Search Results (27)

Optical fringe projection is an outstanding technology that significantly enhances three-dimensional (3D) metrology in numerous applications in science and engineering. Although the complexity of fringe projection systems may be overwhelming, current scientific advances bring improved models and methods that simplify the design and calibration of these systems, making 3D metrology less complicated. This paper provides an overview of the fundamentals of fringe projection profilometry, including imaging, stereo systems, phase demodulation, triangulation, and calibration. Some applications are described to highlight the usefulness and accuracy of modern optical fringe projection profilometers, impacting 3D metrology in different fields of science and engineering. Full article

This paper investigates the fracture surfaces and fracture performance of recycled aggregate concrete (RAC) using fringe projection technology. This non-contact, point-by-point, and full-field scanning technique allows precise measurement of RAC’s fracture surface characteristics. This research focuses on the effects of recycled aggregate replacement rate, water-to-binder (w/b) ratio, and maximum aggregate size on RAC’s fracture properties. A decrease in the w/b ratio significantly reduces surface roughness (Rs) and fractal dimension (D), due to increased cement mortar bond strength at lower w/b ratios, causing cracks to propagate through aggregates and resulting in smoother fracture surfaces. At higher w/b ratios (0.8 and 0.6), both surface roughness and fractal dimension decrease as the recycled aggregate replacement rate increases. At a w/b ratio of 0.4, these parameters are not significantly affected by the replacement rate, indicating stronger cement mortar. Larger aggregates result in slightly higher surface roughness compared to smaller aggregates, due to more pronounced interface changes. True fracture energy is consistently lower than nominal fracture energy, with the difference increasing with higher recycled aggregate replacement rates and larger aggregate sizes. It increases as the w/b ratio decreases. These findings provide a scientific basis for optimizing RAC mix design, enhancing its fracture performance and supporting its practical engineering applications. Full article

Three-dimensional shape measurement plays an important role in various fields. As a way of three-dimensional measurement, fringe projection profilometry (FPP) is widely used because of its non-contact, simple structure, and high stability. One of the key challenges affecting measurement accuracy is the gamma effect. With the development of FPP technology, multi-color channels are gradually applied to the measurement, and the response of different colors in the projector-camera system (pro-cam system) is not exactly the same. Therefore, more accurate gamma correction for different color channels is required. To solve this problem, a model of joint gamma correction for different color channels is proposed. In this model, the light is subdivided into three channels: red; green; and blue (RGB). In the pro-cam system, the different responses of different colors and the influence of background light intensity on gamma correction are comprehensively considered, and some error compensation is made for color crosstalk. Compared with the traditional gamma correction methods, the gamma correction method proposed in this paper is more accurate and has a larger effective working range after correction. This method is particularly beneficial in scenarios where multiple color channels are used for measurement, as it more accurately reflects the true measurement results for each channel. The effectiveness and accuracy of the method are validated through experiments. Full article

This work studies enhancing the capabilities of compact laser spectroscopes integrated into space-exploration rovers by adding 3D topography measurement techniques. Laser spectroscopy enables the in situ analysis of sample composition, aiding in the understanding of the geological history of extraterrestrial bodies. To complement spectroscopic data, the inclusion of 3D imaging is proposed to provide unprecedented contextual information. The morphological information aids material characterization and hence the constraining of rock and mineral histories. Assigning height information to lateral pixels creates topographies, which offer a more complete spatial dataset than contextual 2D imaging. To aid the integration of 3D measurement into future proposals for rover-based laser spectrometers, the relevant scientific, rover, and sample constraints are outlined. The candidate 3D technologies are discussed, and estimates of performance, weight, and power consumptions guide the down-selection process in three application examples. Technology choice is discussed from different perspectives. Inline microscopic fringe-projection profilometry, incoherent digital holography, and multiwavelength digital holography are found to be promising candidates for further development. Full article

