Advancements in Remote Visual Measurement Technology · 2015-10-08 · © 2015 General Electric...
Transcript of Advancements in Remote Visual Measurement Technology · 2015-10-08 · © 2015 General Electric...
© 2015 General Electric Company. All rights reserved
Advancements in Remote Visual
Measurement Technology
Tom Britton
Aviation Specialist
GE Inspection Technologies
Remote Visual Inspection (RVI)
© 2015 General Electric Company. All rights reserved
UltrasonicRemote Visual
Inspection Radiography Eddy CurrentTesting
Machines
Data Management Software
Film, Equipment
and Chemistry
Digital
Radiography
(FS, CR, DR)
X-ray Generators
Instruments
and Probes
Automated
Systems
Ultrasonic and X-
ray
Standard
Customized
Video Borescopes
Borescopes
Fiberscopes
PTZ Cameras
Collaboration SW
Re-Measurement
SW
Inspection
Services
Rentals
Rhythm Acquire Inspection Works
Rhythm Review - Inspection
Manager
Rhythm Archive - Inspection
Connect
GE Inspection Technologies
Metrology
3D Computed Tomography
Flaw Detectors
Thickness
Gauges
Hardness Testers
System
Instrumentation
Transducers
Installed Sensors
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3
Mentor Visual iQThe Power of Productivity in your hands
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4
• Faster, easier
navigation
• Pinch to zoom
• Precise cursor
placement
• Efficient text and
arrow annotation
• Use with gloves
• Clear, bright
resolution
HDR
Touchscreen
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• 6.75 lbs
• Aircraft
compliant
• Lithium-ion
battery
• Easily stores in
overhead
compartments
• Battery or AC
capable
Portable
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6
• Designed to IP65,
MIL-STD-810G
and MIL-STD-
461F standards
• High temperature
resistance
• Stands up to
severe
environments
• Dustproof
• Waterproof
Durable Design
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Mentor Visual iQ
7
• Modern dual action User Interface (UI)
with trigger function
• 6.5” XGA LCD with Touchscreen-
supports gesture based zooming
• Interchangeable probes
• 16 GB internal memory
• Wi-Fi and Bluetooth connectivity
• DisplayPort Digital Video interface
• USB 3.0 & USB-slave ports
• Detachable 2-hr Battery
• IP65 Environmental rating
• 3D Surface Scan & 3D-Stereo
Measurement
• Integrated Portable design
• New 4mm High Res. with tip optics suite
• Mentor TM Inspection Connect platform
Feature Overview
Imagination at work.
© 2005 by Everest VIT, Inc.
Comparison (Scalar)
Measurement
Technology
Remote Visual
Inspection
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Comparison Measurement Principles
•Comparison measurements use the size of a known
object (often set in place by the manufacturer, or
introduced with the probe) to measure other objects
in the same view and plane.
•Such measurements are made using frozen or
recalled images.
•Choose optical curvature distortion correction for tip
•Probe must be perpendicular to item of interest to be
measured.
•Item of interest to be measured must be the same
approximate distance from the probe tip as the
reference measurement used.
5
© 2015 General Electric Company. All rights reserved
Comparison Measurement
Technology
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Scaling Pixels- basis for measurements
• The Computer counts the number of pixels between the 2
cursors.
• It then divides that number into the value assigned by the
inspector.
• Each and every pixel on screen is given the same calculated
value.
• Assigning a value to each pixel is the basis for Comparative,
Shadow
• and Traditional Stereo Measurement
Comparison Measurement – How It Works
• The bolt head is a known 0.500 inches.
• The inspector marks both sides with a cursor.
• The computer counts the number of pixels between the cursors.
• In this case, there are 50 pixels so the value per pixel is 0.010 in
• (0.500 inch/50Pixels = 0.01 inches per Pixel)
• So now our unknown hole diameter is 25 PIXELS wide or
• 25 Pixels X .010 in/pixel = 0.250 inches
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When & Why To Use Comparison
Measurement
•Do not have a 3DPM or stereo tip
•Need to measure further away than a 3DPM
or stereo tip will allow (Object to be measured
is too big to fit within the field of view)…such
as Combustor Liner crack measurements
•Cannot place obtain a “measurable” 3DPM
or Stereo image
•Ideal for checking the approximate size of
many items quickly
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Freeze the image – Select Comparison Measurement
How To Perform Comparison Measurements
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Select a tip
How To Perform Comparison Measurements
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Select a measurement type
How To Perform Comparison Measurements
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Mark known dimension points
How To Perform Comparison Measurements
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Enter known dimension
How To Perform Comparison Measurements
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Place cursors on item of interest
How To Perform Comparison Measurements
Imagination at work.
