3D VISION - polimi.it

3D VISION

3D acquisition through active and passive systems and measurement systems integration

Description3D Vision Lab is part of the Measurement and Experimental Techniques area, in the Mechanical Engineering Department. The main research’s fields of the group are based on non-contact measurements. The 3D Vision lab develops innovative and experimental solutions built on two and three dimension vision systems, like stereoscopy, structured light and time of flight cameras. Applicarions range from industrial to medical, but also in sports, nautical and forensic fields. The laboratory has the capacity to create their own prototypes, that generally pass trought a metrological qualification before leading possibly to an industrial product.

ReferencesSIGMA project, E-GATE project, SIRICA project, ABB, National Instrument, Milan A.C., Villa Beretta, Steriline, LABANOF, North Sails, Politecnico di Milano Wind tunnel.

D I PA RT I M E N T O D I M E C C A N I C A

Department AddressDipartimento di Meccanica Building B23via La Masa, 1 20156 Milano - Italytelephone: +39 02 2399 8500fax: +39 02 2399 8202e-mail: [email protected]

Websitewww.mecc.polimi.it

Laboratory AddressBuilding B23via La Masa, 120156 Milano - Italy

Instrumentation & Facilities• Different industrial cameras (Near InfraRed cameras,

High Dynamic Range cameras, High Speed cameras, Industrial smart cameras).

• Lighting solutions to enhance 2D vision-based measurements.

• Stereoscopic systems to perform 3D measurements.• Structured Light and Time of Flight sensors for dense

3D point clouds reconstructions.• Anthropomorphic robot.

Activities

Industrial field• Development of 3D object recognitions based on

different 3D vision systems for bin picking purposes.• Development of a stereoscopic vision system that

permit the duplication of a sensorized tool movement with an industrial anthropomorphic robot.

• Development of low cost thermo-cameras based on NIR and HDR cameras.

• 2D and 3D measurements of mechanical parts for quality analysis.

Nautical field• Dense point cloud reconstructions and geometrical

analysis of sail shapes both in wind tunnel and in full scale conditions.

• Particle images velocimetry (PIV) with high-speed cameras in wind tunnel.

• Non-contact measurements of objects displacement exposed to wind forces.

Sports and rehabilitation• Motion analysis and gesture recognition for post

traumatic rehabilitation.• Motion measurement of a sportsman during particular

exercises.• Measurement of cyclist motion during wind tunnel

analysis.

Forensic applications• 3D face reconstruction based on sheet of light

triangulation.• 3D measurement of crime scene.

Rev.0

Additive Manufacturing

Additive manufacturing of metallic parts by selective laser melting and direct metal deposition

DescriptionThe mission of the laboratory is the research on materials and processes as well as on the design and characterization of products related to additive manufacturing with metals. The lab is equipped with a selective laser melting system based on powder bed consolidation and on several fiber laser sources equipped with coaxial cladding heads, fitted on anthropomorphic robot arms. A 3D X-Ray CT Scan microtomograph for non-destructive inspection of parts is also available to support the lab activities.

ReferencesBLM group, Fonderia Maspero SrL, Marposs SpA, Sapio SPA, Titalia SpA, Ansaldo Group, Agusta Westland.




Laboratory AddressBuilding B16/B23via La Masa, 1 and 3420156 Milano - Italy

Activities

Design and optimization of structural and functional parts produced by Additive Manufacturing techniques• Design for Additive Manufacturing: structural/functional

design and optimization of parts and systems.• Light-Weight Design: system inertia reduction with

Topological Optimization and Lattice Structures.

Process optimization and monitoring• Process development and optimization for AM of

metals.• Process modeling and simulations by analytical and

numerical methods and experimental validation.• Inline monitoring strategies based on optical and

mechanical methods for defect recognition.• Statistical process control methods and analytical

solutions for data analysis and possible applications of closed-loop process control.

Development and characterization of alloys for AM• Design and testing of new alloys (steels, Al-base,

Ti-base).• Characterization & testing of SLM processed materials.• Optimization of thermal treatments of additive

manufactured alloys.• Investigation on surface coating and surface finishing of

AM parts.

Characterization of AM products and evaluation• Non-destructive testing of AM parts by X-ray

CT-microtomography.• Material characterization by microstructural and

mechanical (static and dynamic) testing.• Testing of structural performance of parts.

Rev.0

Instrumentation & Facilities• Renishaw AM250 selective laser melting system,

featuring a build volume of 250 mm × 250 mm × 300 mm.

• Direct Energy Deposition system with 1-3 kW IPG fiber lasers, two cylinder feeder, coaxial head and anthropomorphic ABB robots.

• Equipment for powder mixing, milling, sieving and handling.

• 3D X-Ray CT-Scan microtomography equipment that can be operated with X-ray energies from 10 to 160 keV, in a volume of diameter 15 cm and height 22 cm.

• Software Materialise Magics, to repair/modify 3D models, generate lattice structures and prepare the builds.

CABLE DYNAMICS

Experimental tests for the evaluation of the dynamic properties of cables, dampers, spacers

DescriptionThe knowledge of the cable damping properties allows to correctly estimate, through numerical models, its response to external inputs such as the wind disturbance. Moreover, because of the small damping associated to this kind of structures and the consequent instability issues arising when they are immersed in force fields (e.g. cross wind), the use of suitable damper devices are often mandatory.

Certifications• Test “Stockbridge Type Dampers Dynamic

Characterisation” (ISO9001:2008 certification).• Test “Stockbridge Type Dampers Effectivness Test”

(ISO9001:2008 certification).