Fringe projection is an important technology in three-dimensional measurement and target recognition. The measurement accuracy depends heavily on the calibration of the absolute phase and projector pixels. An easy-to-implement calibration method based on the Random Sample Consensus (RANSAC) algorithm is proposed to exterminate the phase error data and elevate the measurement accuracy in a fringe projection system. The reconstruction experiments of a double-sphere standard demonstrate that the uncertainties in radius and sphere-distance measurement are reduced to one thousandth of the measured value or even less, and the standard deviation in multiple measurements is restricted to within 50 μm. The measurement accuracy provided by the proposed RANSAC method can be improved by up to 44% compared with that provided by traditional least squared method (LSM). The proposed calibration method is easy and simple to implement, and it does not need additional hardware, but rather a calibration board. Full article

Additive manufacturing technologies enable lightweight, functionally integrated designs and development of biomimetic structures. They contribute to the reduction of material waste and decrease in overall process duration. A major challenge for the qualification for aerospace applications is the surface quality. Considering Ti-64 laser powder bed fusion (LPBF) parts, particle agglomerations and resulting re-entrant features are characteristic of the upper surface layer. Wet-chemical post-processing of the components ensures reproducible surface quality for improved fatigue behaviour and application of functional coatings. The 3D SurFin^® and chemical milling treatments result in smoother surface finishes with characteristic properties. In order to characterise these surfaces, three methods for surface texture measurement (contact and non-contact) were applied, namely confocal microscopy, fringe projection and stylus profilometry. The aim of this work was to show their suitability for measurement of laser powder bed fusion as-built and post-processed surfaces and compare results across the evaluated surface conditions. A user-oriented rating of the methods, summarising advantages and disadvantages of the used instruments specifically and the methods in general, is provided. Confocal microscopy reaches the highest resolution amongst the methods, but measurements take a long time. The raw data exhibit large measurement artefacts for as-built and chemically milled conditions, requiring proper data post-processing. The stylus method can only capture 2D profiles and the measurement was restricted by particle agglomerations and craters. However, the method (process and instrument) is entirely standardised and handheld devices are inexpensive, making it accessible for a large group of users. The fringe projection method was the quickest and easiest regarding measurement and data post-processing. Due to large areal coverage, reproduction of location when performing repeat measurements is possible. The spatial resolution is lower than for confocal microscopy but is still considered sufficiently high to characterise the investigated surface conditions. Full article

The evaluation of concrete surface roughness is crucial in the field of civil engineering. The purpose of this study is to propose a no-contact and efficient method for the measurement of the roughness of concrete fracture surfaces based on fringe-projection technology. A simple phase-correction method using one additional strip image is presented for the phase unwrapping to improve the measurement efficiency and accuracy. The experimental results indicate that the measuring error for plane height is less than 0.1mm, and the relative accuracy for measuring a cylindrical object is about 0.1%, meeting the requirements for concrete fracture-surface measurement. On this basis, three-dimensional reconstructions were carried out on various concrete fracture surfaces to evaluate the roughness. The results reveal that the surface roughness (R) and fractal dimension (D) decrease as the concrete strength increases or the water-to-cement ratio decreases, consistent with previous studies. In addition, compared with the surface roughness, the fractal dimension is more sensitive to the change in concrete surface shape. The proposed method is effective for detecting concrete fracture-surface features. Full article

In this paper, the multiscale analysis of the reproduction accuracy of jaw geometry obtained via the use of selected orthodontic materials is discussed. Impressions were made from two types of impression material. An accuracy assessment of the model geometry mapping was performed using noncontact systems, including a fringe projection optical 3D scanner, computed tomography, and a focus variation microscope. Measurements were made in three modes for comparison, as were the silicone and polyether impression materials. These modes were a jaw model and impression, an impression and plaster model, and plaster and jaw models. The research results are presented as colorful maps of deviations. Data analysis showed that deviations were the smallest in the case of silicone and that the best fit occurred between the silicone impression and the plaster model. The conducted research confirmed the validity of the assumptions considering the use of multiscale analysis for geometric analysis. The use of modern multiscale measurement methods allows for shorter and more efficient prosthetic operations. At present, these devices are expensive and complicated to use, but developments in technology should simplify the process, and prosthetic professionals should be aware of the possibilities described in the paper. Full article

