Structured light system calibration method with optimal fringe angle

Li, Beiwen; Zhang, Song

doi:10.1364/ao.53.007942

Cited by 46 publications

(9 citation statements)

References 31 publications

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Section: Data Comparison Between Ct and Sls Systemmentioning

confidence: 99%

“…The SLS system has highresolution, high-speed, and low-cost characteristics to achieve the 3D scanning of three-dimensional objects. The SLS is an optical system that could capture and reconstruct three-dimensional objects in realtime with an accuracy of 0.2 mm [22]. The resolution of the SLS system could be adjusted according to various scenarios in the application.…”

Section: Introductionmentioning

confidence: 99%

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In situ monitoring of direct energy deposition via structured light system and its application in remanufacturing industry

Zhang

Shen

Suresh

et al. 2021

Int J Adv Manuf Technol

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The Direct Energy Deposition (DED) process utilizes laser energy to melt metal powders and deposit them on the substrate layer to manufacture complex metal parts. This study was applied as a remanufacturing and repair process to fix used parts, which reduced unnecessary waste in the manufacturing industry. However, there could be defects generated during the repair, such as porosity or bumpy morphological defects. Traditionally the operator would use a design of experiment (DOE) or simulation method to understand the printing parameters' influence on the printed part. There are several influential factors: laser power, scanning speed, powder feeding rate, and standoff distance. Each DED machine has a different setup in practice, which results in some uncertainties for the printing results. For example, the nozzle diameter and laser type could be varied in different DED machines. Thus, it was hypothesized that a repair could be more effective if the printing process could be monitored in real-time. In this study, a structured light system (SLS) was used to capture the printing process's layer-wise information. The SLS system is capable of performing 3D surface scanning with a high-resolution of 10 µm. To determine how much material needs to be deposited, given the initial scanning of the part and allowing the realtime observation of each layer's information. Once a defect was found in-situ, the DED machine (hybrid machine) would change the tool and remove the flawed layer. After the repair, the nondestructive approach computed tomography (CT) was applied to examine its interior features. In this research, a DED machine using 316L stainless steel was used to perform the repairing process to demonstrate its effectiveness. The lab-built SLS system was used to capture each layer's information, and CT data was provided for the quality evaluation. The novel manufacturing approach could improve the DED repair quality, reduce the repair time, and promote repair automation. In the future, it has a great potential to be used in the manufacturing industry to repair used parts and avoid the extra cost involved in buying a new part.

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Section: Data Comparison Between Ct and Sls Systemmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

In situ monitoring of direct energy deposition via structured light system and its application in remanufacturing industry

Zhang

Shen

Suresh

et al. 2021

Int J Adv Manuf Technol

Self Cite

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show abstract

“…Through connecting each row, the matrices can be rearranged into two M×N vectors, which are denoted as I1 and I2. To compare two matrices, the two vectors are generated in this way, and the PCC can be calculated as a metric of similarity of the two generated vectors [22]. The PCC is calculated as: Figure 12 shows the complete repair process, starting from SLS scanning of the defect sample to the nondestructive evaluation of the fixed part.…”

Section: Fig10mentioning

confidence: 99%

In-situ Monitoring of Direct Energy Deposition via Structured Light System and its Application in Remanufacturing Industry

Zhang

Shen

Suresh

et al. 2021

Preprint

Self Cite

View full text Add to dashboard Cite

The Direct Energy Deposition (DED) process utilizes laser energy to melt metal powders and deposit them on the substrate layer to manufacture complex metal parts. This study was applied as a remanufacturing and repair process to fix used parts, which reduced unnecessary waste in the manufacturing industry. However, there could be defects generated during the repair, such as porosity or bumpy morphological defects. Traditionally the operator would use a design of experiment (DOE) or simulation method to understand the printing parameters’ influence on the printed part. There are several influential factors: laser power, scanning speed, powder feeding rate, and standoff distance. Each DED machine has a different setup in practice, which results in some uncertainties for the printing results. For example, the nozzle diameter and laser type could be varied in different DED machines. Thus, it was hypothesized that a repair could be more effective if the printing process could be monitored in real-time. In this study, a structured light system (SLS) was used to capture the printing process’s layer-wise information. The SLS system is capable of performing 3D surface scanning with a high-resolution of 10 µm. To determine how much material needs to be deposited, given the initial scanning of the part and allowing the real-time observation of each layer’s information. Once a defect was found in-situ, the DED machine (hybrid machine) would change the tool and remove the flawed layer. After the repair, the nondestructive approach computed tomography (CT) was applied to examine its interior features. In this research, a DED machine using 316L stainless steel was used to perform the repairing process to demonstrate its effectiveness. The lab-built SLS system was used to capture each layer’s information, and CT data was provided for the quality evaluation. The novel manufacturing approach could improve the DED repair quality, reduce the repair time, and promote repair automation. In the future, it has a great potential to be used in the manufacturing industry to repair used parts and avoid the extra cost involved in buying a new part.

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“…In contrast to the above solutions, lower‐cost methods exist which need little or no additional hardware. For example, Li and Zhang () and Wang and Zhang () only used the maximum cumulative phase difference of all pixels to define the optimum direction of a fringe pattern. They stated that the best results were obtained when the pattern direction was perpendicular to the camera–projector base.…”

Section: Introductionmentioning

confidence: 99%

Development of a new dual‐pattern fringe projection scanner

Abzal

Saadatseresht

Varshosaz

2019

The Photogrammetric Record

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This paper proposes a new fringe projection scanner that uses a dual pattern to prevent phase retrieval errors or complications. The pattern comprises two horizontal and vertical patterns, however, just one of them is involved in computing the coordinates of an object point. To define the pattern, a photometric stereo component is used to extract the geometric properties of the object. The extracted data is employed to form a decision mask, each pixel of which defines the best pattern (horizontal, vertical or both) related to one of the object points. In this way, the scanner determines which pattern to use to obtain the most accurate results. Experiments suggest not only the avoidance of phase retrieval problems, but also an increase in the accuracy of the measurements (by 56% in this test).

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Structured light system calibration method with optimal fringe angle

Cited by 46 publications

References 31 publications

In situ monitoring of direct energy deposition via structured light system and its application in remanufacturing industry

In situ monitoring of direct energy deposition via structured light system and its application in remanufacturing industry

In-situ Monitoring of Direct Energy Deposition via Structured Light System and its Application in Remanufacturing Industry

Development of a new dual‐pattern fringe projection scanner

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