ReferencesSalvi Spa, Dervaux, Terna, Sadeven, Cariboni, Mosdorfe, Sefag-Pfisterer, Enel, EDF.





Instrumentation & Facilities• Gearing Watson electro-dynamical shaker + amplifier

(V617/DSA4-8k).• Unholtz&Dickie electro-dynamical shaker + amplifier

(SA15-S452).• B&K 1050 controller.• Electro-mechanic actuator for the “50m length” cable

span tensioning.• HBM 250 kN load cell for the “50m length” cable span

tensile load.• Kistler 30 kN piezoelectrical load cells for Stockbridge

dissipative force.• B&K accelerometers for the cable and the Stockbridge

vibratory state.• Strain gage for the cable stress close to the clamp.• Laser transducers for the cable nodes vibrations.• Accelerometers and load cells conditioning and

amplifiers.

Activities

Cable self damping• Decay Method.• Power Method.• Inverse Standing Wave Ratio.

Stockbridge damping performances• Force vs displacement FRF.• Mechanical impedance.• Imposed constant speed or constant displacement.

Cable effectiveness test• Cable + damper damping test.

Spacers characterization• Stiffness and damping properties.• Hysteretic cycle.• Short circuit test.• Slip force test.

Rev.0

ELECTRIC DRIVES

Design and control of static power converters and electric drives

DescriptionThe laboratory of electric drives and power electronics can test electric motors, power converter and control system both for industrial application and automotive applications (hybrid and full electric vehicles).Thanks to two different test rigs electric drive of a power up to 100 kW and torque up to 1500 Nm can be tested. In the laboratory, battery cell life test and identification test can also be performed.

ReferencesABB, Siemens, Ansaldo, HSD, CIFA, OEMER, Nice, Bosch Rexroth, Ferrari, Piusi, Whirpool, Skema.





Activities

HSD AC motors High efficiency Electric Motor Testing• No load test and magnetizing curve.• Parameters identification test.• Load test, efficiency measurement and thermal

behavior.• Full speed test in field weakening condition.• Test on ac induction and ac permanent magnet

synchronous motor.

Electric drive test for household application• Parameters identification test.• Load test, efficiency measurement and thermal

behavior.• Full speed test in field weakening condition.• Test on ac permanent magnet synchronous motor with

vector sensorless control.

Battery life cicle test• Rated current charge/discharge test for cell capacity

identification.• Life test under rated condition.• Life test under variable current and temperature

condition.• Equivalent Electric circuit identification test.

Battery Power Electric drive for hybrid electric vehicle test• Traction curve identification.• Regenerative Braking test.• Drive cycle test.• Overall efficiency measurment.

Small PEM Fuel Cell (<1.5 kW) Test bench• Equivalent Electric circuit identification test.• Parameters identification test.• Load test, efficiency measurement and thermal

behavior.

Solar Simulator• MPP Validation.• Solar Inverter Tests-Rig.

Rev.0

Instrumentation & Facilities• Development system for Embedded hardware

and software (microchip, Freescale, TI) and Static Converters.

• 100kW Motor test bench (2500Nm/6500 rpm).• Regenerative Motor Test Bench (35Nm/7500

rpm) with PC based Data Acquisition and Control system and Power Analyzer Yokogawa PZ4000.

• Power Supply Units (1500W): 600V-2.5A; 300V-15A, 12,5V-120A.

• E4360A Modular Solar Array Simulator Mainframe, E4362A Solar Array Simulator DC Module, 130V, 5A, 600W.

• dSpace Real-Time board for electrical drives prototyping.

• Electrolyzer for Hydrogen production.• Active load for battery cells testing.• Scopes, Current probes, Insulated Voltage probes,

Industrial Electrical Drives, Laboratory Power Supplies.

HAPTICS AND VIRTUAL PROTOTYPING

State-of-the-art Virtual and Augmented Reality technology

DescriptionThe Virtual Prototyping Lab is a laboratory for research and teaching equipped with state-of-the-art Virtual and Augmented Reality technology. The Lab is used for developing multisensory interactive virtual prototypes for design review and for simulation and testing purposes, real-time rendering on high performing workstations.





Instrumentation & Facilities• Cyviz - VIZ3D: rear-projected stereovision 3D passive

visualization system.• NVIDIA 3D Vision: stereoscopic kit allowing stereo

vision for any Direct3D and OpenGL application.• A.R.T. Tracking System: infrared optical tracking system.• VICON 460 system: optical tracking system for motion

capture, using 1280 X 1024 pixels optical cameras.• Head Mounted Display: 5DT 3D HMD, Nvisor ST,

NOMAD for optical see-through and video see-through display.

• Eye-tracking system: Nvisor ST HMD integrated with Viewpoint eye tracker system.

• Virtuose 6D35-45: 6 DOF haptic system for haptic interaction and manipulation of virtual objects.

• MOOG Haptic Master: 3DOF haptic system with a wide workplace and exerting 250N force feedback.

Activities

Interactive Virtual Prototyping• Product design review.• Multisensory virtual prototypes.• Interactive prototypes of industrial products.• Haptic interaction with virtual products.

Monitoring and Maintenance• Augmented Reality for diagnostic and prognostic.• Augmented Reality for remote product maintenance.• Haptic-based simulation and training of maintenance

operations (assembly/disassembly).