The increasing demand for electric drives challenges conventional powertrain designs and requires new technologies to increase production efficiency. Hairpin stator manufacturing technology enables full automation, and quality control within the process is particularly important for increasing the process capacity, avoiding rejects and for safety-related aspects. Due to the complex, free-form geometries of hairpin stators and the required short inspection times, inline reconstruction and accurate quantification of relevant features is of particular importance. In this study, we propose a novel method to estimate the creepage distance, a feature that is crucial regarding the safety standards of hairpin stators and that could be determined neither automatically nor accurately until now. The data acquisition is based on fringe projection profilometry and a robot positioning system for a highly complete surface reconstruction. After alignment, the wire pairs are density-based clustered so that computations can be parallelized for each cluster, and an analysis of partial geometries is enabled. In several further steps, stripping edges are segmented automatically using a novel approach of spatially asymmetric windowed local surface normal variation, and the creepage distances are subsequently estimated using a geodesic path algorithm. Finally, the approach is examined and discussed for an entire stator, and a methodology is presented that enables the identification of implausible estimated creepage distances. Full article

Metal additive manufacturing technologies have great potential for future use in load-bearing aerospace applications, requiring a deeper understanding of mechanical performance and influencing factors. The objective of this study was to investigate the influence of contour scan variation on surface quality, tensile and fatigue strength for laser powder bed fusion samples made of AlSi7Mg0.6 material and to create high-quality as-built surfaces. The samples were produced with identical bulk and different contour scan parameters to accommodate the investigation of the impact of as-built surface texture on mechanical properties. The bulk quality was evaluated by density measurements according to Archimedes’ principle and tensile testing. The surfaces were investigated using the optical fringe projection method, and surface quality was assessed by the areal surface texture parameters $Sa$ (arithmetic mean height) and $Sk$ (core height, derived from material ratio curve). Fatigue life was tested at different load levels, and the endurance limit was estimated based on a logarithmic-linear relation between number of cycles and stress. All samples were found to have a relative density of more than 99%. Surface conditions distinctive in $Sa$ and $Sk$ were successfully created. The resulting mean values of the ultimate tensile strength ${\sigma }_{ult}$ are between 375 and 405 MPa for 7 different surface conditions. It was confirmed that the influence of contour scan variation on bulk quality is insignificant for the assessed samples. Regarding fatigue, one as-built condition was found to perform as well as surface post-processed parts and better than the as-cast material (compared to literature values). The fatigue strength at the endurance limit for ${10}^6$ cycles is between 45 and 84 MPa for the three considered surface conditions. Full article

The inspection of railway fasteners to assess their clamping force can be used to evaluate the looseness of the fasteners and improve railway safety. Although there are various methods for inspecting railway fasteners, there is still a need for non-contact, fast inspection without installing additional devices on fasteners. In this study, a system that uses digital fringe projection technology to measure the 3D topography of the fastener was developed. This system inspects the looseness through a series of algorithms, including point cloud denoising, coarse registration based on fast point feature histograms (FPFH) features, fine registration based on the iterative closest point (ICP) algorithm, specific region selection, kernel density estimation, and ridge regression. Unlike the previous inspection technology, which can only measure the geometric parameters of fasteners to characterize the tightness, this system can directly estimate the tightening torque and the bolt clamping force. Experiments on WJ-8 fasteners showed a root mean square error of 9.272 N·m and 1.94 kN for the tightening torque and clamping force, demonstrating that the system is sufficiently precise to replace manual measurement and can substantially improve inspection efficiency while evaluating railway fastener looseness. Full article

The rising global population, in conjunction with the increasing demand, decreasing labor supply, and increasing costs in the agricultural sector, has induced a need for automation in this industry. Many of these tasks are simplified using depth images and are accomplished using the help of 3D sensing technology such as stereo vision and time of flight methods. While there are various merits to these approaches, there is a need for high-speed, high-accuracy 3D profiling approaches in this rapidly advancing industry. Fringe Projection Profilometry is a variation of structured light technology, which has the advantage of having high speed in the kilohertz range, and sub-millimeter accuracy, which could be extremely beneficial for this sector to adopt. In this article, we seek to provide a tutorial on this technology, explain its various principles along with the basic methodology, and expound on its advantages. We demonstrate some example results using soybean roots and spinach leaves to show its utility, discuss potential reasons as to why this has not yet been widely adopted by this industry, review its potential limitations, and examine possible ways those limitations can be addressed so that they do not present a roadblock in its adoption. Full article

