Laboratorial test monitoring applying photogrammetric post-processing procedures to surface displacements

Most of the traditional laboratorial methods for monitoring displacements and strains at the surface of the specimen present several constraints, namely: (i) limitations in hardware positioning; (ii) costly equipment and human resources; and (iii) time-consuming data processing. Consequently, the development of new methods capable of eliminating these drawbacks is of utmost interest.Herein, a new technique for laboratorial test monitoring is presented. By using photogrammetry and image post-processing, all the above mentioned drawbacks are overcome. Furthermore: (i) both displacement and strain fields can be monitored at a practically unlimited number of target points at any stage; (ii) it is a cost effective method, since data is acquired with non-professional digital cameras; and (iii) it is a fast procedure since data is automatically processed. Additionally, high precision is reached allowing an accurate characterisation of the fracture localisation process, including the establishment of a correlation between the latter and the localisation of cracks and their evolution in time.     

消隐点共线约束逐点畸变校正算法

对逐点图像畸变校正算法进行分析和研究。分析了基于四点共线交比不变性的逐点畸变校正算法的校正精度,指出该算法由于初始使用图像点含有误差导致计算其他图像点产生了精度改变,同时给出了计算结果误差较小时的图像点位置和相对距离的选取方法。基于上述分析,提出了基于消隐点共线约束的逐点畸变校正算法。该算法利用消隐点来提高直线拟合精度,利用共线特征来约束校正图像点精度。该算法不仅可以优化基于四点共线交比不变性算法校正的图像点,同时也可以优化初始使用的图像点,从而提高所有图像点畸变校正精度。基于MATLAB的仿真实验显示:对于400万像素的镜头,校正后图像点最大误差是初始图像点噪声的29.05倍。针对实物图像对基于四点共线交比不变性法校正的图像点,基于消隐点共线约束法校正的图像点和未校正采集图像点的交比值进行对比,结果表明本文提出算法优于四点共线交比不变性算法的结果。     

Complete 3D surface reconstruction from unstructured point cloud

In this study, a complete 3D surface reconstruction method is proposed based on the concept that the vertices of surface model can be completely matched to the unstructured point cloud. In order to generate the initial mesh model from the point cloud, the mesh subdivision of bounding box and shrink-wrapping algorithm are introduced. The control mesh model for well representing the topology of point cloud is derived from the initial mesh model by using the mesh simplification technique based on the original QEM algorithm, and the parametric surface model for approximately representing the geometry of point cloud is derived by applying the local subdivision surface fitting scheme on the control mesh model. And, to reconstruct the complete matching surface model, the insertion of isolated points on the parametric surface model and the mesh optimization are carried out. Especially, the fast 3D surface reconstruction is realized by introducing the voxel-based nearest-point search algorithm, and the simulation results reveal the availability of the proposed surface reconstruction method.     

Algorithm for the generation of mandrel protection curve and trajectory scheme for spinning machine

Spinning process is an effective and flexible method that has been widely employed to produce metal components having an axisymmetric rotational geometry, such as components for jet engines, turbines, radar reflectors, satellite nose cones, etc. Safe performance of mandrel and staff is critical to spinning process. In this paper, the safety aspects, i.e., temperature, leakage of hydraulic system, material deformation, roller path that related to spinning process operations, were in-depth analyzed. Moreover, a concept of mandrel protection curve was presented to avoid the potential dangers, and the relevance algorithm to generate mandrel protection curve was also developed. Then, based on the generation algorithm of mandrel protection curve, the redundant point problem was analyzed, and a new algorithm for rejecting redundant points was designed to enhance efficiency and safety. Finally, Multi-passes and constant linear velocity were adopted for higher product precision during complex spinning product manufacture. The common open-architecture CNC system and hydraulic servo system were used to realize the algorithm researches. The results show that the researched algorithms are effective to guarantee mandrel and staff’s safety and improve product precision.     

一种不同高度目标的视觉定位新算法

本文提出一种针对平面上方高度已知目标的视觉定位算法。该方法避开了复杂的摄像机参数标定过程,直接运用射影几何的基本性质实现了平面内目标的单目视觉定位。在此基础上,进一步运用成像深度的多义性实现对高度已知目标的平面坐标定位。最后进行了初步的精度分析,给出了算法应用的建议。该定位算法无需预先知道摄像机的参数,也无需对姿态进行特别的规定,可以根据实际场景来布局定位参考点,降低定位误差。实验表明其具有实现简单,精度高的特点。     

Accuracy of electrostatic lens computations with FOFEM

The increased speed of personal computers enables fast computation of rotationally symmetric electrostatic lenses with the first-order finite element method in meshes with a large number of mesh points. In order to produce an estimate of accuracy of the computed potential, we propose a simple procedure based on doubling the number of mesh points in each coordinate. In this way, we can produce for the lower-density mesh at each point the information about error of the potential and visualize the sources of the computation errors.     

