Development of a precise 3D Scanning system for Industrial applications.

The project is to develop a system to acquire CAD model of any regular shaped object for quality assurance and rapid prototyping. It can be used in vast variety of areas because it is actually a quality control product which can be used for measurement as well as reverse engineering process. Further

Project Title

Development of a precise 3D Scanning system for Industrial applications.

Project Area of Specialization

3D/4D Printing

Project Summary

The project is to develop a system to acquire CAD model of any regular shaped object for quality assurance and rapid prototyping. It can be used in vast variety of areas because it is actually a quality control product which can be used for measurement as well as reverse engineering process. Furthermore this project can be modified as well, it can be made advance by using different methods such as AI implementation.

Project Objectives

To develop a system that can create a CAD model of any regular shaped object through reverse engineering process. Non-contact measurement method is implemented in order to get a precise dimension of the object. Data points are determined by using a 2d low profile laser scanner. The main objective is to acquire the CAD model through the proposed system and share it not only locally but globally to monitor the entire process .

Project Implementation Method

Project Description:

We are proposing to design a system that takes a 3D scan of any regular shaped object (for eg. Mobile Phone) through a 2D laser scanner, we will be using FDRF627 which a 2D low profile laser scanner, usually used for profiling in Industries.

We will be developing this system to generate a CAD Model of any regular shape object whose CAD model does not exist or if the production of that object has stopped a while ago and we want the production of that object again.

Scanning and Hardware:

Scanning part is done by our 2D low profile laser scanner, capable of providing 2D scans of a 3D/2D surface. Our scanner can take scan of a surface of an object at a time. To recreate the 3D model, we need to take scans of the surface 6 times from all possible axis and the merge the scans on any CAD software that will recreate our 3D model. we wil be moving the laser scanner linearly on our hardware in z axis, rest of the two axes will be taken care of by our hardware that will move in all the directions for the scanner to take scans.

Interfacing:

Interfacing of scanner with our system by using a device such as a laptop or a pc is done by an ethernet cable from which we will be getting the data of our scans in our system in real time.

CAD model generation:

The scans now will be merged through a software like Autodesk or Solid Works for the generation of the CAD model which can be used further for prototyping and industrial production of that tool, part or object.

Final Outcome:

Final CAD model would be 3d printed via a 3d printer to check the actual dimensional aspects for further prototyping.

Benefits of the Project

The main aim for this project is to create a 3d model of any object at low costs, quickly and precisely. On the other hand if we use old techniques to recreate the 3d model it would be time consuming, less precise and expensive. The need of this project is reverse engineering of parts that need to be created in a CAD model for future production and for modification. It is the requirement of all most every industry to produce a precise product at a very low cost.

Technical Details of Final Deliverable

Our hardware consist of two parts mainly.

Upper platform:

Upper platform consist of a stepper motor that is used to move the scanner in linear motion to take scans. A threaded rod is coupled with the scanner using a bellow coupler to decrease jerk from the scanning surface that may damage our scanner. the whole platform is rested on 2 smooth rods with the help of 4 linear bearing to make the movement as smooth as possible. Arduino UNO is used coupled with CNC shield to control the stepper motor as Arduino is unable to provide proper current to the motor that needs 0.9A (Arduino can only provide max 200mA current from all pins combined). 

Lower platform:

Lower platform is the main platform on which the object needs to be placed.

This platform consist of three acrylic platforms

Inner Scanning Platform:

This platform is used to keep our scanning object. This platform will be responsible for scanning of four surfaces of our object. A servo motor is connected with the platform that will be responsible for moving the platform in 360 degree. An IMU (MPU 6050) is used to keep the platform stable at 0, 90, 180 and 270 degree positions, so that scans can be as precise as possible

Figure 1 (First Axis)

Figure 2 (Second Axis)

Figure 3 (Third Axis)

Figure 4 (Fourth Axis)

Outer Rotating Platform:

The inner platform is connected in this platform, this platform is responsible for moving our object on two other axes. A motor is connected to move this platform in two axes. A servo motor capable of moving 180 degree is connected and an Arduino is used to give them commands and move the platform in the said direction.

Figure 6

Figure 7 (Axis 5 perspective 1)

Figure 8 (Axis 5 perspective 2)

Figure 9 (Axis 6 perspective 1)

Figure 10 (Axis 6 perspective 2)

Outermost Fixed Platform:

This platform is fixed on a wooden sheet. Rotating platforms are connected to this platform with a motor.

HARDWARE IMPLEMENTATION:

The laser scanner is placed on upper platform that will move linearly on a single axis taking one scan at a time. This approach is taken because we need to keep vibration as low as possible in the scanner as the scanner is fragile and may get damaged with vibrations. The lower platform will move from axis to axis as shown above (fig. 1,2,3,4,7 and 9). The movement in 5th and 6th axis is easy as we have used a 180? servo motor (that includes potentiometer for feedback and checking position relative to the value provided) so these position will be achieved by moving the motors on the desired location. The inner platform is connected with a 360? servo motor that would require an IMU as a feedback to tell the motor its position while changing the platform from one axis to another. The lower platform will change its position then the scanner will take the scan. After scans of all the sides are gathered they will be merged with the help of Matlab or any other related software.

This is the complete hardware:

CAD Model of the Hardware:

Final Deliverable of the Project

Hardware System

Core Industry

Manufacturing

Other Industries

Education , Others

Core Technology

3D/4D Printing

Other Technologies

Sustainable Development Goals

Industry, Innovation and Infrastructure

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com