High-Accuracy 3-Dimensional Measurement Systems


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 Industrial and Engineering

  Breuckmann 3D white light scanners produce high-resolution 3D scans with millions of data points.  Even the smallest objects can be accurately recorded in three dimensions using this close-range scanner.  Scans may be used for quality inspection or may be converted into realistic 3D models and can provide the basis for reproductions and/or archival records.

  Using the Breuckmann StereoScan NEO 3D Scanner technlogy, the inner shell of a cellphone was scanned to identify any production errors.  This was done by obtaining a number of views while the shell was moved by means of a manually rotated plate.  Attached to the plate were markers allowing for automatic alignment of the views.  From the digitized model, several 3D features were selected in order to control manufacturing tolerances.

 Breuckmann StereoSCAN 3D scans phone case

 Breuckmann STL 3D scan data

  The StereoSCAN Neo is used to perform a spot inspection of an extruder screw in order to control the production process.  The measurement consisted of taking a number of views of the extruder screw and aligning the individual views using the contour of the object.  The digitized 3D model of the extruder screw was then compared to the CAD data and deviations were monitored as a pseudo-color map.

 StereoSCAN 3D STL model of extruded screw

 Breuckamnn OptoCAT extruded screw 3D mesh comparison screenshot
  Wyman Gordon is a major supplier of forgings to both military and commercial aerospace manufacturers. The need to generate critical high accuracy measurement data in a hostile forging environment presents unique challenges. These challenges include the need to measure large components (up to 23 ft long), measuring dies while they are still hot, and a need for both discreet point probing as well as high-density point cloud acquisition, all in a setting where thermal extremes and particulate contamination are virtually guaranteed. In addition, there is a frequent need to reverse-engineer patterns and tooling that may be up to 50 years old.

 3D STL model result without pre-treatment

 3D scanning of US Telex reflective surface parts
Breuckmann 3D scanner positioned on vehicle to 3D scan road structure

 3D scan data of test track road surface

 Breuckmann 3D scanner positioned to scan Dishwasher brush

Measuring the shell of a cell phone using markers and a rotating table

3D scan of Inner shell of cellphone

Extruded Screw

NaviSCAN 3D system showing Breuckmann  StereoSCAN

Shiny surfaces measured without coating

Scan data without spray or coating

Vehicle equipped with 2 mounted scanners

Section of scanned test track showing imperfections in road surface.

Measuring the Inner shell of a Cell Phone

Measurement of an Extruder Screw

Spot Inspection of production control

Comparing captured data to CAD data

Measurement of Hot Forging Dies

Meeting Challenges in adverse conditions

  With these considerations in mind, Wyman Gordon purchased a NaviSCAN 3D system incorporating a Breuckmann StereoSCAN 3D scanner.  The 3D Arena measurement system satisfies all the criteria for portability, functionality, accuracy, and durability.

  The measurement of a discrepant part and hot welded dies was performed on the plant floor, with no adverse effects from either environment or part size.

Thin Wall Metal parts Scanned Without Surface Treatment

Shiny Surfaces pose no problem for scanner

Test Track Road Surfaces

Measuring Large Scale 3D surfaces

Dishwasher Brush

Digitization of a brush for washing dishes

  Telex, a telecommunications customer, had fragile metal parts which required high accuracy cross sectional information.  Because of the tendency of the material to flex under the lightest pressure, equipment that touches the part, such as articulated measurement arms or coordinate measuring machines could not provide the solution.  Accurex Measurement used the Breuckmann SmartSCAN-HE structured light scanner to collect dimensional information about the part.

  The scan data was collected in about a second.  In practical terms this means that there is very little possibility of an object moving during the data acquisition stage.  This was particularly useful capability in this case because the fragile nature of the part meant that it would most likely be deformed if any effort was made to clamp it down during the measurements.

  Because much of the part consists of shiny materials, many scanners would require the use of a non-reflective powder.  However, the SmartSCAN-HE was able to measure the reflective surfaces without any coating.

  Measurements have been carried out at a number of test tracks in various countries.  As the topographic data of the test track road surfaces is used for computer simulations of chassis movements it needs to be very accurate with depth determined to a local accuracy of 1mm or better.  A further requirement is that all the scans be tied into on very large dataset.

    A vehicle is equipped with two scanners.  They are mounted side-by-side on a fixture which is firmly attached to the van's roof rack.  The StereoSCAN NEO consists of a light projector and digital camera rigidly attached to either end of a fiber composite bar.  The scanners are positioned so as to capture overlapping images to allow the adjacent field of view to be stitched together.  The controlling software, OptoCAT which has been customized for this particular application by means of its built-in macro programming language capability.  OptoCAT also allows for the alignment of overlapping point clouds so that the scanning system can be used to measure large parts.

SmartSCAN-HE technology  by Breuckmann was used to digitize a designer brush for washing dishes.  The requirements for the scan were that there could be no pre-treatment of the object surface, particularly spraying with powder; no contact measurement; a low measuring time; and the surface data of a closed volume model would be delivered in STL format.

  Because the alignment of single view by means of the object geometry is realized interactively, no special fixing of the object is necessary.  The scans of the brush were taken by putting the brush in different positions to develop a full 3D model.

Scanning to identify production errors


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