© 2005 by Everest VIT, Inc.
Shadow Measurement
Technology
Remote Visual
Inspection
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ImagerShadow
Tip
Fiber
Bundle
Shadow
Slit
Aperture
Z1 Z2
Shadow Measurement Technology
Clos
eFar
• Full FOV of defect target
• Image is darker due to shadow creation
• Target should be on a perpendicular plane
Imagination at work.
MViQ3D Phase Measurement
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Phase Shifting Scanning Typical Setup
CameraProjector
Object
Image 0
Image 1
Image 2
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Phase Shifting in the XLG3
LED
Arrays
Shadow
PatternViewing
Optics
LED
Arrays
3D Phase Tip
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3D Phase Measurement Technology
3D Phase Measurement Technology
Red LED Fringe Pattern projected onto
surface
And the fringes have structure:
- 120 deg phase shift
- Sinusoidal Intensity
Imager3D PM Tip
Z1 Z2
LEDs
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Optics Configuration Fringe patterns are projected using 2
sets of LEDs on each side of viewing
optics.
Object distance at each point is
computed using pattern trajectories
(triangulation) known from
calibration.
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By projection of a sequence of binary
coded stripe patterns, the subsequent
light levels for each scene pixel are
forming a unique binary word revealing
the individual stripe number. To minimize
the effect of bit errors, the stripe patterns
are designed to change only one bit per
stripe (Gray codes)
At least 3 phase shifted gray gradient
patterns are needed for a precision
analysis of position from the gray values.
Three simultaneous color patterns are
also used in certain applications.
Phase Shifting TechnologyReference
http://en.wikipedia.org/wiki/Struct
ured-light_3D_scanner
http://en.wikipedia.org/wiki/3D_s
cannerArea
http://www.vrac.iastate.edu/%7E
song/publications/papers/2006-
oe-realtime.pdf
http://patents.com/us-
7821649.html
© 2015 General Electric Company. All rights reserved
Fringe Phase Images
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Fringe Phase Images
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Fringe Phase Images
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Image CaptureTest Fields
Bright Set x 2
Dark Set x 1
Middle Set x 3
Merged Set
3D Phase Measurement Measurement Types
& 3DPoint Cloud Visualization
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MViQ – User Interface: Measurement Operation
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GE Confidential
Image Enhancements - Views
• MViQs provides multiple image Views
• Normal, HDR, Bright, Dark
MVIQ Advanced Image Processing Technology
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GE Confidential 34
Image Enhancements - ViewsStandard View HDR View
Bright View Dark View
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35GE RVI
10/8/2015
3D Surface Scan Measurements
3D Surface Scan
Key Features• Measurement on
Demand
• Measure from any
attack angle
• Wide-view 105o FOV
• Auto Tip-ID
• 6 Measurement
Types
3D Surface Scan Measurement(full-screen view)
Stereo Measurement(two half screen views)
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36GE RVI
10/8/2015
Length Area Measurement
Multi-Segment Length Point to Line Measurement
Depth Measurement
Depth Profile Measurement
6 Types of 3D Surface Scan Measurements
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37GE RVI
10/8/2015
Length Measurement
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38GE RVI
10/8/2015
Multi-Segment Length
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39GE RVI
10/8/2015
Area
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40GE RVI
10/8/2015
Point to Line
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41GE RVI
10/8/2015
Point to Line
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42GE RVI
10/8/2015
Depth
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43GE RVI
10/8/2015
Depth on Plane - for Blade Clearance
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44GE RVI
10/8/2015
Depth Map
Point Cloud
3D Surface Scan Measurement
Automatically
find Point
furthest from
reference plane
(-0.179”)
New Measurement Type: Depth Profile
Measurement
3D Surface ScanningPhase Measurement Technology
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45GE RVI
10/8/2015
New Measurement Technique: Depth Profile
• Place two cursors
• System creates perpendicular cut
• Displays cross section
• Automatically finds deepest point
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Profile Cut View
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Cross- Section: Profile View
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Unmeasurable Areas
RED: No 3D Data
Too far away, Shiny Surface, Out of sight (no scanning),
Glare, Speckle, Hot spot, Motion, …...