Fringe projection profilometry (FPP) and digital image correlation (DIC) are widely applied in three-dimensional (3D) measurements. The combination of DIC and FPP can effectively overcome their respective shortcomings. However, the speckle on the surface of an object seriously affects the quality and modulation of fringe images captured by cameras, which will lead to non-negligible errors in the measurement results. In this paper, we propose a fringe image extraction method based on deep learning technology, which transforms speckle-embedded fringe images into speckle-free fringe images. The principle of the proposed method, 3D coordinate calculation, and deformation measurements are introduced. Compared with the traditional 3D-DIC method, the experimental results show that this method is effective and precise. Full article

The use of non-contact scanning equipment in metrology and in dimensional and geometric inspection applications is increasing due to its ease of use, the speed and density of scans, and the current costs. In fact, these technologies are becoming increasingly dominant in the industrial environment, thus moving from reverse engineering applications to metrological applications. However, this planned transfer requires actions to ensure the achievable accuracy by providing traceability of measurements. In the present study, a comparison between the devices is carried out and a specific standard artefact is designed, equipped with multiple ceramic optically friendly entities, and allowing a wide variety of geometric dimensioning and tolerancing (GD&T). Four different 3D scanning sensors are used in the experimentation. Three of them are based on laser triangulation, and the fourth is a structured blue light sensor (fringe pattern projection). The standard artefact is calibrated with a high accuracy, using a coordinate measuring machine (CMM) and probing sensors. With this CMM, reference values of multiple predefined GD&T are obtained. The evaluation methodology maximises the accuracy of each device in measuring the dimensions of the artefact due to the good dimensional (milling and turning), surface (control of machining variables), and the dimensional and spatial distribution characteristics. The procedure also includes the same treatment of the captured point clouds (trimming, filtering, and best-fit algorithm, etc.) in each of the four 3D scanning sensors considered. From this process, very reliable measurements of the maximum achievable accuracy of each device (deviations from the CMM measurements) are finally obtained, and a multi-characteristic comparison between the four sensors is performed, also with high reliability. Full article

The camera and projector are indispensable hardware parts of a color fringe projection 3D measurement system. Chromatic aberration between different color channels of the projector and camera has an impact on the measurement accuracy of the color fringe projection 3D profile measurement. There are many studies on camera calibration, but the chromatic aberration of the projector remains a question deserving of further investigation. In view of the complex system architecture and theoretical derivation of the traditional projector radial chromatic aberration method, a phase target based on projector radial chromatic aberration measurement and the correction method are proposed in this paper. This method uses a liquid crystal display with a holographic projection film as the phase target. The liquid crystal display sequentially displays red, green, and blue horizontal and vertical sinusoidal fringe images. The projector projects red, green, and blue horizontal and vertical sinusoidal fringe images to the phase target in turn, and calculates the absolute phases of the display fringes and reflection fringes, respectively. Taking the green channel as the reference channel, a phase coordinate system is established based on the phases of the vertical and horizontal directions displayed on the display screen, using the phase of the reflection fringes on the display screen as the ideal phase value of the phase point. Then, the phase coordinate system of the red and blue channels is transferred to the green phase coordinate system to calculate the chromatic aberration of the red-green channels and the blue-green channels, and pre-compensation is conducted. Experimental results prove that this method can measure and calibrate the radial chromatic aberration of the projector without being affected by the image quality of the camera. The correction effect of this method is that the maximum chromatic aberration of the red-green channel decreases from 1.9591/pixel to 0.5759/pixel, and the average chromatic aberration decreases from 0.2555/pixel to 0.1865/pixel. In addition, blue-green channel maximum chromatic aberration decreased from 1.8906/pixel to 0.5938/pixel, and the average chromatic aberration decreased from 0.2347/pixel to 0.1907/pixel. This method can improve the projection quality for fringe projection 3D profile measurement technology. Full article