Rev.0

LA.S.T. LABORATORY FOR SAFETY OF TRANSPORT SYSTEMS

Ground vehicle design and testing, with particular attention to Active Safety

DescriptionMain activities of the Laboratory involve testing and modelling of vehicle systems with emphasis on suspension systems, tyres, braking systems, drivelines of conventional or electric vehicles. NVH, durability, thermal and mechanical performances are derived either experimentally or by numerical simulations. The measurement of the parameters affecting the vehicle dynamics, e.g. vehicle inertia properties, is performed by original and dedicated test rigs. Patented load cells and measuring hubs are available. The measurement and simulation of vehicle ride comfort is one of the keycompetences of the Laboratory.

CertificationsMeasurement of the mass properties of a rigid body by means of InTensino. ISO 9001:2008.

ReferencesBrembo, Daimler, Evobus, Fiat Powertrain, Ferrari Automobili, Fiat Chrysler Automobiles, Ford USA, Honda RD America, IDIADA, IVECO, Lamborghini Automobili, Maserati Automobili, SameDeutz-Fahr, Toyota Motor Europe.




Laboratory AddressBuilding B6via Durando, 620156 Milano - Italy

Activities

InTenso• Measurement of the Centre of Gravity location of full vehicles.• Measurement of the Inertia Tensor of full vehicles.The rig is composed by a ‘carrying system’ (usually a steel cage), which bears the body under test; three rods connect the carrying system to an external fixed frame. The rods are connected to the frame and to the carrying system by low-friction Hooke joints. A load cell is fitted on each rod. The orientation of the rods is measured by means of 6 absolute 17 bit encoders positioned on the upper Hooke joint. The Centre of Gravity location and the Inertia Tensor are computed knowing the angular acceleration of the carrying system and the forces acting on it.

InTensino• Measurement of the Centre of Gravity location of rigid bodies

up to 500 kg.• Measurement of the Inertia Tensor of rigid bodies up to 500 kg.The rig is composed by a ‘carrying system’ which bears the body under test; three rods connect the carrying system to an external fixed frame. The rods are connected to the frame and to the carrying system by low-friction Hooke joints. A load cell is fitted on each rod. The orientation of the rods is measured by means of 6 absolute 13 bit encoders positioned on the upper Hooke joint. The Centre of Gravity location and the Inertia Tensor are computed knowing the angular acceleration of the carrying system and the forces acting on it.

RuotaVia• Design and testing of tyres.• Design and testing of suspension systems.• Design and testing of braking systems.• NVH measurements.The RuotaVia rig is composed by a horizontal axis steel drum, providing a running contact surface for wheels. An asyncronous motor+neuro controlled inverter drives the drum up to 400 km/h.

Measuring Hubs• Measurement of the forces acting at the tyre contact patch,

custom design.The measuring hubs are based on a statically determined three cantilever/spoke structure replacing the wheel centre. Strain gauges are fitted on each spoke. The statically determined connection consist of three spherical joints with an additional degree of freedom along the axis of the spokes. A telemetry system has been designed and employed to transmit the force signals to a data storage unit.

6 axis load cell• Measurement of the forces.These sensors can measure the 3 forces and 3 moments acting at a point of a structure They are based on a statically determined three cantilever/spoke structure. Strain gauges are fitted on each spoke. The data from the strain gauges are processed on board and forces are provided in engineering units. Different gains, low-pass and high- pass filters are available directly on the cell.

MaRiCo Dummy• Objective measurement of vehicles ride comfort.• Comparison between different seats.The dummy can reproduce the vertical and longitudinal accelerations at the body-seat interfaces that would be respectively sensed by a human subject. It can be adjusted to simulate different human subjects, from 5 percentile to 95 percentile, and to accommodate to different seats configuration. The dummy has a vibrating mass moving along the spine axis. An adjustable magnetic damper controls the motion of such a mass.

Outdoor tests• Performance comparison between winter tires, snow chains

and other anti-slip devices.

Instrumentation & Facilities• InTenso test rig: measurement of the mass

properties of full vehicles.• InTensino test rig: measurement of the mass

properties of rigid bodies up to 400 kg.• RuotaVia test rig: twin drum providing a rolling

contact surface for tyre or suspension or driveline test and development.

• Measuring hubs: measurement of the forces acting at the tyre contact patch.

• (Special patented) 6 axis load cells: measurement of forces for NVH or durability purposes.

• MaRiCo dummy: objective measurement of the ride comfort of vehicles.

Rev.0

MANUFACTURING

Support the Manufacturing and Production Systems research line

DescriptionThe Manufacturing Lab mission is to integrate all the activities required to transform ideas into products. In order to fulfill this mission it is organized in the following areas: MI_crolab - Micro Machining Laboratory; SITEC Laboratory for Laser Application; WJ Lab - Waterjet Laboratory; Geometrical Metrology Lab; Manufacturing Systems Lab.

CertificationsISO 9001:2008 certification for the following activities:• Coordinate Measuring Machine (CMM) performance

verification according to ISO 10360.• Masters calibration by means of CMM according to

ISO 15530.• Calibration of Vernier calipers according to ISO 13385.• Calibration of micrometers for external measurement

according to UNI 9191.

ReferencesAdige S.p.A., Biesse S.p.A., Comau S.p.A., Marposs S.p.A., Media Lario Technologies S.r.l., Speroni S.p.A, Tenova S.p.A.





Activities

MI_crolab - Micro Machining Laboratory• Test and analysis of micro tools.• Cutting strategy analysis.• High precision micromachining.• Feasibility studies for high precision workpieces.

SITEC Laboratory for Laser Application• Laser welding.• Laser cutting.• Laser cladding.• Laser based heat treatments.• Laser surface texturization.• High precision micro-laser welding and cutting.• Laser process monitoring.

