IDENTIFYING THE RIGHT METHOD OF SCANNING IN REVERSE ENGINEERING TECHNIQUE Mihalache A., Nagit G., Ripanu M. I.

, Manole I. (Technical University Gh. Asachi, Department of Machine Manufacturing Technology, Iasi, Romania) In this paper we aim to illustrate the how reverse engineering techniques prove themselves useful in everyday industrys leading technologies. There are presented the processs main phases as well as the schematics of different reverse engineering solutions or used methods, but also the technical considerations standing between good production rates and the limitations of the systems which may tilt the balance in long cost terms. Introduction Reverse engineering is considered, nowadays among the most useful technological processes widely used mainly because of its short term benefits but also because of the increasable shorter period of time to completion [1]. Fig. 1 illustrates the manner in which RE offers the possibility to shorten times between what is designed and what it is produced.
RAPID CONCEPTION

TESTS CAM ADDS VALUE TO THE PRODUCT

CAD

REVERSE ENGINEERING

Fig. 1 Product development cycle The generic process of RE is composed of three steps: scanning, point cloud processing and application specific development of the geometric model. In terms of strategy requirements, we must foresee: - Why use RE to produce one part? - The number of parts to be scanned - Parts dimensions large or small - Parts geometrical complexity - Parts material hard or soft - Parts overall look shiny or opaque - Desired accuracy linear or volumetric Digitization Phases, Technical solutions Phase I Scanning. It involves scanning strategies and the choice of the proper scanning techniques, the preparation of the part to be scanned and the process of scanning itself in order to capture all the required data which illustrate the appropriate geometrical form of the scanned object [2]. Phase II Point processing. This involves importing the points cloud, reducing the noise from collected data as well as the sheer number of points. This is done by using predefined filters.

It is important for the operators to know the algorithms of the filters in order to appreciate correctly which filter is suitable to each task. This also allows us to join multiple data sets, because most times there is more than one scanning sessions to achieve fully geometrical features of the scanned object [1]. Phase III Applications to geometrical model development. CAD models generation from points cloud is probably one of the most challenging operations inside RE technology, mainly because powerful algorithms are required to simulate surfaces accurately [3]. Most of the CAD systems are not designed to storage large amounts of data which is why new RE modules or software solutions are needed in points cloud processing. This phase depends on RE real purpose. For instance, if we scan one machine/tool for injection molding in order to obtain a new one, we would be interested in its geometrical model and the G code for the CNC center. We can also use RE to check what has been produced over what has been designed [2]. Coordinate Machine Measurement CMM CMM is the first of its kind technology which automates the process. A free form surface which is not a plane cannot be measured with traditional equipments like calipers. Those one require special attention. Ones CMM main component is its sensor which is touch-sensitive and coexists on x, y, z axis. Fig. 2 illustrates a CMMs schematics.

Fig. 2 CMM schematically representation CMMs generate points in 3D coordinates as the probe moves along the objects surface. Operators may maneuver manually the probe around the object to gather data or operate in automatic mode in which case the probe will move itself. Different CMM builders offer schemes which are meant to help in path planning for the probe to follow. More advanced systems allow the upload of original CAD model for the machine to establish itself the path planning strategy. The CMM will analyze the CAD model for discontinuities or tight spaces. Tight space is a real big problem because the probe must be in contact with the surface for the measurement to be done accurately [4]. Active 3D stereo Computer based systems tend to develop scanning solutions by means of video cameras. To get 3D information, the most known method would be stereo acquisition, in which two cameras operate like human eyes. The biggest concern is finding a correspondence between one point from the cameras image and the same point from the other ones image. If this is done, we will have a precise stereo map [1]. Active stereo, using laser illumination, allows in

depth measurements far more precise than the traditional methods. There are three categories: continuous wave modulation, time of flight and structured-light triangulation. In Fig. 3 we can observe schematic representations of the three above mentioned categories:
LASER

INITIAL PHASE PHASE DIFFERENCE INITIAL DETECTOR ANGLE B TRIANGULATION LASER LASER P LASER WAVE P OBJECT LASER

r
OBJECT

INITIAL PHASE TIME DIFFERENCE

CAMERA

OBJECT LASER PULS P

DETECTOR

continuous wave modulation

time of flight

structured-light triangulation

Fig. 3 Active stereo Sheet-of-light It projects a light plan over the object in such manner that the plan intersects the object and forms a line. That line becomes a projection on to camera image plan. The main advantage is represented by the speed of data collection comparative to lasers, thats why they are better suited to RE applications [3]. Operations are: the line forming process along the objects surface, triangulation along the line, illumination source and the cameras performance. Fig. 4 illustrates both one scanner using the sheet-of-light method and one using coded light.

sheet-of-light scanner schematic

coded light scanner schematic

Fig. 4 Types of illumination scanners

The coded light method does not use a laser but a projector with patterns installed in front of the lenses. The patterns can have different shapes; one widely used being that of a chess table. By the means of speed, we tend to consider the third one the best, but in reality changing patterns can be quite a time consuming [2]. That why the sheet-of-light method proves to be the best one. Conclusions For starters lets acknowledge that CMMs are mechanical systems. Though computer controlled and using the latest electronics for the measurement system, they are still limited to physics in case of one probe manually handled around the object to be scanned, as close as possible to its surface. Cameras, on the other hand, are sensors capable of measurements from distance and thus require far less mechanical precision in movement. CMM accuracy depends on probes mechanical control but the accuracy of active stereo systems depends on its sensors. Being able to scan over some distance offers two advantages. The first one refers to the possibility to avoid deterioration either of the object or the probe. As one probe moves along the object it may scratch its surface if the user fails to handle it properly. More, if the surface temperature is too hot or too cold the heat transfer may damage the measurement probe. The second advantage is the ease of path planning. At a CMM, the operator must carefully choose the path in order to cover the entire surface of the object, but that doesnt mean avoiding corners. A laser or camera may go around the object to collect measurements in the same way a photographer would takes pictures of the object. But as technology, computer vision is far more expensive than the traditional CMM, and by means of microns in accuracy terms, the CMM proves to be consistent and reliable once more. Acknowledgement: This paper was realized with the support of EURODOC Doctoral Scholarships for research performance at European level project, financed by the European Social Found and Romanian Government. References: 1. Eilam E. Reversing: secrets of reverse engineering. Wiley Publishing Inc., 2005. 2. Ivo Rodrigues Montanha Junior, Andr Ogliari and Nelson Back. Guidelines for Reverse Engineering Process Modeling of Technical Systems, pg. 2-8. 3. C. Martin Schuster, President, Laser Design Inc. Minneapolis, Minnesota. Laser Scanning Improves Reverse Engineering and Inspection Tasks. 9401 James Avenue South, Suite 132, Minneapolis, MN 55431, www.laserdesign.com, pg.1-3. 4. Manzoor Hussain M., Sambasiva Rao CH. and Prasad K. E. Reverse engineering: point cloud generation with CMM for part modeling and error analysis. ARPN Journal of Engineering and Applied Sciences, VOL. 3, NO. 4, AUGUST 2008 ISSN 1819-6608, pg.1-4.