Measurement Report for Harley Davidson Motor...

Measurement Report

for Harley Davidson Motor Company

Subject: Presentation of the principle of operation and

possibilities of SMARTTECH’s 3D scanners together

with Geomagic Control in order to provide complex

quality inspection.

SMARTTECH Sp. z o.o. tel./fax: (22) 751 19 16

Racławicka 30 NIP: 118-15-38-553

05-092 Łomianki [email protected]

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Contents

1. Purpose of the measurement.............................................................................................................. 2

2. 3D scanning - obtaining the object’s geometry .................................................................................. 3

3. Work in SMARTTECH3Dmeasure ......................................................................................................... 5

4. Analysis in Geomagic Control .............................................................................................................. 7

Summary ............................................................................................................................................... 18

1. Purpose of the measurement

The purpose of the 3D scanning provided by SMARTTECH is to present the measurement

method and the potential of 3D scanners. The scanned objects were parts sent by Harley

Davidson. The obtained data was further processed in Geomagic Control in order to provide

quality control.

To provide inspection we require:

3D scanner, dedicated to the scanning of black surfaces, with high accuracy and

resolution,

specialized software for quality inspection.




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2. 3D scanning - obtaining the object’s geometry

In this case the motorcycle producer supplied us with black glossy elements. Measurement

was done in order to check the depth of engraved VIN numbers on a flat and cylindrical

surface.

Figure 2.1. Engraved VIN number that needed to be scanned and measured.

The producer stated that there's no possibility to cover the object with an agent that would

whiten the surface - titanium oxide. The SMARTTECH, in order to meet this requirement,

used a specialized 3D scanner with the ability to scan black surfaces – MICRON3D color

24MPix - and with the highest available resolution on the market - 24MPix.




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Figure 2.2. Scanner MICRON3D color 24MPix.

This specific model has a measurement volume of 200 x 150 x 120 mm and an accuracy of

0,03 mm. The very high resolution of this 3D scanner allows us to get 900 points on one

square millimeter. A single scan takes about 15 seconds.

In this case, in order to ensure the accuracy of the results, the objects were covered with an

anti-glare agent (which was necessary) but still retained the original black color.

The result of a single scan is a cloud of points (each point is described with X, Y, Z

coordinates).

Figure 2.1. The 3D scanning of the object.




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3. Work in SMARTTECH3Dmeasure

To control the 3D scanner we use software SMARTTECH3Dmeasure. This program allows

us to visualize results and enables us to do initial operations on the cloud of points.

Furthermore, the software is capable of working with very large datasets (even over 300 000

000 points). The measurement can be done using 3 different methods: a single scan, scanning

on a rotary stage, and with positioning markers. In SMARTTECH3Dmeasure we adjust the

appropriate parameters to the 3D scanning environment and scanned object. The software

allows us also to export the clouds of points to files with ply., obj., or vrlm. format which are

compatible with the most popular quality inspection and reverse engineering software

solutions (including Geomagic Control).

Figure 3.1. The result of the 3D scanning visible in SMARTTECH3Dmeasure. The VIN

number on the cylindrical surface.




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Figure 3.2. The result of the 3D scanning visible in SMARTTECH3Dmeasure. The VIN number on the

flat surface.

In this particular case we need only to make a single measurement for each object. The only

task to be done in software SMARTTECH3Dmeasure was initial cleaning from the noises that

could appear during the 3D scanning. We also cut out all irrelevant surfaces, leaving out only

the surface with the engraved number.

Figure 3.3 Engraved letters on the cylindrical surface.




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Figure 3.3 Engraved letters on the flat surface.

Once we have our data (the point clouds) prepared, we export them to the quality inspection

software.

4. Analysis in Geomagic Control

The advantages of the program are:

comprehensive verification,

simpler and more reliable control of parts,

import of data from a 3D scanner and CAD software,

automatic adjustment of the 3D scan to CAD model,

creation of a map of deviations, as well as control of dimensions and tolerances

(GD&T),

automatically generated reports will help with the presentation of inspection results,

repetition of the process for another part with only two clicks.

