input to an algorithm for defining points accessibility. For each measurement point, the algorithm determines all feasible inspection probe orientations, as a subset of the total set of available orientations for a given CMM probe. A heuristic algorithm then groups the measurement points into a set of clusters which provide the maximum number of probe orientations. This methodology was applied to three examples which contain solid model and free-form surface representations.     

基于C-B样条的三角形和四边形曲面生成

文章给出了基于C-B样条的由网格数据产生三角形和四边形曲面片的方法,C-B样条是由基底函数{sin t,cos t,t,1}导出的一种新型样条曲线,它可以克服现在正在使用的B样条和有理B样条为了满足数据网格的拓扑结构而增加多余的控制点,求导求积分复杂繁琐,阶数过高,从而讨论其连续拼接时增加了困难等缺点,如何将它推广成曲面就成为一个重要问题。作者利用边-顶点方法构造插值算子,再将这些算子进行凸性组合,将C-B样条曲线推广成三角形曲面片和四边形曲面片,它可以用于CAD的逆向工程中散乱数据的曲面重构。     

基于曲率自适应的航空零件法矢量测量研究

现有的法矢量测量技术无法满足测量准确度和实时性的双重要求,法矢量计算方法不能适用于不同曲率的曲面。利用双目立体视觉,本文提出了一种基于曲率自适应的法矢量测量方法。首先,在双目立体视觉的基础上,基于变曲率曲面特征建立制孔区域曲面模型,提出投影点的布局方法;然后,基于三维重建的投影点数据,提出了基于曲面曲率自适应识别的法矢量计算方法;最后,针对小曲率曲面样件的测量结果,与三坐标测量仪测得的法矢量进行对比,用以验证本双目视觉测量方法的精度。实验结果表明:该方法测量法矢量误差为1.6°。该方法可有效提高法矢量测量的准确度,满足大型航空零件现场测量的工程要求。     

基于B样条自由曲面体间最短距离计算算法研究

提出了一种快速求解B样条曲线间最短距离的算法。该算法首先运用ULB方法,计算出两条NUBS曲线控制多边形间一对距离为极小值的点,以此对极小值点的连线方向作为曲线间最短距离的矢量方向,然后用爬山法求出两曲线在该矢量方向上的一对极值点,并以此对极值点作为拟牛顿迭代法求解非线性方程组的初始值,这样大大减少了求解方程组根的迭代次数,可快速求出精确解。最后把该算法扩展到NURBS自由曲面。     

贵州少数民族文化遗产的逆向工程应用研究

以少数民族文化遗产的保护和开发方法研究为目的,从实物测量、三维CAD模型、曲面模型评价体系、CAD模型重建等方面详细阐述了逆向工程技术在文化遗产保护方面的应用.选用有代表性的贵州少数民族文物--布依族酒壶、水壶以及木制傩戏面具作为研究对象,采用Hiscanner 激光扫描测头对其进行数据采集,扫描得到的点云数据可刻录到光盘上作为文物数据永久保存;更进一步地,采用目前流行的逆向工程软件Geomagic studio对点云数据进行数据精简、数据滤波、数据修补、提取特征线等处理后得到NURBS曲面;为保证曲面模型重建的精度,在曲面重建模型后对其误差评价,通过控制误差的方式指导曲面模型重建,使重建的文物曲面模型能真实完整地反映原状;最后,在功能强大的三维造型软件Solidworks中导入重构的NURBS曲面进行曲面缝合、放样等,将其生成实体CAD模型,并对模型的局部特征进行适当的再设计以实现文物实体模型的优化.对该模型进行快速成型制造可得到文物复制品或成品模具,即实现逆向工程技术在文化遗产保护中的应用研究.逆向工程技术应用于少数民族文化遗产文物保护是一个全新的课题,该项技术的应用能进一步推动文化遗产保护措施的发展,也能为类似课题的研究提供借鉴.     

