GOM Webinar – Optical 3D Metrology for Automotive Testing

GOM Webinar – Optical 3D Metrology for Automotive Testing


hello everybody and welcome to our gum webinar about optical 3d metrology for automotive testing we are very happy to have you with us my name is dominic machi and together with my colleague Thomas lint I will host this webinar today this webinar will take approximately 45 minutes and we have opened the questions and answer to love the WebEx software so if you have questions please feel free to ask by other Q&A section and we are happy to answer those questions during the webinar and at the end let’s have a look at the agenda what’s in there for you today I want to start with a introduction of the GOM company to see what we are doing and what we can offer you and afterwards we want to jump into a whole bunch of different testing applications where our metrology solutions are used today and to show you how you can benefit from optical metrology so let me start with the company introduction so gom is a producer and manufacturer of optical metrology solutions and geom operates on the market for more than 20 years now and all the metrology solutions that gum offers comprised of hardware and software and are used for 3d coordinate measurements as well as for material and component testing as said before all optical systems are based on the processing of digital images thus this is one of the key no house that gom has and along with this knowledge about digital image processing comes also the application knowledge about the use of the results of the 3d coordinates and this might be in the quality control or material research applications as well as for component testing the company GM is located in Braunschweig in the north of germany and was founded in nineteen nineteen as a spinoff from the Technical University of Braunschweig the company is still privately owned today and also managed by the owners and development production and administration are centred in Braunschweig together with our partner companies we have a strong network all over the globe to support your installations and your requests locally wherever you are on the world with all our partners we have about 800 employees in our worldwide network here’s an extract of our current customer database and as you can see our technology has established across different industry branches and we are very happy to have over 10,000 systems installed worldwide and that we support all these installations this slide shows all the products that gom offers together with typical results that are generated with our metrology metrology solutions and again all systems comprised of hardware and software which is the gum inspect and the gum correlate software let’s have a closer look on to some of these products starting with the 8 o’s 3d scanner of gom this system measures in a non-contact way 3d coordinates all over the surface of your components and thus captures the 3d shape of any part or component and having the precise 3d shape you can use this result to calculate deviations to see ID and to carry out and dimension analysis this leads to different application areas where our 80 system is used today these applications range from quality control to rapid prototyping but also in accompanying the manufacturing or the virtual assembly are done with our systems the 80 s can box is an optical 3d measuring machine that combines goms 3d scanner a test with a standardized robotic measurement cell and thus provides a fully automated set up in terms of the measurement of the 3d capturing of your components and also the inspection later on of these components within in the software as you can see the 80 scan box family can offer solutions for different component sizes ranging from a gear up to a full body in white the try top system is a mobile optical coordinate measuring machine that measures the 3d coordinates of applied measuring markers these measuring markers are sticked to the surface of your testing object and you can use the 3d point cloud for dimensional analysis as well as for 3d displacements and deformation analysis you can see here the system is especially handy when it comes to very large objects and if you want to measure 3d coordinates on these large objects you can see in the example a whole ship was measured with a try top system for retrofit applications to derive dimensional informations about this ship where no see ad file was available this leads me to the aroma system which is our optical metrology solution for the deformation analysis in 3d this system also measures 3d coordinates on the surface of your testing object this might be done in a full field way but as well in a point-based way and the system is capable of tracking these 3d coordinates over time and as you can derive 3d displacements velocities and accelerations as well as calculate the complete strained asst tribution on the surface of your parts and also strain rates if you want to have a look on those measures the error my system is a very flexible system in terms of the applications where it might be used you can see two examples one showing a point based measurement and analysis that was carried out it was a 3d motion analysis of a sled crash test but as well you can use the system in a full field way for material research for example to calculate the strain distribution on the surface of your of your specimens you see the long list having said this again the RMS system is very flexible in terms of the measuring tasks that you can accomplish with it all in all the metrology solutions from gum helped to simplify complex measurement ask both in product development and production by providing clear and complete results that make it easy to discuss about the results and to make people understand what happens