The performance of a 3-D inspection process as measured in terms of accuracy and repeatability of point cloud data obtained through the process is of great importance for proper utilization of data. This paper attempts to characterize effect of different operating conditions on system performance and to estimate a set of best operating conditions for the Capture Geometry Inside system CSS-1000. The system consists of a milling machine to cut the part one layer at a time and a vision system made up of a line-scan camera and associated software to capture images of the cut surfaces. These images are stacked to construct a 3-D point cloud data of the part. The mill-head rotation speed, milling feed rate and part orientation are some of the operating conditions studied. Accuracy is measured by comparing measured dimensions of the part with dimensions obtained from the process while spread of point cloud data from the best-fit
plane on a surface provides a measure of repeatability. Tests were done on parts made up of two different materials: Aluminum and Delrin®, under two different sets of operating conditions. The results show improvement in accuracy under the new set of operating conditions for aluminum parts while repeatability improves for Delrin parts.
Orientation and stacking of parts has been mostly based on their external features. There are a number of parts which need to be oriented and stacked based on internal features, either because internal features are of primary importance or because of lack of appropriate external features. Issues concerning the orientation and stacking of parts based on their internal features are investigated and two-dimensional axi-symmetrical parts have been classified into groups based on both internal and external features. Fundamental methodologies have been developed for orienting and stacking of parts based on internal features and experimental verification has been performed for many cases. Results indicate that parts can be oriented efficiently and at high speeds. In addition, it can be concluded from these experiments that in many cases, the widely accepted rule that orientational position of parts should be preserved does not necessarily hold.
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