Haptic modeling for a virtual coordinate measuring machine

Introducing a haptic device into coordinate measuring machine (CMM) inspection path planning leads to the proposal of a novel CMM off-line inspection path planning environment, a haptic virtual coordinate measuring machine (HVCMM), which makes use of the haptic modeling technique for CMM off-line programming. The HVCMM is an accurate model of a real CMM, which simulates a CMM's operation and its measurement process in a virtual environment with haptic perception. In this paper, a simple and effective mechanics model is implemented for the proposed HVCMM. The HVCMM enables CMM off-line programming to take place exactly as if an operator were in front of a real CMM and moving a real CMM probe. Even more, operators can feel the collision between the CMM and a part. Since there is a force feedback when the probe reaches the surface of the part, besides showing the contact in the HVCMM environment, it is much easier to generate a collision-free probe path than using other off-line inspection planning methods. The HVCMM not only facilitates inspection path planning, but also speeds it up because the operator does not need to slow the probe down when it is approaching an object. Combined visual and force feedback is the best indicator for selecting measurement points.     

Automatic sampling for CMM inspection planning of free-form surfaces

Coordinate measuring machines (CMMs) are used to examine the conformity of the produced parts with the designer's intent. The inspection of free-form surfaces is a difficult process due to their complexity and irregularity. Many tasks are performed to ensure a reliable and efficient inspection using CMMs. Sampling is an essential and vital step in inspection planning. Efficient and reliable approaches to determine the locations of the points to be sampled from free-form surfaces using the CMM were developed. Four heuristic algorithms for sampling based on the NURBS features of free-form surfaces are presented. The sampling criteria are equiparametric, surface patch size and the surface patch mean curvature. An algorithm for automatic selection of sampling algorithms performs complexity checks on NURBS surfaces, including the surface curvature changes and surface patch size changes, and selects the suitable sampling algorithm. Extensive simulations were performed using the developed methodologies to evaluate their performance using free-form surfaces with different degrees of complexity and compared with the uniform sampling pattern. The CMM measurement errors and manufacturing form errors have been simulated in these studies. The developed algorithms provide a useful tool in selecting the effective sampling plans for the tactile CMM inspection planning of free-form surfaces.     

Optimized stereo reconstruction of free-form space curves based on a nonuniform rational B-spline model

Analytical reconstruction of 3D curves from their stereo images is an important issue in computer vision. We present an optimization framework for such a problem based on a nonuniform rational B-spline (NURBS) curve model that converts reconstruction of a 3D curve into reconstruction of control points and weights of a NURBS representation of the curve, accordingly bypassing the error-prone point-to-point correspondence matching. Perspective invariance of NURBS curves and constraints deduced on stereo NURBS curves are employed to formulate the 3D curve reconstruction problem into a constrained nonlinear optimization. A parallel rectification technique is then adopted to simplify the constraints, and the Levenberg-Marquardt algorithm is applied to search for the optimal solution of the simplified problem. The results from our experiments show that the proposed framework works stably in the presence of different data samplings, randomly posed noise, and partial loss of data and is potentially suitable for real scenes.     

逆向工程中圆锥体组件加工信息快速高精度检测与生成方法研究

提出一种圆锥体组件加工信息快速高精度检测与生成的方法。首先,使用Delaunay网格划分法对圆锥体组件点云数据进行处理,得到其三角网格模型;其次,利用最小二乘拟合方法计算圆锥体组件点云数据各空间点最近邻域平面及其法向量,并构建空间点与法向量之间的映射关系,再根据该映射关系提取锥角;最后,通过对圆锥体组件点云数据的整体形貌分析提取锥高,利用锥角与锥高之间的关系计算出底面圆半径,通过计算的方式快速得到圆锥体组件的高精度加工信息。实验结果表明:该方法与几何测量方法相比,圆锥体组件的锥角θ、锥高h和底面圆半径r的误差分别降低了77.64%、70.53%和73.48%,时间减少了81.74%,能够实现圆锥体组件快速高精度加工信息检测与生成。     

采用UG二次开发的逆向工程数据处理方法

在分析三坐标测量机输出文件规则的基础上,针对逆向工程数据处理中存在的重复操作、精度不高等问题,利用UG的二次开发工具UG/OPEN GRIP,编写了"点云分层"和"数据投影"两个程序,减少了数据处理的重复操作,提高了UG软件在逆向工程中的应用效率,为逆向工程中的应用问题找到了一种新的解决思路和方法.     

