Optical Augmented Reality Metrology, the future of Metrology?

Measuring Key points on a complex featureless surface can be extremely difficult, locating the points in a cost-effective manner is half the challenge. Figuring out where they are on the CAD model and the real model is the other.

 

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Let’s introduce ProjectionWorks: Direct Project. Direct project allows you to instantaneously project every point which needs measuring, these can then be measured with nearly any metrology device, let’s use a HEXAGON ROMER arm for now.

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Once you’ve taken your measurements just hit one button in whatever software you’re using (SA, Polyworks etc.) and the Projection updates with the measurement you just took. You get a live visualisation of exactly what is going on with your part in comparison to the CAD model.

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Let’s say you then sand down a location on the part. Retake the measurements, hit the button and you’ve got you live projection of the work you just did. Direct project shows you your part imperfections and turbo charges your workforce’s efficiency in resolving them.

Who’s using ProjectionWorks

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This technology can be used to disrupt any manufacturing industry where visual instruction can be used to increase quality and efficiency
 
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A3L are the lead supplier of ProjectionWorks to the UK and Europe. For more information please feel free to contact us:

www.a3l.uk.com

+44 (0) 7984 520549

Mike.Sorbie@a3l.uk.com

Demos of Augmented Reality at MRO, Engineering and Metrology Trade Shows

We’ll be demonstrating our Augmented reality products this year at various trade shows in Europe and the UK. If you’re at these events get in touch and we’ll have a coffee. Mike.sorbie@A3L.uk.com

Show

Date

Location

Exhibiting?

Northern Manufacturing & Electronics

27/09/2017

Manchester, UK

Attending

3DMC

09/10/2017 – 11/10/2017

Aachen, Germany

Exhibiting & Speaking

Digital Construction week

18/10/2017

London, UK

Attending

NEC Advanced Engineering

01/11/2017 – 02/11/2017

Birmingham, UK

Exhibiting

Aviation Forum

07/11/2017 – 08/11/2017

Hamburg, Germany

Exhibiting

This disruptive manufacturing technology has saved more than 200 hours per plane and a potential $111 million for the F-35 program alone

Technology we will be demonstrating

We will be demonstrating most of our Augmented reality product range

AssemblyWorks

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Assembly instructions can be shown directly to a worker on the part they’re using. Showing them what to do, how to do it and where. Any other information like tools can also be shown.

HarnessWorks

 
 

Wire paths and connectors can be projected directly onto a magnetic harness board eliminating the need for Mylar and storing hundreds of boards for each harness. Production speed is increased and error rates get dramatically reduced, the technician can spend more time building the connectors and harness instead of searching through harness documents.

Direct Project

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Real time metrology data can be displayed directly on the part showing variations from previous data or deviation to the CAD model.

 
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A3L are the lead supplier of ProjectionWorks to the UK and Europe. For more information please feel free to contact us:

www.a3l.uk.com

+44 (0) 7984 520549

Mike.Sorbie@a3l.uk.com

Photogrammetry: How to quickly build a 3D model of anything with just a laptop and a camera for free

In this article, we’re going to teach you how to build a basic 3D model using just a camera and a laptop. We will use a free piece of software called Vsfm. We won’t go into any details of how this works in this article.

Photogrammetry: Structure from motion

Structure from motion (SfM) is a photogrammetric range imaging technique for estimating three-dimensional structures from a two-dimensional image, It’s a form of computer vision. With that said, let's start!

Overview

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Setup

We’ll be using a range of free software for this so let’s get started!

  1. Download VSfM http://ccwu.me/vsfm/
  2. Unzip VSfM
  3. Download CMVS-PMVS https://github.com/pmoulon/CMVS-PMVS
  4. Unzip CMVS-PMVS
  5. Open CMVS-PMVS-master/binariesWin-Linux
  6. Open the relevant folder for your system
  7. Copy the contents of the folder you just opened
  8. Open the VSfM folder you unzipped in Step 2
  9. Paste the contents you just copied, you will be asked to replace or skip the files. Click replace
  10. Done!

Generating a model

Now you’ve got everything set up here comes the fun part! Making your first 3D model. So, I’ll guide you through a quick overview process to get you started.

Get some photos

First, we need Photos of whatever it is you want to turn into a 3d model. You want between 20 and 50 photos’ initially. If you’ve got a really good computer then you can get away with more. Make sure you’re using a good camera, keep flash off and try to keep the light and shadows on the object constant.

If it’s a flat surface take the photos in a scanning motion.

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Otherwise Take photos about every 20 degrees 360 degrees around the object. Increase the height after one 360 and repeat.

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Processing

1, Open Vsfm

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Open VSFM, by clicking the VSFM.exe in the folder you unzipped earlier. Two windows will open, the interface and the log window.

2, Load the images

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Wait for the images to load in

2, Click compute missing matches

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Allow the software to complete the missing matches

3, Click compute 3D reconstruction

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Allow the software to build the sparse cloud, this may take a little longer

4, Click Run dense cloud reconstruction

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You will be prompted to Save the file

This process may take a while but it’s the last one to make the model!

5, Once it’s finished Press tab and you should see a point cloud of your model!

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Controls:

You can reload your model at any time by clicking the SFM tab then clicking Load NView match and finding the file you saved earlier for the dense cloud.