基于预分割轮廓的CT图像亚体素表面检测方法

针对基于CT(computed tomography)图像检测分析中的点云提取精度与完整性问题,提出一种基于预分割轮廓的高精度、高完整性的亚体素表面检测方法。首先采用Otsu分割算法提取CT图像的体素级轮廓点集,并以此作为粗定位轮廓自适应地生成用于亚体素表面检测的完备感兴趣区域(region of interest,ROI);然后提出一种基于梯度非极大值抑制的表面体素判定方法,避免了梯度阈值选择难题;最后基于3D Facet模型定位亚体素级表面点位置。实验结果表明,该方法能有效改善传统亚体素检测方法的轮廓丢失、伪边严重等问题,轮廓定位误差小于0.2个体素,同时能够取得3倍以上的计算加速比。     

截面包络法加工复杂螺旋面的几何仿真算法

以截面包络法数控加工螺旋面为例,给出了一种基于啮合基本定理的点接触包络加工表面的几何仿真算法。通过分析数控加工中刀具与工件的相对进给运动,得到刀触点的啮合方程式,由此可求得加工表面上的刀触点—几何仿真点。几何仿真的计算结果,用于螺杆加工的编程误差分析取得了良好的效果,对于提高数控编程精度具有重要意义     

基于拓扑关系的交线快速生成方法

三角网格是逆向工程中常用的数据模型。由于模型拓扑关系的复杂性，目前在网格模型的交线生成过程中数据点排序与分离存在诸多缺陷。提出了一种利用网格模型拓扑关系的交线生成与分离算法，该算法充分利用了网格模型的拓扑关系，对各种拓扑类型的数据点完成排序、分离，实现任意复杂拓扑关系的交线生成，为逆向工程中曲线框架的构造提供了依据。     

ALGORITHM OF PRETREATMENT ON AUTOMOBILE BODY POINT CLOUD

As point cloud of one whole vehicle body has the traits of large geometric dimension,huge data and rigorous reverse precision,one pretreatment algorithm on automobile body point cloud is put forward.The basic idea of the registration algorithm based on the skeleton points is to construct the skeleton points of the whole vehicle model and the mark points of the separate point cloud,to search the mapped relationship between skeleton points and mark points using congruence triangle method and to match the whole vehicle point cloud using the improved iterative closed point(ICP)algorithm. The data reduction algorithm,based on average square root of distance,condenses data by three steps, computing datasets' average square root of distance in sampling cube grid,sorting order according to the value computed from the first step,choosing sampling percentage.The accuracy of the two algo- rithms above is proved by a registration and reduction example of whole vehicle point cloud of a certain light truck.     

Geometric tolerance evaluation: A discussion on minimum zone fitting algorithms

Estimating any geometric tolerance requires to sample a cloud of points on the feature to check, and then to fit an ideal substitute geometry respect to which to evaluate errors. Usually, points will be sampled by means of a CMM, and then a suitable software algorithm will be applied to them.

Algorithms that can be found in literature show some limitations: they may be very slow, the solution they propose is just an approximated one, or some degenerate situations cannot be managed.

We will propose a categorization of algorithms found in literature, highlighting merits and defects for them. Moreover, a new algorithm will be proposed. This algorithm will be tested against classical algorithms to show its advantages.     

基于自组织网格的涡轮叶片NURBS曲面重构

涡轮叶片的制造过程中,常采用有限元方法进行铸造变形控制。本文研究了针对有限元网格离散点的NURBS曲面重构方法。方法包括4个步骤:(1)基于网格相邻点分析的边界曲线提取和初始曲面构造;(2)具有自组织特征的基于曲率的离散点抽样和压缩,并进行曲面分片;(3)采用叠代法进行NURBS曲面逼近;(4)简化的NURBS曲面拼接算法。对工程数据的处理结果分析表明,该方法的数据处理精度可以达到工程要求,并且能够较好地保留数据的几何特征。     

小波变换对突变信号峰值奇异点的精确检测

研究了小波变换对突变信号峰值奇异点的精确检测机理和方法,采用了离散小波变换的直接算法,避免了塔式算法在本检测方法中的某些局限性。通过模拟算例和应用实例的验证,证明即使在有严重噪声干扰的情况下,该方法也很容易实现对突变信号峰值奇异点的准确检测和精确定位,具有相当高的定位精度（其误差不大于1个采样点）和分析精度（不存在累积误差）,同时具有较高的实时性。     

面向同步建模分析的三角网格局部光顺优化算法

对于大型复杂的几何体,不可能仅通过一次算法自动剖分即得到高质量单元,剖分过程容易出现边界单元狭长、曲面内部单元尖锐等问题,由此,提出局部光顺优化算法。算法结合全局光顺方法以及局部网格拓扑结构优化方法的优点,避免了全局性优化算法计算量过大的缺陷,较传统优化算法,具有较好稳定性,通过实验验证,优化后的单元整体大小均匀、形状规整,在提高数值计算效率方面有较好表现。     