An overview of the most important functions of editing point clouds:

several types of selecting point clouds,

deletion of selected point clouds,




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noise removal,

simplification/reduction of the size of point clouds,

point clouds smoothing,

creation of triangle mesh.

An overview of the most important functions for the mesh of triangles:

finding and fixing errors,

editing edges,

editing individual triangles,

smoothing,

filling holes,

simplifying triangle mesh,

reducing the number of triangles,

recalculation of triangle mesh,

flipping normals,

dividing triangle mesh into smaller parts,

dividing triangle mesh,

mirror.

First, we analyze the depth of the letters engraved on the flat surface.

First step – selection of a flat surface that will function as a reference. Below you can see an

example area from which the flat surface was selected.




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Figure 4.1. The area from which the reference surface was selected. The view in Geomagic Control

Once we selected the flat reference surface, we create a deviation color map.

Figure 4.2. Calculating the surface of the object.

In order to measure the depth of the groove we need to measure the deviations to the reference

surface. We measure the distance from the reference surface in the groove and on the edges.




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This approach will guarantee that the results are referential, since the surface on which the

letters were engraved wasn’t perfectly flat.

Figure 4.3. Measurement of the depth of the grooves.

It is also possible to select a reference surface locally for a given letter (optionally, for a set of

letters).

Figure 4.4. Selecting a reference surface.




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Figure 4.5. Deviation color map.

Figure 4.6. Measurement of the depth of the grooves.

We also analyzed the letters on the cylindrical surface. The scanned part is relatively small,

therefore we might acquire inaccurate data.




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Figure 4.7. Creating a cylinder from the scanned data.

The diameter of the cylinder is a few millimeters smaller than in reality and because of that

the deviation color map displays inaccurate results.





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If we measure the cylinder’s diameter manually, e.g. using a caliper, we can manually

generate a cylinder with required diameter. Just like presented below.

Figure 4.8. Aligning the cloud of point to the manually created CAD cylinder.

And perform the analysis of the depth of the grooves.





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Figure 4.10. Measurement of the depth of the groove.

Another solution is to do cross-sections on the scanned area and to create the surface using

lofts. Below you can see how to quickly do that in Geomagic Design X.

Figure 4.11. Creating a segment of the reference surface using cross-sections in Geomagic Design X.




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The analysis performed on the surface created by using cross-sections.


Figure 4.13. The analysis of the depth of the grooves.

The same cross-sections can be performed in other CAD software, for example in

SolidWorks.




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For this purpose, we need to generate a set of cross-sections in Geomagic Control.

Figure 4.14. A set of cross-sections generated in Geomagic Control using only one function.

Figure 4.15. The curves generated in Geomagic Control.

Next, we need to export those cross-sections to a file in an IGES format and open it in a

program that supports files with this extension.




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Figure 4.16. The curves opened in SolidWorks. The loft function.

Figure 4.17. Segment of a future parametric surface created based on the curves in Geomagic

Control.




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Summary

The 3D measurement was performed by SMARTTECH on motorcycle parts provided by

Harley Davidson. The parts were black and glossy with no possibility to cover them with anti-

glare white agent. For this reason SMARTTECH used a specialized 3D scanner MICRON3D

color 24 MPix with a detector with 24 MPix. This 3D scanning unit is capable of scanning

black color with very high accuracy and resolution. The parts were covered only with a

transparent - easily removable - matting agent.

The measurement results are very accurate and detailed which, together with Geomagic

Control, allows us to provide complex quality inspection. The entire process, starting from the

3D scanning and finishing with the groove analysis takes about 8 minutes.

Using a 3D scanner with appropriate software gives us possibilities and precision unreachable

for the traditional – manual – method.

During this measurement we used a 3D scanner with a measurement volume of 200 x 150 x

120 mm that assures the accuracy of 0.03 mm and 900 points on a single square millimeter.

The SMARTTECH 3D scanners do not require end-user calibration before starting the

measurement. Thanks to the sealed cover and a specialized ISA (Internal Shock Absorbing)

system, the scanner is ready to use directly out of the case.

The SMARTTECH 3D scanners can be certified in independent measurement laboratories

which makes them referential, just like CMM machines.

Measurement Report for Harley Davidson Motor...

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