during the tests and during these different measuring situations and due to the full field a manner of the of the results it helps also to in increase the product quality and quality assurance throughout the whole lifecycle of your products going over to our applications overview to show you all the applications where our metrology solutions are used today and the system can be used for example for static load tests to analyze these load tests this might be a stiffness analysis where the parts are loaded mechanically or our systems namely the tri-tip system is also used today for measuring environmental tests where components are put into climate chambers and subjected to thermal load or thermal deformation this being another case of static load tests and you can compare these different load cases with our dry top system going over from static to dynamic testing the RMS system is capable of capturing dynamic events and dynamic tests examples range from aerodynamic tests of front bumper and wind tunnel testing over to component testing such as door slam or car a car tire deformation on the testing bench up to really high speed events in the safety and crash engineering world where we use cameras that are capable of capturing images at a very high frequency to be able to sample these events and thus also provide free D data and afridi analysis in these cases we will not cover all of these application examples during the webinar we will jump into some of these and this we will have a closer look to let me start with a static component test example this application example comes from a stiffness analysis that was carried out on the Assembly of the card or in combination with the a pillar or the door hinges on the a pillar and the goal of this test was to simulate the loading conditions on that card or that might occur during the use of the of the passengers of the car and this loading might occur due to people leaning on the upper door frame resting their arms on the window frame of the car door but also people that lift themselves out of their own seats by pulling themselves on the on the window frame or on the handle this might be daily used situations where this loading my toe cure this test was measured in a point wise way and to see the deformation or the displacements on the door hinge and the a-pillar to analyze the performance of these components and also the counter sinking of the door was of interest and at the end also the functional analysis was carried out to see if the door still opens and closes properly after this loading situations let’s have a look on the test setup or the measurement setup all you have to do to prepare your testing object for the measurement with that write-up system is to place scale bars in the onto the component or the testing object and so called coded targets that we use to orientate our images in 3d space and additionally you stick circular point Marcus which are our measuring Marcus and and you stick these markers wherever you want to have 3d coordinates measured and here in this example the stickers or the measuring Marcus were applied onto the car door itself and on the chassis or the the frame surrounding this car door to be able to calculate a rigid body motion compensation afterwards I’m comparing the different load cases there was a measurement carried out with the car door being unloaded and the second measurement was done with having a weight with a defined which induces a defined load onto the car door in this setup and to make measurements you simply go around your parts with the with the measuring camera and take pictures so you don’t have to take your testing object to the measuring room or to fix it in a rigid way to some arm or anything you can go freely around with the camera around your testing object to measure the 3d co-ordinates having said this the initial result is our 3d point clouds for every measuring marker that you sticked to the surface you will have one free d coordinate measured and again we have measured the undeformed and the deformed state and to analyze the deformations we want to or we brought our 3d data into the global car coordinate system by using the CID file so the software is able to import all native cat formats as well as free cat formats and then we transformed our measuring results into this car coordinate system to be able to analyze the deform patience by using a common set of 3d points that were measured we can also reference both point clouds that we captured according to the different load stages and and thus in the way in the end we can derive the 3d displacement of the door having this result that you can see to the right again here it’s a pretty clear and a pretty complete picture in my point of view that you get from this component you have the 3d displacement vectors showing the magnitude in the direction of the displacements happening to each of these point markers and thus I think it’s pretty clear result that shows what happened during this test due to the loading of the car door as we measure in 3d we can also carry out a detailed analysis by looking onto the displacements happening in one spatial direction here in this case we look onto the displacements in the Z Direction showing the counter sinking of the door together with so-called deviation labels that show the numerical values next to the vectors itself another detailed analysis was carried out on the a-pillar or the measuring points from the a-pillar showing clearly what happened to ya the a-pillar due to this loading and also showing the different directions and magnitudes of this displacement again a pretty clear result and a pretty yeah it’s just good to discuss with these kinds of results to make it discussions easier and to shorten these times that needed for discussion going from