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OPTOCAT UserGuide Old

OPTOCAT 2009 CURRENT VERSION Content Safety instructions. 7 General hints for a good measurement. 9 system components. 11 Connections optoTOP and optoLINK.

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100% found this document useful (1 vote)

2K views280 pages

OPTOCAT UserGuide Old

OPTOCAT 2009 CURRENT VERSION Content Safety instructions. 7 General hints for a good measurement. 9 system components. 11 Connections optoTOP and optoLINK.

Uploaded by

helderbcsantos

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

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Brief Instruction Manual

stereoSCAN3D, smartSCAN3D, optoTOP, naviSCAN

OPTOCAT 2009 CURRENT VERSION

Content

Content
1 2 Safety instructions and general hints.............................................................. 7
1.1 1.2 2.1 2.2
2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7

Safety instructions.................................................................................................. 7 General hints for a good measurement .................................................................. 7 System components .............................................................................................. 9 Setting up the hardware ........................................................................................11
Connections stereoSCAN and optoLINK ...................................................................... 11 Connections optoTOP and optoLINK .............................................................................. 12 3D Connections smartSCAN (SE version) and optoLINK .................................................. 13 3D Connections smartSCAN -HE and optoLINK ................................................................ 14 Connections on the optoLINK I ........................................................................................ 15 Connections on the optoLINK II ....................................................................................... 17 Connections on the computer .......................................................................................... 18
3D

Setting up the system ....................................................................................... 9

2.3
2.3.1 2.3.2 2.3.3 2.3.4

Software installation ..............................................................................................19

Requirements................................................................................................................... 19 Setup 3GB mode ............................................................................................................. 20 Installation of OPTOCAT 2009 ........................................................................................ 20 Manual driver installation ................................................................................................. 26

2.4
2.4.1 2.4.2 2.4.3 2.4.4

Additional software tools .......................................................................................27

OLWizard ......................................................................................................................... 27 BCAM Viewer................................................................................................................... 28 XNView ............................................................................................................................ 29 Remote control................................................................................................................. 29

2.5
2.5.1 2.5.2

Measurement volume and working distance .........................................................30

stereoSCAN .................................................................................................................. 30 optoTOP........................................................................................................................... 30
3D

OPTOCAT basics ............................................................................................. 31

3.1 3.2
3.2.1 3.2.2 3.2.3

Starting OPTOCAT ...............................................................................................31 General functions in OPTOCAT ............................................................................31

Change Unit ..................................................................................................................... 32 Movement and marking ................................................................................................... 32 Context menu................................................................................................................... 33

3.3 3.4
3.4.1 3.4.2 3.4.3 3.4.4 3.4.5

Data formats .........................................................................................................38 Brightness adjustment for a scan ..........................................................................39

Lookup Tables ................................................................................................................. 39 Ambient Light ................................................................................................................... 39 Brightness Dialog ............................................................................................................. 40 Brightness Adjustment ..................................................................................................... 41 Multiple Exposures .......................................................................................................... 44

3.5
3.5.1 3.5.2

Manual Masking ....................................................................................................45

Manual 2D-Masking ......................................................................................................... 45 Manual 3D-Masking ......................................................................................................... 47

OPTOCAT task overview ................................................................................ 48

4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 Initialisation ...........................................................................................................48 Calibration.............................................................................................................48 Scan .....................................................................................................................48 Processing ............................................................................................................49 Inspection .............................................................................................................49 Tools .....................................................................................................................49 Support .................................................................................................................50 Customer ..............................................................................................................50 Project define ........................................................................................................51 Project predefines .................................................................................................52 Scanner initialisation .............................................................................................52 Initialisation dialog.................................................................................................53

Initialisation ..................................................................................................... 51
5.1 5.2 5.3 5.4

Content

5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.4.7 5.4.8 5.4.9 5.4.10 5.4.11 5.4.12 5.4.13 5.4.14

Capture ............................................................................................................................ 53 Masking ............................................................................................................................ 54 Triangulation .................................................................................................................... 55 Mesh Filter (Only Admin Mode) ....................................................................................... 57 Processing ....................................................................................................................... 58 Texture ............................................................................................................................. 59 Indexmarks (For Index Mark Matching and Reference Matching only) ........................... 60 Find (For Index Mark Matching and Reference Matching at Admin Mode only) ............. 61 Reference ( For Index Mark Matching and Reference Matching at Admin Mode only ) . 63 Edge Detection ................................................................................................................ 64 Information ....................................................................................................................... 65 Options ............................................................................................................................. 66 Advanced (Only Admin Mode) ......................................................................................... 67 Template (for task Parameter only) ................................................................................ 68

Calibration........................................................................................................ 69
6.1
6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.1.6 6.1.7

Calibration stereoSCAN3D .....................................................................................69

Changing the Field of View of a Sensor .......................................................................... 69 Preparations..................................................................................................................... 71 Adjust Sensor.................................................................................................................. 73 Sensor Calibration ........................................................................................................... 75 Visualisation ..................................................................................................................... 83 Phase Correction ............................................................................................................. 83 Fast Grab Delay ............................................................................................................... 84

6.2
6.2.1 6.2.2 6.2.3 6.2.4 6.2.5

Calibration smartSCAN 3D .....................................................................................87

Changing the Field of View of a Sensor .......................................................................... 87 Preparations..................................................................................................................... 88 3D Sensor configuration and calibration strategy for smartSCAN ..................................... 90 3D 3D-HE smartSCAN -duo and smartSCAN ......................................................................... 91 3D smartSCAN -basic ......................................................................................................... 95

