Surface capture using near-real-time photogrammetry for a computer numerically controlled milling system

Wildschek, Reto

Surface capture using near-real-time photogrammetry for a computer numerically controlled milling system

Master Thesis

1989

Publisher

University of Cape Town

Department

Department of Mechanical Engineering

Faculty

Faculty of Engineering and the Built Environment

Abstract

During the past three years, a research project has been carried out in the Department of Mechanical Engineering at UCT, directed at developing a system to accurately reproduce three-dimensional (3D), sculptured surfaces on a three axis computer numerically controlled (CNC) milling machine. Sculptured surfaces are surfaces that cannot easily be represented mathematically. The project was divided into two parts: the development of an automatic noncontact 3D measuring system, and the development of a milling system capable of machining 30 sculptured surfaces (Back, 1988). The immediate need for such a system exists for the manufacture of medical prostheses. The writer undertook to investigate the measurement system, .with the objective to develop a non-contact measuring system that can be used to 'map' a sculptured surface so that it can be represented by a set of XYZ coordinates in the form required by the milling system developed by Back (1988). This thesis describes the development of a PC-based near-realtime photogrammetry system (PHOENICS) for surf ace capture. The topic is introduced by describing photogrammetric principles as used for non-contact measurements of objects. A number of different algorithms for image target detection, centering and matching is investigated. The approach to image matching adopted was the projection of a regular grid onto the surface with subsequent matching of conjugate grid intersections. A general algorithm which automatically detects crosses on a line and finds their accurate centres was developed. This algorithm was then extended from finding the crosses on a line, to finding all the intersection points of a grid. The algorithms were programmed in TRUE BASIC and specifically adapted for use with PHOENICS as an object point matching tool. The non-contact surface measuring technique which was developed was used in conjunction with the milling system developed by Back (1988) to replicate a test object. This test proved that the combined system is suitable for the manufacture of sculptured surf aces. The accuracy requirements for the manufacture of medical prostheses can be achieved with the combined measuring and milling system. At an object-to-camera distance of 0.5 m, points on a surface can be measured with an accuracy of approximately 0.3 mm at an interval of 5 mm. This corresponds to a relative accuracy of 1:1600. Back (1988) reported an average undercutting error of 0.46 mm for the milling system. This combines to an uncertainty of 0.55 mm. Finally, the limitations of PHOENICS at its prototype stage as a surface measuring tool are discussed, in particular the factors influencing the system's accuracy. PHOENICS is an ongoing project and the thesis is concluded by some recommendations for further research work.