保证拓扑正确的高精度等值面提取技术

基于体数据的等值面提取是反求工程的重要组成部分。针对传统移动立方体算法存在二义性和提取精度较低等缺陷,新算法首先在立方体内采用三线性方法构造出精确等值面,然后引入面肩点、体肩点和变形点作为等值面的关键点,并对其几何属性进行分析,提出了一种自动保持拓扑正确的高精度等值面三角化算法。不同于以往的移动立方体算法,新算法无需事先生成多边形的基本构形列表,也不必进行旋转和互补等操作。对于任一给定的立方体配置,一旦计算出相应的变形点,新算法自动地对等值面进行三角化。最后给出的实例显示了新算法的有效性。     

Tool-path generation from densely scattered measure points based on CQEM

An algorithm of tool-path generation from densely scattered measure points is presented in this paper based on constraint quadratic error metrics (CQEM). In the algorithm where the surface to be machined is represented directly with measured points, first, a mesh interpolating the points is dynamically constructed according to cutter sizes and slicing plane locations. Second, the initial C-C points are generated from the intersection points between the mesh and the slicing planes. Finally, the initial C-C points are optimized with CQEM. The algorithm shows capability to save memory usages and to achieve a higher precision in path location calculation.     

复杂参数曲面高精度刀具轨迹规划算法

在对等残余高度刀具轨迹规划算法加工参数曲面研究的基础上,提出带有误差补偿值的复杂参数曲面高精度刀具轨迹规划算法——高精度刀轨误差补偿算法。通过分析刀触点及与之相应的相邻路径上的粗、精刀位对应点间的关系,引入误差补偿值以提高精对应刀位点的求解精度,得到经过合理简化的误差补偿值表达式,并得出粗、精对应刀位点与理论刀位点的距离误差表达式。高精度刀轨误差补偿算法可以在满足插补运算实时性要求的前提下,使相邻轨迹上与刀触点相对应的刀位点的参数值计算精度得到极大提高,进而提高复杂参数曲面的加工刀具轨迹精度。以使用平底铣刀为例进行仿真加工,结果表明高精度刀轨误差补偿算法适合进行对复杂参数曲面的高精度加工。     

Constant cusp toolpath generation in configuration space based on offset curves

Constant cusp is a common strategy for generating tool paths in many NC machining applications. Cusps need to be regulated to ensure high precision without wasting machining efforts. Constant cusp strategies frequently operate on NURBS surfaces or triangular meshes and, thus, have to deal with the issues of patch-boundary oscillations or long, stretched triangles. To avoid these issues, one can operate in a pre computed configuration space (c-space). The c-space is given in form of a regular quadrilateral heightfield mesh, which may be adaptively subdivided, where the slope is large. This simple data structure is memory efficient and is widely used in CAD/CAM frameworks. In this paper we introduce an algorithm for creating a constant cusp tool path with the help of a given c-space. The constant cusp algorithm iteratively produces curves in the c-space by fitting a tube around the current curve and intersecting the tube with the c-space mesh to detect the subsequent curve. As tool paths are handed to the machine controller in form of point sequences, it suffices to operate on piecewise linear curves. The tube becomes a concatenation of cylinders, which we derive using geometric considerations. In each iteration of the constant cusp algorithm, intersection points of the cylinders with the not yet traversed part of the mesh are detected and checked for their validity. The validity check can efficiently remove global or local self-intersections of the new curve by just deleting the respective points. In a final step, the detected intersection points are connected to form constant cusp tool paths. Dealing with piecewise linear curves, we achieve low computation times for real-world data sets.     

Comparison of chaos optimization functions for performance improvement of fitting of non-linear geometries

Fitting algorithms play an important role in the whole measuring cycle in order to derive a measurement result. They involve associating substitute geometry to a point cloud obtained by an instrument. This situation is more difficult in the case of non-linear geometry fitting since iterative method should be used. This article addresses this problem. Three geometries are selected as relevant case studies: circle, sphere and cylinder. This selection is based on their frequent use in real applications; for example, cylinder is a relevant geometry of an assembly feature such as pin-hole relationship, and spherical geometry is often found as reference geometry in high precision artifacts and mechanisms.In this article, the use of Chaos optimization (CO) to improve the initial solution to feed the iterative Levenberg–Marquardt (LM) algorithm to fit non-linear geometries is considered. A previous paper has shown the performance of this combination in improving the fitting of both complete and incomplete geometries. This article focuses on the comparison of the efficiency of different one-dimensional maps of CO. This study shows that, in general, logistic-map function provides the best solution compared to other types of one-dimensional functions. Finally, case studies on hemispheres and industrial cylinders fitting are presented.