WJ Lab - Waterjet Laboratory• Special cutting heads design and test.• Waterjet process customization.• Cutting parameters optimization.• WJ process monitoring.• High precision pure and abrasive waterjet cutting.

Geometrical Metrology Lab• Optical 3D micro-measurements.• Dimensional and geometrical calibrations.• CMM inspection planning.• CMM performance verification.• Statistical data analysis.

Manufacturing Systems Lab• Analysis, performance evaluation and design of

manufacturing systems.• Production planning and scheduling under uncertainty.• Process planning and machine tool simulation.

Conventional Processes• Dynamic behavior analysis of tool and machine tool.• Process monitoring and optimization.• Cutting tools test and analysis.• Cutting strategy analysis.• Sheet metal forming process analysis and optimization.• Tube forming process analysis and optimization.

Instrumentation & Facilities• Ultra precision 5 axis CNC machining center Kern

EVO.• Manufacturing Laser systems 3 kW IPG Ytterbium

Fiber Laser.• Micro-Laser system with 1 mJ IPG Pulsed

Ytterbium Fiber Lasers.• Water Jet cutting system Tecnocut IDRO 1740

with Flow intensifier pump up to 380 MPa.• Infrared camera FLIR SC3000

(Spectral range 8 ÷ 9 μm, T: -20 ÷ 1500 °C).• Piezoelectric Dynamometers for cutting forces

measurement in turning and milling.• Alicona Infinite Focus micro coordinate

measurement system (resolution up to 10 nm).• Zeiss Prismo 5 VAST MPS HTG coordinate

measuring machine (E0,MPE = 2,0 + L/300 μm).• Microrep DMS 680 universal length measuring

system (E0,MPE = 0,5 μm).• Virtual Factory Framework Virtual Reality

Environment.• CAD/CAM SW, VERICUT, ARENA, SIMIO,

SIEMENS NX, ABAQUS,CATIA, IBM ILOG.

Rev.0

MATERIAL TESTING

Static and dynamic tests on specimens and small components

DescriptionThe laboratory is equipped with several resonant and universal testing machines for static and dynamic tests on metallic and composite materials. Each testing machine features extensometers with different gage lengths and temperature ranges. Furnaces and environmental chambers are available to perform tests at low and high temperature.

ReferencesAgusta Westland, Ansaldo Energia S.p.A., Avio Aero, Brembo S.p.A., ENI S.p.A., Radici, Scuderia Toro Rosso, Tenaris.





Activities

Static and dynamic tests on metallic materials and small components.• Tensile and compression static tests according to

international standards or customized in order to fulfill the customer needs.

• High cycles fatigue (HCF) and low cycles fatigue tests (LCF). Temperature range: -40/+1000°C.

• Dynamic tests with customized load spectra.• Static and dynamic tests for the characterization of the

components (e.g. stiffness).• Further kinds of test (e.g. flexural, shear) or test

conditions (temperature, standard) can be arranged upon request.

Fracture mechanics• KIc determination according to ASTM E399.• JIc determination according to ASTM E1820.• Measurement of Fatigue Crack Growth Rates according

to ASTM E647 and under customized load spectra.• Temperature range for Fracture mechanics tests:

-100/+1000°C.

Multi axial tests• Biaxial and triaxial static tests, applied by means

of three independent controlled actions: axial (max 250 kN), torsional (max 2200 Nm), pressure (max 100 MPa).

• Biaxial and triaxial low cycle fatigue tests (LCF). Tests can be performed under strain control.

• Biaxial high temperature low cycle fatigue tests (LCF) up to 1000°C.

• Axial-torsional high cycles fatigue (HCF) tests. Axial and torsional axial can be applied either in phase or out of phase.

• Dynamic tests with customized load spectra.

Tests on plastic and composite materials• Static tests on composite materials according to ASTM

standards (e.g. D6671, D5379 D6484, D695).• Static tests on plastic materials according to

ASTM 3039 and ISO 527 standards.• High cycles fatigue (HCF)and low cycles fatigue tests (LCF).• Other kinds of test (e.g. flexural, short beam test) or

test conditions (high/low temperature, standard) can be arranged upon request.

• Adhesive testing (DCB, Lap shear).

Creep, Creep Crack Growth and Creep-Fatigue Crack Growth tests• Creep strain analysis through extensometry of round

section specimens at high temperature.• Crack initiation and propagation analysis of pre-cracked

C(T) specimens through potential drop system at high temperature.

• Crack initiation and propagation analysis of pre-cracked C(T) specimens in a creep-fatigue interaction context.

Instrumentation & Facilities• MTS809 servohydraulic triaxial machine. Ranges:

±250 kN axial; ±2000Nm torsional; 100MPa pressure.• MTS and Instron servohydraulic monoaxial machines.

Max. force range: from ± 20 kN to ±250 kN.• MTS Alliance electromechanical machines.

Range: ±100 kN and ±150 kN.• Rumul Cracktronic resonant testing machines.

Max flexural and torsional moment:160 Nm.• Rumul Testronic resonant testing machine. Range: ± 100 kN.• Italsigma 2TM831 rotary bending machines.

Max bending moment: 35 Nm.• Creep-Fatigue and Crack Growth testing machines. Max

load 12 kN. Max temperature 1200°C.• Induction heaters. Max temperature: 1200°C.• Furnace MTS 653.01. Max temperature: 1400°C.• Environmental chamber with built-in controller MTS.

Temperature: -128/+315°C.• Induction heaters. Max temperature: 1200°C.• Fixtures and extensometers for fracture mechanics.

Temperature range: -100/+1200°C.• Extensometers for tensile and LCF tests.

