ddi dense point cloud processing presentation oct 2009

Dense 3D Scan Point Cloud Dense 3D Scan Point Cloud Processing Software ReviewProcessing Software Review

Peter KennedyPeter Kennedy

Michael RaphaelMichael Raphaelwww.directdimensions.comwww.directdimensions.com

[email protected]@[email protected]@dirdim.com

410-998-0880410-998-0880

http://www.directdimensions.com/

• About Direct Dimensions, Inc.

• Technical Expertise Areas

• Products and Capabilities

• Typical Workflow

• Points to Polygons

• Case Studies – C5A Interference Study– Texas A&M NASA Gulfstream 2– Graving Dock

• Interactive Discussion

Table of ContentsTable of Contents


rapid solutions to 3D problems...rapid solutions to 3D problems...Direct Dimensions, Inc.Direct Dimensions, Inc.

• Leading Experts in Close-Range 3D Imaging• Widest Toolset for Portable 3D Metrology• Specialists in Manufacturing Problems• Reverse Engineering to CAD Models

• Raw Data into Surfaces & Solids• Engineering for “Design Intent”

• Complex 3D Inspection and FAI’s• Thousands of Successful Projects• 14-years of Experience, Staff over 20• One-Stop-Shop for Expert 3D Scanning

Technical Expertise AreasTechnical Expertise Areas

Military/AerospaceMilitary/Aerospace AutomotiveAutomotive IndustrialIndustrial

Consumer ProductsConsumer Products MedicalMedical Art/ArchitectureArt/Architecture

1000s of Projects for 100s of Customers1000s of Projects for 100s of Customers

Direct Dimensions, Inc.Direct Dimensions, Inc.

Hardware• FARO Portable CMMs & Scanners • FARO Large-Volume Scanners• LDI SLP Laser Scanner• Basis Software Surphaser• Steinbichler Comet 5 White-Light• Kreon Zephyr Laser Scanner• Konica Minolta VIVID and Range7• ViALUX z-Snapper 3D Camera

Software• PolyWorks • Geomagic• Rapidform• Imageware• 3D-Doctor• Pointools• FARO CAM2• Rhino3D• RevWorks• Verisurf

Products and CapabilitiesProducts and CapabilitiesDirect Dimensions, Inc.Direct Dimensions, Inc.

Example Data Alignment and Processing Software

Typical Dense Point Cloud Processing WorkflowTypical Dense Point Cloud Processing Workflow

Example Data Collection Equipment

Aligned Point Clouds and Polygonal Models

Aligned Point Cloud Polygonal Model

Final CAD

Typical Dense Point Cloud Processing WorkflowTypical Dense Point Cloud Processing Workflow

Modeling Software

Points to PolygonsPoints to PolygonsDense Point Cloud Polygon Model Creation

• User has large amount of control • Distributed processing • Still a significant time investment

with a high density point cloud

Do not take advantage of distributed processing at this time

C5A Interference StudyC5A Interference StudyProject OverviewProject Overview

• Customer Interested in virtual test fit of a large cargo pallet

• Massive interior cabin also contains many small components required by customer

• Interior cabin measurements:• 121 feet long

• 13.5 feet high

• 19 feet wide

• Large Scale Object including Small details required high resolution scans

C5A Interference StudyC5A Interference StudyDetail OverviewDetail Overview

C5A Interference StudyC5A Interference StudyMeasurement ToolsMeasurement Tools

Surphaser HSX IR 3D Spherical Laser Scanner

Faro Laser Tracker

C5A Interference StudyC5A Interference StudyScanning ApproachScanning Approach

C5A Interference StudyC5A Interference Study

Sphere Location Close-Up

• Approximately 2 billion points collected• Very large file sizes- File I/O slow• Must retain full resolution on small details throughout the aircraft • Project timeline- 4 weeks total from scanning to delivery of engineered surface model

C5A Interference StudyC5A Interference StudyProcessing ChallengesProcessing Challenges

C5A Interference StudyC5A Interference StudyProcessing SolutionsProcessing Solutions

High-End Workstations accelerate processing and alignment - Dual quad core cpu’s- Nvidia Quadro FX4600 GPU-16GB+ RAM-15,000 RPM SAS hard drives

• 64-bit PolyWorks V10 utilized for alignment of Surphaser scans• N-pairs of center points alignment in IMinspect module used

• Multiple Users align scans to Laser Tracker coordinate system concurrently• Section out specific areas of interest for full resolution and decimate remainder• Break up large point clouds into manageable sections for downstream CAD work

NASA Gulfstream IINASA Gulfstream IIProject OverviewProject Overview

Vortex generators on top of wing

• Customer designing new wing and needed a model of current configuration

• Scanned using Surphaser HSX IR• No tracker used for coordination• Small details required very high resolution

scans (ex. vortex generators)• PolyWorks used for alignment and point

cloud export• Imageware used for modeling• SolidWorks utilized for stitching surface

models into solids

NASA Gulfstream IINASA Gulfstream IIProject ChallengesProject Challenges

• Capturing entire airplane at resolution required for smallest detail

• 38 Surphaser scans containing roughly 2 billion points (not all scans full 360 degrees)

• Ensuring scan encompassed all areas of interest

• Scan alignment without master coordinate system from laser tracker

• Chrome surface finish on leading edges of wings and engine nacelles

NASA Gulfstream IINASA Gulfstream IIProject SolutionsProject Solutions

• Utilized high-end workstations running 64-bit PolyWorks V10.1.17 to import PTX files for alignment and export of clean point clouds

• Paid special attention to ensure comprehensive scan coverage • Adequate coverage of spheres critical to alignment quality• Took obvious occlusions such as engine pylons and wings into account

• Iteratively aligned scans using 6” spheres placed on and around the aircraft• Proved to be more difficult than the laser tracker approach

• Blue painters tape was applied to shiny areas on the aircraft

• Existing condition of 1960’s-era dry dock

• Structural failure occurred

• 800’ long, 75’ high, 100-ft across

Graving DockGraving DockElectric Boat Corp.Electric Boat Corp.

• Raw data assembled virtually and organized into geographical segments


• Portions of the finished polygon shell

• High level detail allows for accurate analysis


• Polygons were then NURBS surfaced

• Final model as a solid in Pro-E

• 3 different models assembled: Coffer Dams (gray), Rock Wall (red), Concrete Columns (blue)



Thank You!Thank You!Questions?Questions?

Michael Raphael Michael Raphael

and and

Peter KennedyPeter Kennedywww.directdimensions.comwww.directdimensions.com

[email protected]@[email protected]@dirdim.com

410-998-0880410-998-0880

http://www.directdimensions.com/

ddi dense point cloud processing presentation oct 2009

Technology