Experimental study of the effect of digitizing parameters on digitizing uncertainty with a CMM

Planning of an automated digitization or inspection process takes time and requires experience. The accuracy of digitization and inspection depends directly on the planning of digitization strategies. This paper uses the fractional factorial experimentation approach to investigate the relationship between digitizing (inspection) uncertainty and digitizing (inspection) parameters with a coordinate-measuring machine (CMM). The parameters include travel speeds, pitch, probe angles (part orientations), probe sizes and feature sizes. Robust digitization (inspection) strategies are identified given the part geometry, dimensions and accuracy. Finally, future research directions are highlighted.     

基于改进ICP算法的叶片型线轮廓度误差评定

针对传统最近迭代点(ICP)算法存在配准精度较低的问题进行算法改进。首先,考虑到三坐标测量机测量数据呈现有序排列、且一一对应的特点,使用了一种基于矢量对齐法的型线数据初配准方法进行初配准;其次,在传统ICP算法配准的基础上,对待配准数据进行非均匀有理化B样条(NURBS)曲线拟合,再利用自适应粒子群算法对测量数据进一步精配准;最后,采用基于最小区域的叶片型线轮廓度误差评定方法进行误差评定。实验分析结果表明:改进方法相对于传统ICP算法,可在原有收敛值基础上达到进一步收敛的效果,轮廓度误差相对减小28.57%。该方法有效提高了叶片型线轮廓度误差评定的精确度,可为叶片的加工质量提供可靠判定。     

Research and implementation of NURBS interpolator with continuous feedrate for high-speed machining

Using non-uniform rational B-splines (NURBS) rather than piecewise lines and arc segments as a toolpath makes it much easier to achieve high-speed control in die and mould machining. When NURBS is used as a toolpath, two issues must be solved. The first is how to convert the discrete cutter location (CL) data offset from a CAD model into a NURBS curve. The second is how to maintain low velocity fluctuation while interpolating the NURBS curve with limited calculation time. This study proposes a NURBS toolpath generation method from line segments and a real-time NURBS interpolator for CNC machines to achieve the goal of high-speed machining. A CL data simplification method with shape holding is presented based on identifying and correcting the defect point from the original CL data, and removing redundant CL data within shape-maintaining requirements. Then the conversion of all simplified CL data to NURBS curves is done by applying NURBS fitting or interpolation with optional directional constraints. A precise method based on nonlinear mapping between the NURBS's parameter and arc length is proposed and implemented to obtain a continuous feedrate and machining quality. The simulation performed on CL points for a wave surface demonstrates that the proposed approach reduces the NC blocks to 6% while staying within the tolerance of deviation. The machining experiment shows that the proposed approach can increase machining quality while reducing machining time by about 22%.     

NURBS curve interpolation algorithm based on tool radius compensation method

This paper focuses on developing an algorithm that can generate toolpaths in NURBS form for smooth, high speed and accurate machining. The initial toolpaths are obtained by tool radius compensation method which is based on the workpiece boundary offsetting. According to different lengths and the continuous short block (CSB) criterion, these offset linear segments can be regarded as CSBs or long straight segments. Junctions are located where the curvature value is greater than the preset curvature threshold value or where it changes abruptly, or at the two end points of any long straight segment. During machining, the NURBS fitting module first looks ahead several CSBs and converts them into parametric curves in real time. During the conversion, continuities of the position, slope or even curvature at the transition of the parametric curves and unfitted line segments can be guaranteed. Then the acceleration/deceleration feedrate-planning scheme is proposed to determine the transition feedrate at the junction between the fitted curves and unfitted long straight segments, and the corner feedrate within the fitted curve. Simulations and experiments show that the proposed algorithm can significantly improve machining accuracy and reduce cutting time to satisfy today’s high-speed and high-accurate machining requirements.