Gage length: 8/50 mm. Temperature: -40/+1200°C.• Creep testing machines, stress relaxation, cyclic creep

testing frames. Max load 30 kN, Max temperature 1100°C.

Rev.0

MEASURING DEVICES AND CALIBRATION

Experimental characterization of mechanical and civil structures with innovative techniques

DescriptionThe laboratory facilities (more than 1200 sensors, calibration and loading devices) allow performing static and dynamic tests on elements with scales ranging from millimeters to hundreds of meters. Vision-based measuring devices allow the 3D motion estimation and the reconstruction of shape and strain conditions. Fit for purpose measurement systems can be developed according to the customers’ requests.

Accredited StaffNDT qualification conforming to EN 473, ISO 9712 and SNT-TC-1° in testing by electrical resistance strain gauges (Level 1 and Level 2).

CertificationsAccredited laboratory for acceleration transducer calibration: Settore Accelerometria of Politecnico di Milano, Laboratorio Accreditato di Taratura LAT 104.

ReferencesABB, AgustaWestland, Comune di Milano, Veneranda Fabbrica del Duomo di Milano, Officine Galileo, ASI (Agenzia Spaziale Italiana), ESA (European Space Agency).





Instrumentation & Facilities• Electrodynamic shakers - max force 25 kN @ 3.5 kHz.• 3D Digital Image Correlation (DIC) systems for 3D

strain field reconstruction.• 3D vision-based scanners with customized working

volume.• Infrared imaging for contactless thermal field

measurements and non-destructive defect detection.• Scanning Laser-Doppler vibrometer for the modal

analysis of mechanical systems.• Thermo-vacuum chamber for characterization of

material and structure between -180 and 200°C.• Instrumentation for mechanical, thermal and acoustic

measurements.

Activities

Large structures dynamic testing and monitoring• Bridges dynamic testing with natural or artificial

excitation.• Modal analysis and operational modal analysis.• Large dynamic exciters for civil structure excitation.• Long-term continuous structures monitoring.

Artistic and historical landmarks monitoring and protection• Historical and artistic structures monitoring.• Statue vibration and seismic isolation.• Long-term continuous monitoring.

Vision-based measuring systems• 3D shape reconstruction with stereoscopy or

structured light projection.• Contactless measurement of strain field for mechanical

analysis, such as welded joints analysis or composite material testing.

• Failure analysis of civil structures and concrete beams.• Remote monitoring of bridges vibration by means of

vision devices.• Dynamic measurement of structures vibration,

including harsh environment measurements like helicopter blades tracking during operation.

Measurements for space• Development of FTIR spectrometers for remote

planetary observation.• Development of imaging devices for space missions.• Characterization of materials in cryogenic conditions.• Qualification of components for space missions.

Rev.0

NON-DESTRUCTIVE TESTS

Non-destructive testing and structural health monitoring of mechanical components

DescriptionExperimental and numerical activities regarding non-destructive testing and structural health monitoring of structural materials (metals, composites and polymers) and mechanical components are performed. Traditional and advanced techniques are applied, while innovative ones are developed considering production, maintenance and service stages. In-service monitoring and prognostics are studied and applied, as well.

Accredited Staff• III level ultrasonic testing according to ISO 9712: 1• III level magnetic particles testing according to

ISO 9712: 1• III level liquid penetrants testing according to

ISO 9712: 1• II level magnetic particles testing according to

ISO 9712: 2• II level liquid penetrants testing according to

ISO 9712: 2• II level visual testing according to ISO 9712: 3

CertificationsISO 17025:2005: liquid penetrants testing.

ReferencesALSTOM Ferroviaria S.p.A., ATM S.p.A., Brembo S.p.A., CIFA S.p.A., Italcertifer S.p.A., Lucchini RS S.p.A., Tenaris/Dalmine S.p.A.





Activities

Experimental and numerical characterization of NDT capabilities• Characterization of experimental “Probability of

Detection” curves for different NDT methods.• Characterization of numerical “Model Assisted

Probability of Detection” curves for different NDT methods.

• Interaction between NDT capabilities and the damage tolerant design approach.

Traditional and advanced ultrasonic testing of materials and components• Phased array monitoring of fatigue crack propagation in

adhesive bonded composite lap-joints.• TOFD inspection of welded and seamless metallic pipes.• Guided waves monitoring of pipes and rails.• Residual stress measurements in railway wheels by

EMAT.• Application of creeping waves to coarse grain metals.

Structural health monitoring by ultrasonic Lamb waves• Determination and characterization of dispersion curves

in metallic, composite and polymeric components.• Definition of an innovative way to induce a single anti-

symmetric propagation mode of Lamb waves.• Analysis of the reflection and transmission of Lamb

waves through artificial delaminations in composite laminates.

• Analysis of the reflection and transmission of Lamb waves through natural defects, obtained by low energy impacts, in composite laminates.

Structural health monitoring of railway axles by acoustic emission• In-service monitoring of railway axles by means of

acoustic emission.• Comparison of acoustic emission response with optical

and ultrasonic NDT approaches during crack propagation tests.

• Comparison of acoustic emission response with low frequency vibrations during crack propagation tests.

Eddy current testing of corrosion-fatigue phenomena• Experimental eddy current measurements of developing

corrosion-fatigue damage in small-scale specimens and full-scale components.

• Correlation between damage and eddy current response at different stages of corrosion-fatigue life.

• Numerical simulations of eddy current response at different stages of corrosion-fatigue life.

