SBIR-STTR Award

An accurate, non-contact system is proposed for automated 3D measuring and modeling of aircraft, aircraft parts, and associated equipment, especially stores (bombs, additional fuel tanks, etc.). It will replace currently-used systems that require extensive operator involvement in both measuring and modeling. The proposed system has two components: an existing state-of-the-art measuring system and a chosen state-of-the-art modeling system. The proposed research is aimed at optimizing, customizing, and integrating these two components into a fully automated, highly accurate, non-contact measuring and modeling system. The measuring component is a high-power projector system with innovative hardware and software, emerging as the most successful in target-free digital photogrammetry. It shows superior automation, accuracy, and reliability in many industrial applications, such as measurement and processing for antennas, automobiles, and aircraft. The modeling component, to be selected in Phase I from several advanced software packages, will transform 3D point clouds generated by the measuring system into useful 3D models, such as polygons and NURBS surfaces. Automation and faithful representation of measured surfaces will be crucial in this process. Research performed in Phase I will focus on further software automation, optimization, and customization, and on seamless data transfer between the two components.The proposed non-contact, automated measuring and modeling system is anticipated to have a substantial market in aerospace, automotive, nuclear-power, and other industries, as well as in the military and in federal government agencies. Many tasks in manufacturing demand high accuracy and automation, which makes the system attractive, e.g., for reverse engineering, inspection of tools and parts, precision alignment, and deformation monitoring. Deformation-analysis capabilities can benefit agencies concerned with transportation safety and accident investigation, or with ruggedness of military hardware tested after a simulated explosion. The proposed system can be of significant value to quality control in antenna manufacturing, by virtue of innovative software allowing the shape of an antenna to be instantly analyzed and compared to design.

The Air Force topic "Automated Surface Mapping and 3D Model Generation" calls for measuring and modeling of aircraft, aircraft parts, and stores in a non-contact and automated manner. Two components of an automated 3D measuring and modeling system were identified and evaluated in Phase I, which will satisfy all requirements and needs of the Topic. The photogrammetric component using non-contact targeting, and the modeling component creating NURBS surfaces will be integrated into a system capable of producing near-error-free surfaces. This system will be able to successfully measure and process dark surfaces and surfaces of different materials, colors, and textures. It will operate indoors or outdoors, in daylight or darkness, and, especially, in unstable environments. This last capability is crucial when measuring aircraft or aircraft parts in windy conditions. The primary task is to establish procedures and protocol for the integration of the components. Other tasks include the interface between them, especially for measurement-error detection by the modeling component; automation; and optimization. Photogrammetric tasks ensuring 3D integrity of the results in all situations include algorithms enhancing 3D accuracy and reliability, especially in unfavorable measurement configurations; detecting outliers and increasing the system's robustness; and reducing or eliminating regional 3D deformations. It is anticipated the prototype system will be unsurpassed in the areas of speed and volume of measured and processed data, in accuracy, as well as in automation, robustness, and versatility