this application example of a mechanical load test with two states I want to present to you another a static load test that was carried out in a thermal chamber here a front bumper was measured once at room temperature and taking this measurement as the reference and then a second measurement was carried out at a elevated temperature and as you can see the preparation again takes maybe five to ten minutes all you have to do is to place the stickers the measuring markers place your scale bars and the coated targets and then go around with your camera to capture the 3d coordinates here’s the result from the comparison of the 3d point clouds once measured at 85 degrees C in this case compared to the room temperature and again you see the the vectors showing the magnitude and direction of displacement for each of these measuring Marcus due to the thermal loading of this component you can also use the try tub measuring system for a gap change analysis so by placing measuring markers on both sides of your components that you want to analyze the gap in between you can easily carry out this gap change analysis to see how this gap widens or shrinks due to the thermal deformation here’s another example showing the gap change of another feature from the front bumper all this is done based on the same raw data that you capture with the try top system this brings me to a first dynamic component test example where our metrology solutions were used here we measured the door slam test and this test is carried out to simulate a misuse of the car door by passengers slamming them with high high speed and of interest of course is the motion behavior of the door but also to find out what is the performance of the damping materials is it working properly and this might be derived from the magnitude of vibrations happening to the outer door panel and at the end again to see if the function of the door is still correct so is the door closing and opening properly how to cope with these kind of dynamic events with our optical metrology we can measure these kinds of events by using cameras or sensors that have a high image recording frequency here in this case we measured the event with 500 images a second and thus were able to sample multiple 3d data sets during this short time event again the the measuring setup is very easy and goes or it takes not a long time to prepare your testing object for the measurement again we placed these measuring markers on our testing object we have placed them for sure on the component the car door the window and window frame itself as we want to analyze that the displacements happening to this component and on the other hand we apply these markers also around on the chasis again to carry out a rigid body motion compensation as this whole test setup will move due to the unloading by the door slam here’s a typical result that is generated with our Aramus system showing the captured video overlaid with the 3d displacement vectors that are showing for each point marker the magnitude and the direction of the 3d displacements and again you get a clear and complete picture about the displacement patterns of your component you can clearly see these waves of displacements of wandering through the component due to the to the door slam and as you can see the holy one took only a hundred milliseconds nevertheless we have multiple 3d data sets that captures this event of course you can also inspect single points of these of our measurement setup individually and also plot results in two diagrams this is all done with our software so the reporting is completely integrated and you can just create these kind of measuring reports out of the box with our software another great feature of this system is to be able to analyze the six degree-of-freedom four components that you that you prepared with these markers so we captured the displacements of these of the point markers or this component and grouping them together we can track also the rotations of this whole point group over time during this test so you can see in this example the rotation around the x-axis which is again in the car coordinate system and this arrow showing the direction of the rotations that this component undergoes you to the door slam and again you can plot these results in the diagram for having the visualization that you can see over here going from the door slam test to another dynamic component testing of a rotating object and at this point I want to hand over to my colleague Thomas Lind who will share this application example and the following ones with you Thank You Dominic and too low to y’all i’m thomas linton i will go through the next couple of explanations and the next couple of applications so now we start with our quite high and dynamic application it’s the analysis of a demotion of a cooling fan and first be a little bit discuss about what is behind the motivation and behind the background so the cooling fan has got high thermal influence in the engine compartment and there you have a lot of deflection and deformation which is happening during during the run so you have got wobbling effects you have got deflection effects and you want to see the deformation and the behavior of this cooling fan during the run-up or during the running phase in different temperatures so you’ve got a high risk of hitting further components and this is not very nice also it’s quite tight in the engine compartment and don’t want to lose too much space for deflection of the cooling fan we first marked our element so we put on all reference markers or ritual reflective points on the frame on the blade on each blade and on the center hub we also have the possibility to align our measurement to the cut models as you see here we had a cut model available and we align our measurement so that