Instrumentation & Facilities• Harfang X32: phased array ultrasonic flaw detector

with 2.25, 5 and 10 MHz probes.• RDG500 and RDG2500 ultrasonic flaw detectors

with straight, twin, angled and creeping probes.• UWG1000 TOFD ultrasonic detector with probes

and encoders for C-Scan inspections.• Dedicated equipment for managing Lamb and

guided ultrasonic waves.• CIVAnde software dedicated to NDT simulations.• Nortec 1000S+ eddy current flaw detector with

probes working at a 500-2000 Hz frequency range.• Magnetoscope, different yokes and permanent

magnets for color contrast and fluorescent magnetic particles.

• Color contrast and fluorescent liquid penetrants• Lenses, mirrors and dedicated white and black

lights for visual testing.• AST X-Stress 3000 portable X-ray diffractometer.• Equipment for holographic interferometry and for

transmission and reflection photo-elasticity.

Rev.0

PROCESS METALLURGY AND MATERIAL ANALYSIS

Analytical equipment, processing and mechanical testing systems aimed at investigating materials

DescriptionThe laboratory is equipped with analytical instruments and testing devices for the following investigations:• Microstructure and failure analysis. Optical and

electron Microscopes, hardness and micro-hardness testers and the full range of equipment needed for metallographic sample preparation.

• Physico-chemical bulk and surface analyses. Thermal analyses for phase transformations, bulk chemical analyses and concentration profiles, pin-on-disk tribometer, scratch tester, instrumented micro-hardness testers for the characterization of bulk and surface layers of metals.

• Process metallurgy. Simulation and experimental investigations of metallurgical processes by a set of muffle furnaces that can be operated up to 1200°C in ambient or inert atmosphere, a melting resistance furnace for the production of small amounts of experimental alloys. Plastic deformation processes are studied by a laboratory rolling mill extrusion systems for light alloys, as well as a hot compression/tension testing devices for hot working process optimization.

ReferencesTenaris Dalmine, Siemens, Scuderia Toro Rosso, Brembo, SMS-INNSE.





Instrumentation & Facilities• Zeiss EVO 50XVP Scanning Electron Microscope with

X-ray EDS microanalysis and Electron Backscattered Diffraction System.

• Setaram DSC / GTA thermal analysis system equipped with furnace and rods for temperature cycles of up to 800 and 1600°C.

• Horiba Jobin-Yvon GDP2 glow discharge optical.emission spectrometer.

• CSM pin-on-disk tribometer.• CSM Microindenter instrumented microhardness

(loads from 0,01 to 10 N) and scratch tester (load range 0.3 - 30 N).

• Nabertherm melting furnace (temperature up to 1700°C).

• Carbolite tube furnace (temperature of up to 1200°C, in ambient or inert atmospheres).

• OAM rolling mill (symmetric and asymmetric operation mode, rolls of 150 mm diameter; speed: 0-20 rpm continuously adjustable).

Activities

Microstructure and failure analysis• Microstructure analysis by optical and scanning

electron microscopy.• Quality control & failure analysis.

Physico-chemical bulk and surface analyses• Thermal analysis for phase transformation, melting

temperatures of alloys. • Chemical concentration profiles by GDOES on coatings

and surface treatments.• Adhesion of coatings by scratch test.• Wear properties by pin on disk testing. • Thermal treatment simulations in inert or controlled

athmosphere.

Process metallurgy• Simulaiton of metallurgical processes.• Laboratory casting of metallic alloys.• Rolling of metals at room and high temperatures.• Hot extrusion of small-size profiles of Aluminium,

Magnesium or Titanium alloys.• High-temperature compression tests to optimize hot

working conditions.• High temperature creep and slow-strain rate testing.

Rev.0

RAILWAY ENGINEERING

Testing and characterization of railway systems

DescriptionThe laboratory provides a series of specific test-rig designed for the testing and the characterization of several sub-systems of a rail vehicle. In particular, there are devices for the structural testing of bogies or its subcomponents (e.g. bogie frames, bolsters or suspensions). The laboratory also allows the characterization of measurement devices to be used for homologation purposes.

CertificationsAccredited tests ISO 17025:2005 (Accredia):• Characterization of dynamometric wheelsets

(DM/AI.TSF.DOC.12.002 + DM/AI.TSF.POP.12.001).• Static tests on bogie frames, axleboxes and bolsters (UNI

EN 13749:2011).• Measurement of the friction coefficient between

pantograph contact strips and contact wire of overhead line and measurement of wear rate for contact wire and pantograph contact strips (RFI-DMA-IM.LA\ST TE65).

• Train aerodynamic loads in open air: aerodynamic loads on track workers at the lineside, aerodynamic loads on passengers on a platform and pressure loads in open air (STI HS RST 2008, Direttiva 96/48/CE).

Certified tests ISO 9001:2008 (Italcert):• Rotating bending fatigue on axles (EN 13260).• Dynamic Interaction between pantograph and overhead

contact line: calibration of the measurement system (EN50317, RFI/DI/TC.TE/ST.TE 74D).

Accredited StaffISO 9712:ST - Strain Testing Level 1 and 2Dye penetrant inspection Level 2 and 3Magnetic particle inspection Level 2 and 3





ReferencesAlstom, Ansaldo Breda, Ansaldo Breda España, Bombardier, G.E. Transportation system, Lucchini R.S., Balfour Beatty, Furrer Frey, Metropolitane Milanesi, Pantecnica, RFI, ATM, Ferrovie Nord Milano, Trenitalia, ContiTech, MSA, Mermec, Italcertifer, Contact, DB, Faiveley, Shunk, SNCF, Stemmann.

