iPoint3D曲面检测软件开发与工程应用综述  

The Development and Application Review of iPoint3D Software for Surface Inspection

作　　者：李文龙[1] 李中伟[2] 毛金城[1] LI Wenlong;LI Zhongwei;MAO Jincheng(State Key Laboratory of Digital Manufacturing Equipment and Technology,Huazhong University of Science and Technology,Wuhan 430074;State Key Laboratory of Material Processing and Die&Mould Technology,Huazhong University of Science and Technology,Wuhan 430074)

机构地区：[1]华中科技大学数字制造装备与技术国家重点实验室,武汉430074 [2]华中科技大学材料成形与模具技术国家重点实验室,武汉430074

出　　处：《机械工程学报》2020年第7期127-150,共24页Journal of Mechanical Engineering

基　　金：国家自然科学基金(51535004,51635007,91648111,51675165);湖北省杰出青年基金(2017CFA045)资助项目。

摘　　要：三维光学测量为大型复杂零件精密制造提供了新手段,但实际操作时面临两大难题:其一,非接触式光学测量存在数据规模大、测点噪音与层叠、测点密度不均、初始位姿任意、曲面误差计算难等诸多问题;其二,缺乏统一的数据存储格式、专用检测工艺库和批处理操作,需多款商业软件人机反复交互,效率低下、一致性差。针对这些难题,系统介绍了相位移面阵测量原理、点云微分信息估计、点云精简/光顺、点云-曲面匹配、点云-曲面误差计算等大规模测点处理算法,以此为基础综述了iPoint3D软件开发层次结构、主要功能模块、人机操作界面、IPD数据存储格式,并给出了iPoint3D软件批处理操作的实现方法和检测报告生成流程。最后介绍了完全自主开发的iPoint3D软件在汽车曲轴检测、航空叶片检测、锻造大叶片变形检测、机器人磨削叶片余量分配、机器人铣削蒙皮轨迹计算、核主泵法兰面机器人检测、柔性曲面共形打印视觉定位等工业场景的计算过程和应用效果,并讨论了复杂曲面零件三维光学测量的发展趋势。The 3 D optical measuring provides a new method for the precise manufacturing, but it encounters two challenges: 1) In non-contact optical measuring, there are the problems of large-scale data, measuring noise/overlapping, uneven point density, arbitrary initial pose and intractable point-surface error calculation;2) It requires multi-commercial software to carry out heavy human-computer interaction, due to the absence of uniform data format, special inspection database and batch processing operation. This will lead to low efficiency and consistency in practice. The large-scale data processing algorithms is systematically introduced, such as phase-shifting measuring principle is systematically introduced, differential information estimation, point simplification/smoothing, point-surface matching, point-surface error calculation, and then presents the base development hierarchy, main function module, human-machine operation interface, IPD data format and batch processing operation of i Point3D software. Finally, this paper presents the calculation process and application effect of self-developed i Point3D software in car-crankshaft profile inspection, aero-blade profile inspection, large-blade deformation inspection, blade allowance distribution of robotic grinding, machining path generation of robotic milling, pump-seal-groove robotic inspection and visual localization of flexible-surface conformal printing, and discusses the future development trend of complex surface parts with 3D optical measuring.

关 键 词：iPoint3D软件 PowerScan扫描仪 大规模测点处理 复杂曲面检测 点云-曲面匹配 批处理操作 

分 类 号：TP29[自动化与计算机技术—检测技术与自动化装置]