the z axis which you see here is the blue axis is the round our is the out-of-plane axis here in this case and we are expecting specting our element to the Z direction and want to see the out of plane displacement here we furthermore created a rigid body motion compensation in order to compensate the motion of the center hub this was carried out due to the fact too that we see the only the deflection and deformation of the blade referred to the center hub and generate the measurement result like you see here we have got some image mapping overlay functionalities and some mapping functionalities this looks quite quite stable and but in the end it is a very high very high motion you see here so we are going from 0 up to 3,000 rpm and we have got an image frequency recording of 500 FPS so we see here quite nice that the outer blades have got quite a high deformation relative to the center hub of up to two millimeters this measurement was carried out in at room temperature and you can imagine that in an engine compartment the temperatures are way higher and also the plastic has got way higher thermal in is way higher thermal influenced and reflections is going more and more and is increasing of course you can only you can also see this evaluation by inspecting point point wise elements so by showing the vector field is one possibility also you can plot directly the point coordinates here in this case it’s the point displacement in the Z direction so the out-of-plane direction of the cooling fan into the diagram and you see here quite nice that are the outer areas you have got high deformation and you’ve got the information from the inner area to the outer area up to nearly two millimeters and the room temperature the next application and what you share with you is the motion analysis of an engine during the start-up phase and here in this case it’s a cold start up phase so again a little bit about the motivation and the background of the measurement the engine is undergoing a huge motion during the startup and during the first ignition until you have an idol running this is quite interesting to see in order to have a look at the day at the motion and if you and you can see also the risk of fitting for the components like the air intake for example so we do not want to have any impact in the engine during running we just had a little note here in our presentation so if you have got some questions about the presentation you can feel free to ask during the presentation a Q&A section and my colleague Dominic will answer the questions directly and also after the presentation we have a little Q&A section so we still stay online there was just one little question which came up is the presentation available afterwards yes this presentation and also the audio recording will go up to youtube and there you can look at the presentation and the recording afterwards okay we go back to our presentation here you see the marking of the engine compartment with the markers on the engine cover the markers on the chassis and the markers on some components like the air intake or the battery cover luckily we had a 3d measurement of the engine cover and we aligned our elements and we align our measurement to the cut model and then we are in the coordinate system which is quite nice so we can really inspect every point of our measurement markers in 3d coordinate direct this measurement result is also be also reasonably here quite nicely and you see the deformations and just you see them definitely see the motion of the points during the ignition and it’s quite nice to see that the in the idle running you have got quite high motion of the engine until it smoothly running as already mentioned you can also analyze the points in for the different coordinate directions and you can plot them automatically in the diagram but not only the engine cover itself is of interest also the parts near the engine cover is quite interesting so here you see the emotion of the air intake and of the other elements during the startup and also this elements these elements can be evaluated afterwards due to their coordinate directions a big aspect in the automotive world our wind tunnel tests so the internal tests in general are quite important to see the overall car performance and in real-life conditions so aerodynamic tests are carried out quite often to see the two to see the aerodynamic behavior of the car in general and with this information you can also it’s possible to lower fuel consumption and it’s quite important to see this in in flow field studies in general it’s quite obvious that you carry out a lot of numerical simulations because this wind tunnel tests are quite expensive and with our optimal quality we contribute 3d measurement data which can be then taken to validate Fe models as an example for this you see here a Formula One car on a tire flat track and we have got here the video is going as a run-up so we go here up to a speed of 300 km/h and you see quite nicely the measurement markers which are applied on the front cover and on the bumper so also here we made two point groups let’s say we had a point group of the front cover which you see here in green points and we got point group of the bumper is in blue points again we have a rigid body motion compensation carried out on the front cover so we want to see the deformation of the bumper relatively to the front cover furthermore we made a little bit of an alignment here in this case that the blue arrow you see here is perpendicular to the ground and you see the z axis here is like what you expect to be have the counter sinking here the bumper deflection is quite nicely and quite easy to see you have got deflection which is going up to minus six or even more millimeters in the direction of the ground and the bumper is getting