Activities

Dynamometric wheelset characterization• Static characterization a wheelset or, more in general a bogie,

properly instrumented to measure the contact forces.• Real boundary conditions both at the contact interface (UIC60

cant angle 1/20) and at the axle-boxes (mounting on the test-rig of the entire bogie).

• Direct measurement of the three components of the contact forces acting on each wheel.

• High variety of applicable loads (up to 150kN per wheel in vertical, 40kN in lateral and 20kN in longitudinal direction) and their combinations.

Structural rail components testing• Performs static, dynamic and fatigue tests on railway bogies

and/or their components in accordance with the international standard EN 13749.

• Reconfigurable layout in order to allow the housing of all types of bogies currently in circulation on railways, metros and tramways.

• Possibility to control simultaneously a variable number of hydraulic actuators (up to 10) with different ranges of applicable loads up to a maximum of 1000kN.

Collector stripes test• Performs wear tests on collector stripes reproducing the at

best the real condition encountered in service.• Maximum tension applicable 1200A.• Maximum relative speed between collector stripes and

overhead power line up to 210km/h.• Reproduction of the wind cooling effects and the load

imposed by the pantograph springs.

Pantograph characterization• Allows the characterisation of pantographs reproducing the

dynamic interaction with the catenary.• Possibility to replicate the stagger geometry and pantograph

velocity.• Separate application of the loads in vertical direction for the

two collector stripes.• Real time hardware in the loop control to simulate the

real interaction between the pantograph and a simulated catenary.

Rotating bending fatigue on axles• Imposes a variable load to the central section of the axle

while rotating reproducing the conditions needed for axles fatigue testing.

• Maximum rotation speed 600rpm.• Maximum load 250kN with the possibility to impose load

spectra to the axle.• Possibility to run tests in harsh environmental conditions in

order to reproduce corrosion effects.

Active secondary suspensions• Simulates the transit of a rail vehicle in a curved track.• Reproduce an uncompensated lateral acceleration up to 1.1m/s2.• Possibility to reproduce maneuvers in 3s simulating

effectively the real dynamics of an high-speed vehicle.

Instrumentation & Facilities• Bogies test-rig: reconfigurable test-rig for the testing

of structural rail components.• Dynamometric wheelset test-rig: characterization

and calibration of dynamometric wheelset.• Pantograph test-rig: hardware in the loop device for

the characterization of instrumented pantograph.• Axle test-rig: study of the rotating bending fatigue

and crack propagation phenomena on axles.• Collector strips test-rig: testing on collector strips

reproducing the real in-line conditions.• Aerodynamic tests: in-line testing procedure for the

study of railway aerodynamics.• Secondary suspensions test-rig: simulation of curved

track conditions.

Rev.0

REVERSE ENGINEERING

Computer Vision e Reverse Engineering

DescriptionThe Computer Vision and Reverse Engineering laboratory is specialized in the Reverse Engineering pipeline for study, research and industrial applications: 3D devices calibration and characterization, 3D acquisition and processing, redrawing of CAD models based on 3D data. The 3D capturing equipment permits to acquire industrial components, structures, Cultural Heritage objects with a wide range of geometries, sizes and materials.

ReferencesThe laboratory has contributed to the production of reality-based 3D models for the following patrons:• Scuola Normale Superiore di Pisa.• Comune di Milano - Castello Sforzesco.• Comune di Milano - Civico Museo Archeologico.• Several professors of the Department of Mechanical

Engineering.





Instrumentation & Facilities• Minolta Vivid 9i: triangulation laser scanner with

rotating table, and 1 laptop pc Dell M90 for Vivid Minolta controller.

• GOM Atos: pattern projection scanner.• NextEngine 3D HD: laser scanner mounted on

Manfrotto Tripods.• Calibrated Target for 3D metrology.• Software tools for the post-processing of 3D models.• 2 Kuka KL3: robot for handling 3D scanning systems.

Activities

Camera calibration for photogrammetry and 3D Vision • Radial distortions assessment.• Tangential distortion assessment.• Affine distortion assessment.

Active 3D range sensors characterization (Triangulation and TOF/PS) according to ASTM Committee E57 draft• Global uncertainty assessment.• Precision assessment.• Accuracy assessment.

3D acquisition and modeling based on• Traditional photogrammetry with sparse clouds.• SFM/Image matching with dense clouds/meshes.• Triangulation based laser scanning and dense mesh

generation.• TOF/PS laser scanning and dense mesh generation.• CAD drawing on 3D data gathered manually or

automatically.

3D models optimization for Virtual Navigation• Mesh optimization.• Texturing/Displacement mapping.• 3D segmentation.

Rev.0

TEST OF MECHANICAL COMPONENTS

Static and dynamic tests on real components or structures

DescriptionThe laboratory is equipped with multi-range servo-hydraulic actuators and others facilities to perform tests on full-scale components and structures. The equipment includes servo-controllers, load cells, electrodynamic shakers, modular constraint systems, various transducers (pressure, temperature, displace-ment, acceleration, strain, etc.), with dedicated signal conditioners and acquiring systems.

CertificationsThe laboratory is compliant with AgustaWestland quality standard requirements.

ReferencesAgustaWestland, Cifa, ENI, Pirelli, Ferrari.





Instrumentation & Facilities• Special set-ups for full-scale component testing:

Servo-hydraulic actuators (max force 1000 kN). Electrodynamic shakers (max force 25 kN). Controllers for servo-hydraulic actuators: single and multichannel (MTS 407, MTS Flex Test IIm, MTS Aero GT, MTS Flex Test SE, etc.). Constraint systems with treaded holes or grooves and steel beams to built customized frames for full-scale tests.