Best practices and tips

  • Features! Make sure images you have contain lots of features; the algorithms detect features so the more you have the better the results
An image with no features

An image with no features

An image with many features!

An image with many features!

  • Try to avoid taking photos of shiny surfaces, cover them in Talc powder if need be
  • Keep the object of interest in the centre of the image
  • Try to cover the whole image with the object of interest
  • Try to make sure each image has an overlap of features
  • Practice!

This is only a basic guide on how to do Photogrammetry with some free software, A3L regularly develop and use photogrammetry for advanced scanning applications with an accuracy of less than 1mm. We use photogrammetric applications for building CAD models and Augmented/virtual reality.

 
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A3L are the lead supplier of ProjectionWorks to the UK and Europe. For more information please feel free to contact us:

www.a3l.uk.com

+44 (0) 7984 520549

Mike.Sorbie@a3l.uk.com

Augmented Harness Assembly, the Future of Aerospace and Automotive Harnesses?

Harness Manufacturing is an artform, with skilled workers across the UK assembling thousands of harnesses daily. Here’s the catch though, to build a harness you have to spend an age searching through documents to find the information you really need. Your worker spends a lot of their time searching through documents and not using their skills! Unfortunately, during this search things get misread leading to quality defects and an unwanted increase in production time.

Tradition Harness board

Tradition Harness board

Paperwork!

Paperwork!

HarnessWorks

Let’s introduce Harness works, an Augmented reality system which is designed to accurately display the wire paths, routes, connector pins and any other information you want at exactly the right time and place. No more searching through documents or paper. By showing the information at exactly the right time you drastically increase production and reduce quality issues. Currently HarnessWorks is revolutionising the Aerospace industry and it’s only a matter of time before it breaks into the Automotive and white goods sector.

How does it work

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We take data from any source, then using Rulescript convert this into the Projection file. This whole process normally takes around an hour for a large loom. Once the file has been published it never needs to be touched again for that loom, no need to print Mylar’s or storing the boards anymore.

To ensure dimensional accuracy the projection is calibrated to known point on the harness board, this gives an accuracy of <1mm ensuring that all the wires which are cut to size are within tolerance. HarnessWorks removes the guesswork. This process usually takes less than five minutes.

Reconfigurable board

Projected Board

Projected Board

Traditional Board

Traditional Board

Using projection, a steel board and re-configurable magnetic clips, one board can be used for every wiring loom. Two smaller looms can also be projected onto a single board allowing for a multifunctional Harness board.

Summary

We believe HarnessWorks is the next step in Harness assembly, robotics simply cannot do what a skilled worker does. We’ve shown that enabling the worker to use more of their skills and remove the tedious time-consuming parts of the job will drastically improve production and quality of your organisation.

Latest Harnessboard

Latest Harnessboard

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A3L are the lead supplier of ProjectionWorks to the UK and Europe. For more information please feel free to contact us:

www.a3l.uk.com

+44 (0) 7984 520549

Mike.Sorbie@a3l.uk.com

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How Projection Is Supercharging Manufacturing Productivity and Quality

This technology can be used to disrupt any manufacturing industry where visual instruction can be used to increase quality and efficiency

In today’s modern age information should be readily available at the click of a button…. not 20 minutes of searching through a paper document finding out which cable or fastener to use. It’s a bigger issue than just time though, people inherently make mistakes when they’re pulling mass amounts of information from documents, quality takes a hit and so do your finances.

Projection

Let’s introduce Projection. Projection allows you to display the right information at exactly the right time in the manufacturing process. No need to thumb through large amounts of paper anymore. You can show your workers exactly what to do, where to do it and when to do it. This allows your workers to spend more time on tool using their skill set, speeding up manufacturing time whilst drastically increasing quality. Projection so far is changing Aerospace Assembly and manufacturing by maximising human efficiency.

How does it work

A3L work very closely with DELTA SIGMA in the U.S. delivering manufacturing projection solutions to the UK and Europe using ProjectionWorks.

ProjectionWorks is a family of products designed to add visual work instructions directly onto anything – regardless of shape or size

Assembly

1, Write the script

1, Write the script

2, Display the script

2, Display the script

Assembly instructions can be shown directly to a worker on the part they’re using. Showing them what to do, how to do it and where. Any other information like tools can also be shown.

This disruptive manufacturing technology has saved more than 200 hours per plane and a potential $111 million for the F-35 program alone.

Harness

Wire paths and connectors can be projected directly onto a magnetic harness board eliminating the need for Mylar and storing hundreds of boards for each harness. Production speed is increased and error rates get dramatically reduced, the technician can spend more time building the connectors and harness instead of searching through harness documents.

Paint

Full paint schemes can be projected onto an aircraft and can be switched within seconds. This is perfect for demonstrating paint jobs or masking accurately giving a uniform perfect paint job on every aircraft.

Who's using ProjectionWorks

This technology can be used to disrupt any manufacturing industry where visual instruction can be used to increase quality and efficiency
 
 

A3L are the lead supplier of ProjectionWorks to the UK and Europe. For more information please feel free to contact us:

www.a3l.uk.com

+44 (0) 7984 520549

Mike.Sorbie@a3l.uk.com