nearer to the to the ground or fantastic which is quite nice at high speeds that we’ve got a lower resistance here in this case we also can see these measurements in terms of pointwise analysis and here at the bottom left we’ve got the highest deflections here which is going up to minus eight point five millimeters from at the highest speeds what you can also do you can take some image series at stable conditions so here we took some images images of a conditions at different velocities and in the end you carry out quite a nice analysis and you see the velocities are derived and written on the y-axis at the other side the deflections in that direction are written on the y-axis and on the x-axis you see the different speeds so it’s quite obvious and quite interesting to see the bumper deflection at different velocities so now we are going even faster we are looking at crash and safety aspects with our optical metrology and we go into the world of the airbag deployment we see here the next couple of slides about the deformation of epic housing so airbag housing is quite critical in this case it’s it’s very interesting to see the opening behavior of the airbag housing because if the opening behavior of the airbag housing is not like it should be the whole avec effect is not really working properly and there’s a high risk of hitting the passenger so the epic has to be has to open in the way it should open and the airbag deployment itself only takes some milliseconds so we have to acquire many many images in a very short time and here for this case we have got external high-speed cameras and in the next little video you see how fast this movement and this measurement is going to happen so you really see with the normal I it’s nothing was not possible to see but with very high speed cameras it’s very easy to see and this is what comes out in the end so here in this video we see displacement that so it’s all so again the out of plane displacement and you see the ignition you see the shockwave going through the specimens cover and through the cover of the airbag and in this case you see the opening behavior and opening structure of the avic cover really important at this measurement is that effect infected that the a back cover is opening at the outer stitching so the ever cover should always open at them directly at the stitching area if not the the air bag is not working properly and you’ve got a high risk for the passenger so this is why this measurement was carried out this way and it’s very nice and easy to see at where the air brake cover is opening and what our displacements in the out-of-plane direction another safety and crash aspect is a sled crash test so let a dummy placed on a sled is driving or driving against the wall here in this case and so this measurement was taken at speed of 25 km/h and to see very nicely and very nice the overall evaluation of the motion so the head is undergoing the highest motion in this case but you also see the motion of the seat and the motion of the legs and this is just a little little showcase there are many many more possible evaluations like six degrees of freedom analysis trajectory analysis and furthermore analysis but in this case we wanted to go to the next slide in order to take not too much time for to explain all in detail we got also the side impact crash test as little application recover so here we’ve got an impact with 50 km/h from a site in this measurement is carried out in order to see the deformation of the passenger compartment so the intrusion of the b-pillar going into the passenger safety area and also here we had some point markers on the b-pillar on the front side which are visible here in this case so you see the points here and you see also the points placed here in the back and what we did we made an RV MC over this point group here so we see the difference between the point group you see here and the point group you see here in order to subtract the rigid body motion of the overall car and in the end we only see in the diagram the intrusion of the three points in a certain direction as little summary we just showed some some applications and we just showed some possible evaluations which are easy possibly with our measuring with our optical metrology we have got a wide range of application areas like vibration like stiffness up to up to going to very high crash and safety tests for pedestrian etc in the end nearly everybody wants to verify a numerical simulations with real life data and this is what you get from our metrology if you want to see some more information we just released a new software which is called Don correlate calm correlate is acting as a free evaluation software and it’s very easy to share with this software results within my colleagues or within the departments and also within your university or student colleagues so you can just use the software and evaluate already existing projects and evaluate for the projects so just feel free to go to the gong correlate website this is a free software just feel free to download they are also assemble data available just play around that you see how the software looks like and how it feels okay also as I mentioned we stay a little bit online some more minutes if you have some questions feel free to place them in the Q&A section we will answer all your questions so no worries about that and also this recording will be uploaded in the next couple of days to our YouTube channel it’s the gamma quality channel and you will find many many more information about our products in bout our above the applications we are covering on our youtube channel with dominic and me with thank you for our attention and we’re happy to answer your question in the Q&A section thank you


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