Engineering Research Center for Reconfigurable Manufacturing Systems TA-3 Projects In-Process Metrology The University of Michigan, Ann Arbor
Motivation of TA-3 Build a world-class center of expertise for the research and development of rapid non-contact inspection methods. Conduct R&D motivated by industry inspection needs. Create educational tools in inspection and metrology. Bridge between end-users and equipment/solutions suppliers. (Evaluate specs and performance) NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg. 2
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 Systems University of Michigan, College of Engineering TA-3 Presentation pg. 3
TA-3 Infrastructure: Computer Vision • Algorithms for precise measurement of complex volumes using 3 D 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 Systems University of Michigan, College of Engineering TA-3 Presentation pg. 4
TA-3 Infrastructure: Free Form Surface Inspection Methodology: • Methodology for fixtureless inspection of free form parts Algorithms: • Algorithms to support the above methodology: – 3 D reconstruction algorithms – Automatic tracking algorithms NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg. 5
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 Systems University of Michigan, College of Engineering TA-3 Presentation pg. 6
Reconfigurable Inspection Machine-RIM Same machine New Configuration Engine cylinder head Vision system Laser probes Slide system NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg. 7
RIM –Technology Transfer GEMA – Dundee, MI GM “RIM”- Flint Plant floor testing (2/3 - 2006) NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg. 8
Inspection of Complex Surfaces Objective: • To develop a rapid and accurate reconfigurable optical system for inspecting a part family with sculpture surfaces Probe Controller Stage 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) NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg. 9
Inspection of Complex Surfaces Blade Inspection Machine (BIM) Computer Inspected Part Linear Motion Stages Rotary Stage Non-Contact Laser Probe NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg. 10
TA 3 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 Systems University of Michigan, College of Engineering TA-3 Presentation pg. 11
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 Systems University of Michigan, College of Engineering TA-3 Presentation pg. 12
Full Scale Prototype Four laser probes V-8 Engine Inspection Setup NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg. 13
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 Systems University of Michigan, College of Engineering TA-3 Presentation pg. 14
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 completed 12/07) – Proof of concept • Stage 3 (To be discussed) – Build a prototype NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg. 15
Sight Pipe System Detected Pores CCD Sight Pipe Part Bore Image Top view of the system NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg. 16
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 Systems University of Michigan, College of Engineering TA-3 Presentation pg. 17
Project #3 - In-line Valve Seat Inspection 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) NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg. 18
Experimental Setup For Valve Seats Measurement 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) Current Setup • 2 -axis Aerotech motion stage system • Optimet Conoprobe: single point laser range sensor Setup Improvements • Addition of 3 rd axis system for multiple cross sections • Portable demonstrator (ME 450: senior design class) NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg. 19
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 Blade Inspection Machine (BIM) Grinding Robot NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg. 20
Integration of Measurement and Machining Location Calculator Measuring Machine location Robot Location (Relative to the part) Command + CAD Model - Correction Action Data Processing Part Robot Finished Parts Sensor Measuring Motion Machine • • • 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 Systems University of Michigan, College of Engineering TA-3 Presentation pg. 21
Project #5 - Inspection of Auto-body Panels (New Title: Measurement of Small Curvatures) 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 2050 2000 1950 1900 Z ACCOMPLISHMENTS • Surface defects quantitative characterization • Appropriate technology is currently identified for surface defect analysis and a prototype was designed and is built. 1850 1800 NSF Engineering Research Center for Reconfigurable Manufacturing Systems 1750 University of Michigan, College of Engineering 1700 675 TA-3 Presentation pg. 22 680 X 685 690 695
Set Up and Master Plate for Calibration Research tools Experimental Set Up Sample Master Plate NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg. 23
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 Systems University of Michigan, College of Engineering TA-3 Presentation pg. 24
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. Bore Surface Slip Ring Detector Lens Mirror NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering Laser TA-3 Presentation pg. 25
Rapid Imaging System Set Up Borescope Rotary table Monitor Fiber illumination source NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg. 26
The End Questions are Welcomed! NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg. 27
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 NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg. 28
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