• Other equipment and devices: Load cells. Displacement transducers. Rotation transducers. Pressure and temperature transducers. Accelerometers. Systems for data analysis. Systems for stain measurements.

Activities

Single and multi-actuator tests on mechanical components and large-scale structures• Fatigue tests to define the life of a component.• Application of a load spectrum to simulate a real stress

condition.• Static and dynamic tests to verify the integrity of

components and large-scale structures subjected to the real operating conditions.

• Detection and monitoring of crack propagation during a fatigue test (non-destructive methods, microscope, crack gauges, etc.).

• Determination of the influence of several technological parameters on the fatigue resistance.

Fatigue tests for biomedical applications• Static and fatigue tests to verify the resistance of limb

prosthesis.• Performance optimization of leg prosthesis for sportive

applications.

Dynamical characterization of components• Tests to analyze the dynamical behavior (frequency

response, mechanical impedance, fatigue resistance, etc.) of components and systems using electromechanical shakers.

• Development of control systems for damping of vibrations on “Smart structures”.

Rev.0

VEHICLE DYNAMICS AND CONTROL

Testing and characterization of road vehicles and active control systems

DescriptionMain activities of the Laboratory are focused on testing, modelling and control of vehicles, with particular attention to suspensions, tyres, braking systems, drivelines of conventional, hybrid or electric vehicles, control systems for active safety and performance, ADAS and autonomous vehicle control logics. The laboratory offers facilities and expertise for setting up road tests on the complete vehicle or indoor tests on single components. Commercial and innovative stability control systems (ESP, ABS, EBD, etc.) can be tested with a dedicated test rig based on hardware-in-the-loop technique.

ReferencesPirelli Tyres, Ferrari Auto, FIAT, CRF (Centro Ricerche FIAT), Bridgestone, Tenaris Dalmine, CIFA, Magneti Marelli, Autoliv, Brembo, TRW, SAME, Maserati Auto, CRA-ISMA, Nokian Tyres, Kymko, MV Agusta, Lamborghini Auto.





Hybrid/Electric vehicle power train testing• Detection of motor characteristics (nameplate).• Performance analysis of a complete powertrain.In our laboratories two test benches for the testing of hybrid/electric vehicle power trains are available ranging from small (from 7 kW) to high power trains (up to 200kW and 1300Nm). All electric quantities both on the electric motor and the power electronics can be assessed for measuring the efficiency, the operating range and the control behavior. Also regenerative braking tests can be performed.

Vehicle moving lab• Vehicle dynamics test.• Comfort, handling, performance and stability evaluation.• Validation of numerical vehicle models.• Validation of state estimators.A vehicle moving lab is available in our laboratories. The vehicle standard measuring set-up includes: two measuring hubs, one inertial platform, accelerometers on suspensions upper mounts, measuring steering wheel, external optical device to measure vehicle speed, potentiometers to record suspensions displacements, pressure sensor on brake lines, a GPS platform and CAN-BUS acquisition system. Additional measuring devices can be added. The purpose of the vehicle is to test state estistimator, in particular for vehicle speed estimation, tyre cornering stiffness, sideslip angle, road friction level and others.

Characterization of spring and damper• Characterization of spring and damper.• Evaluation of behavior with different active control

logics.Our laboratories host test benches designed for the testing of suspensions components. Static and dynamic characterization of springs (coil springs, leaf springs etc.) and dampers (viscous dampers, magnetorheological dampers etc.) can be carried out. The force developed as function of deformation, speed and other variables, in case of active or semi-active components, can thus be determined. Test bench can be easily adapted a series of different geometries.

Battery cell testing• Charging\discharging curves generation.• Lifecycle measurements considering constant or real

profile of current.A scalable battery cell test bench with controlled charge/discharge current up to 300A is installed in our laboratories. The bench is also equipped with thermal conditioning of the cells under test. The characterization of the charging and discharging curve under different C rates and temperatures is possible. Life endurance test under standard condition and driving cycle can also be carried out. The system is provided by embedded software able to collect all the necessary data for battery life test analysis.

Vehicle outdoor testing• Contact forces measurements.• Vertical dynamics under load spectrum condition

analysis.• Numerical model development.Our staff have the expertise to install measuring and data-acquisition devices on passenger cars, motorcycles or truck vehicles to perform outdoor testing. Inertial platforms, accelerometers, potentiometers and optical devices represent a standard measuring set-up. Also non-standard measuring devices like strain gauges can be added to monitor stress condition of vehicle components like frame and suspension arms.

Instrumentation & Facilities• Instrumented vehicle for road tests.• Hardware-in-the-loop test bench for ESP/ABS/EBD

control systems.• Dynamometric measuring hubs.• Inertial gyroscopic platform.• Correvit optical sensor.• GPS acquisition platform.• dSpace Real-Time board for data acquisition and

processing.• Full active test bench for test of full scale hybrid/

electric power train.

Activities

HiL test-bench for ABS/ESP/EBD ECU• Measurement of Vehicle behavior during ABS

intervention.• Evaluation of ABS intervention parameters.In this test-bench a vehicle model running on a real-time board is interfaced with an ABS/ESP/EBD unit operating over a real brake system. The test-bench allows to simulate the response of the vehicle in a series of handling maneuvers analyzing the effect of control units operating on brakes to improve handling and stability. Innovative control logics can be implemented on the real-time board comparing their performance against commercial ones.

Rev.0

3D VISION - polimi.it

Documents

Transcript of 3D VISION - polimi.it