PORTABLE LASER SCANNER AUTOMATES REVERSE ENGINEERING AND PART VERIFICATION

Giles Gaskell, North American sales manager for 3D Imaging Products for Wenzel/Xspect Solutions (Wixom, MI) says, "For anyone who is looking for portable 3D imaging technology for reverse engineering or inspection, the MobileScan3D system provides the quality and repeatability of a CMM-based laser scanner in a portable and highly flexible system."

MobileScan3D's configuration is not constrained by a CMM frame or portable CMM arm and has interchangeable laser sensors to adapt to different sizes and shapes of parts, from jewelry to full-sized automobiles. Because MobileScan3D offers full CNC automatic scanning, the accuracy of the acquired dataset is significantly enhanced over the same data acquired by other portable systems and provides automatically structured and ordered data, minimizing subsequent data 'clean-up' and processing time.

In addition, MobileScan3D can also be used for the verification of production parts against nominal geometry data and can either be used in complete CNC mode or in semi CNC mode where the motors can be disengaged and the laser manually guided to define the scan path before re-engagement for CNC scanning. This semi CNC mode allows for rapid set-up for inspection of one-off parts, according to Gaskell.

MobileScan3D comprises a 2-axis CNC swivel head, providing A and B rotational axes. The scanning sensor is mounted to the swivel head using a quick-change adaptor, minimizing changeover times between the three available sensors. The MobileScan3D laser scanner system consists of a tripod with three interchangeable scanning heads; a 100 mm to 290 mm head with accuracy of ± 0.01 mm; a 400 mm to 570 mm head with accuracy of ± 0.05 mm; a 1000 mm to 1800 mm head with accuracy of ± 0.15 mm and an average line length of 43 mm, 185 mm and 270 mm, respectively.

This system has full 3-axis CNC capability and uses a red laser stripe to scan up to 100,000 points per second. Scanning accuracy down to 10 microns can be achieved with the system. The density of scanned lines can be controlled by programming the velocity of the A and B axes of the swivel head. Integral thermal sensors, with environmental control, insure scanned data set accuracy. The sensor body is manufactured from carbon fiber, eliminating and thermal growth due to heat generated from the laser source. The sensor outer-casing is independently mounted, allowing isolation from the sensor optics and electronics, eliminating the potential for calibration errors caused by rough system handling during transit.

The system is controlled by a PC and a small portable controller. It has the ability to non-contact scan with full CNC control using a very simple operator user interface. The scanned ordered dataset is streamed real-time into the accompanying data evaluation software. A full 3D CAD model can be generated for output in STL, IGES, STEP or ASCII file formats. MobileScan3D can be supplied with the Wenzel Pointmaster V5 software or any of the major reverse engineering and verification software packages.

An optional CNC rotary table is also available. This table has a 75 kg payload and allows for automatically performing the full 360 deg scanning of parts. The rotary table is housed in a rugged carrying case with a total carry weight of less than 10 kg. Leveling feet are designed into the case. Full 3-axis simultaneous scanning motion of the system is available for the most complex geometry parts. The 32 bit CNC controller is also housed with a carrying case with total carry weight of less than 10 kg. The scanning heads pack into three camera cases and can be set up anywhere in minutes.

In operation, the MobileSCan3D system can be set up ready-to-scan in less than 10 min. The complete MobileScan3D system is transported in 2 cases; 3 if the rotary table is included. All of the carrying cases snap together for easy transportation as a single unit, which can be attached to a mobile trolley for added convenience. Interconnecting cables are all color coded and sensor set-up and initiation is very fast. MobileScan3D has the fastest set-up time of all portable technologies providing a true 'Scan-to-Go' solution. MobileScan3D can be used with a tripod for maximum portability or can be mounted to a support table.

MobileScan3D provides automatic and ordered dataset generation. The scanning volume is simply programmed by inputting 3 basic parameters; the A-axis start point and end point; the B-axis rotation angle and index increment. With just a few mouse clicks the complete automatic scanning process is initiated. MobileScan3D removes the operator dependency demanded by all prior art systems, whether portable arm or photogrammetry based, and provides higher accuracy datasets in a fraction of the time.

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