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Understand the Point Cloud
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Point Cloud
• Use Point Cloud to validate cursor placement and understand target surface geometry
• Can tilt, spin and zoom image
Point Cloud
Depth Profile Measurement
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Depth Map
• Depth Map is a color view of the Point Cloud
• Blue is closer to the tip
• Red is further away
Depth Profile
Measurement
Depth Map
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52GE RVI
10/8/2015
Point Cloud and Depth Map
If no measurement has been made, entire viewing area is displayed.
If a measurement has been made, view is cropped to a circle drawn around the measurement.
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Reflection on surface of 3DPM image
(Visual Layer)
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Understand the Point Cloud
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3DPM IMAGE EXPORT TO CAD SOFTWARE PACKAGE
Create CSV file from 3D Image
3D Print Indications
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56© 2015 General Electric Company. All rights reserved
Understand the Point Cloud – Choose Correct Measurement Type
Verify Cursor Placement Using Point Cloud
– Prevent Measurement Errors
Incorrect !
Correct !
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57© 2015 General Electric Company. All rights reserved
Understand the Point Cloud
Using Point Cloud to Improve Measurement Integrity
– Prevent Measurement Errors
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3DPM Application Example
Tip-to-Shroud Clearance Measurement
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3DPM Application Example
Depth-Profile Measurement of Erosion Damage
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3DPM Application Example
Blade Leading Edge Damage Measurement
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3DPM Application Example
Corrosion Pit Damage Measurement
0.003”
corrosion
pit depth
Imagination at work.
3D Stereo Measurement & Point-Cloud Visualization
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Stereo Tip Optics
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Stereo Technology
Head Assembly
Light Guide
Aperture
Lens
CCD Imager
Stereo Optical Tip
Two Images
Splitting Lens
Light Guide
Illumination
Tip/Head Construction
Target Object
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Traditional Stereo Measurement Image
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3D STEREO IMAGE
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3D Stereo Basics
• Same Basics for StereoProbe
apply
• Side-by-Side Image Analysis
White Light View in LH
Window
Point Cloud view in RH
Window
• MTD Replaces Index
• Point Cloud generation
• Assisted Verification on
Measurement Verification Block
• Enhanced UI Messages
• Six (6) types of measurements
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New ! Dynamic Warning Messages
User Interface Status Messages are measurement-context sensitive
Final captured image may have warning (orange) band on measurement result
MTD Defect Size Image Status Message
0.966 inch 0.116 inch Measurement 1 None
0.966 inch 0.045 inch Measurement 2 “Move closer to target or move
cursors for better results”
Example:
Status bar
message
Orange
advisory
band around
measuremen
t results
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3D Stereo Hardware / Software
• Uses Same tips as traditional stereo
• New Tip Calibration process and
execution software required
• Systems can be upgraded
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Complimentary 3D solutions for a wide range of measurement applications
Measurement
Technology
Reasons to use Reasons not to use
3D Phase • Measure on demand
• Point cloud visualization
• Full screen view
• Auto Tip recognition
• Only available on 6.1mm
• Excess motion
• Shiny surfaces
• Narrow deep features
3D Stereo • Available on ALL diameters
• Point cloud visualization
• Not as motion sensitive as 3DPM
• Better measurement on reflective
surfaces
• Better repeatability than traditional
stereo
• More difficult to navigate with
dual view
• Struggles with bland surfaces
• Lower image quality
Comparison
(Scalar)
• Good for large measurements ( > 2
inches) which cannot be performed
by 3DPM or Stereo
• Available for all diameters
• Good for quick Go / No-Go
assessment
• Item of known dimension
must be in (or introduced
into) area of inspection
• Inspection target must be
perpendicular to probe
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Coming in Q4 20153D MEASUREMENT HANDBOOK
Contact us.
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GE Remote Visual Inspection
721 Visions Drive Skaneateles, NY 13152
Tel: (888) 332-3848 (Toll-free, USA only)
Tel: (315) 554-2000 (Ext. 1) Fax: (866) 899-4184