6.3
6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 6.3.7 6.3.8

Calibration optoTOP .............................................................................................96

Changing the Sensor Field of View ................................................................................. 96 Preparations..................................................................................................................... 98 Identification of Calibration Plates ................................................................................... 99 Adjust Sensor................................................................................................................. 100 Sensor Calibration ......................................................................................................... 106 Visualisation ................................................................................................................... 113 Phase Correction ........................................................................................................... 113 Fast Grab Delay ............................................................................................................. 113

Scan ................................................................................................................ 114

7.1 Contour matching................................................................................................115
Preparation of the measurement ................................................................................... 115 Initialisation .................................................................................................................... 115 Scan ............................................................................................................................... 116 Pre-align......................................................................................................................... 117 Align ............................................................................................................................... 118 Processing ..................................................................................................................... 120 Parameter ...................................................................................................................... 120 Brightness ...................................................................................................................... 120 Load ............................................................................................................................... 121 Save ............................................................................................................................... 123 Preparation of the measurement ................................................................................... 124 Initialisation .................................................................................................................... 125 Scan ............................................................................................................................... 125 Align ............................................................................................................................... 127 Processing ..................................................................................................................... 128 Parameter ...................................................................................................................... 128 Brightness ...................................................................................................................... 128 Optimize PNT................................................................................................................. 129 Load ............................................................................................................................... 129 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.1.6 7.1.7 7.1.8 7.1.9 7.1.10

7.2
7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6 7.2.7 7.2.8 7.2.9

Index mark matching ...........................................................................................124

Content

7.2.10 Save ............................................................................................................................... 129

7.3

Reference matching ............................................................................................130

Preparation of the measurement ................................................................................... 131 Photogrammetry ............................................................................................................ 132 Initialisation .................................................................................................................... 132 Scan ............................................................................................................................... 132 Align ............................................................................................................................... 134 Processing ..................................................................................................................... 134 Parameter ...................................................................................................................... 134 Brightness ...................................................................................................................... 135 Load ............................................................................................................................... 135 Save ............................................................................................................................... 135 Initialisation .................................................................................................................... 136 Scan ............................................................................................................................... 136 Parameter ...................................................................................................................... 136 Brightness ...................................................................................................................... 136 Grab ............................................................................................................................... 137 Masking .......................................................................................................................... 137 Manual masking ............................................................................................................. 137 2D-Filter ......................................................................................................................... 138 Sort ................................................................................................................................ 138 Load ABS ....................................................................................................................... 138 Save ABS....................................................................................................................... 138 Initialisation .................................................................................................................... 139 Collect ............................................................................................................................ 139 Optimize ......................................................................................................................... 141 Parameter ...................................................................................................................... 141 Brightness ...................................................................................................................... 141 Load Marks .................................................................................................................... 142

7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6 7.3.7 7.3.8 7.3.9 7.3.10

7.4

Single Scan.........................................................................................................136

7.4.1 7.4.2 7.4.3 7.4.4 7.4.5 7.4.6 7.4.7 7.4.8 7.4.9 7.4.10 7.4.11

7.5
7.5.1 7.5.2 7.5.3 7.5.4 7.5.5 7.5.6

Collect Marks ......................................................................................................139

7.6

Automatic ............................................................................................................143
Initialisation .................................................................................................................... 143 Teach ............................................................................................................................. 143 Measure ......................................................................................................................... 151 Single Scan .................................................................................................................... 158 Parameter ...................................................................................................................... 160 Align ............................................................................................................................... 161 Processing ..................................................................................................................... 161 Load ............................................................................................................................... 162 Save ............................................................................................................................... 162 Additional Information .................................................................................................... 163 Initialisation .................................................................................................................... 165 Teach ............................................................................................................................. 167 Scan ............................................................................................................................... 168 Align ............................................................................................................................... 168 Save MAT ...................................................................................................................... 169 Processing ..................................................................................................................... 170 Parameter ...................................................................................................................... 170 Brightness ...................................................................................................................... 170 Pre-Align ........................................................................................................................ 170 Load ............................................................................................................................... 172 Save ............................................................................................................................... 172 Initialisation .................................................................................................................... 174 Combine Systems .......................................................................................................... 174 Scan ............................................................................................................................... 178 Optimize Alignment ........................................................................................................ 178 Processing ..................................................................................................................... 179 Parameter ...................................................................................................................... 179

7.6.1 7.6.2 7.6.3 7.6.4 7.6.5 7.6.6 7.6.7 7.6.8 7.6.9 7.6.10

7.7

Multi Sensor ........................................................................................................165

7.7.1 7.7.2 7.7.3 7.7.4 7.7.5 7.7.6 7.7.7 7.7.8 7.7.9 7.7.10 7.7.11

7.8
7.8.1 7.8.2 7.8.3 7.8.4 7.8.5 7.8.6

Metronor .............................................................................................................173

Content

7.8.7 7.8.8 7.8.9

Brightness ...................................................................................................................... 179 Load ............................................................................................................................... 179 Save ............................................................................................................................... 179

Processing ..................................................................................................... 180

8.1
8.1.1 8.1.2 8.1.3 8.1.4 8.1.5

Re-Processing ....................................................................................................180
Toolbar ........................................................................................................................... 180 Load Project ................................................................................................................... 180 Parameter ...................................................................................................................... 180 Load ............................................................................................................................... 180 Save ............................................................................................................................... 181

8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11

Parameter ...........................................................................................................181 Merge .................................................................................................................181 Smooth ...............................................................................................................185 Cut index marks ..................................................................................................185 Fill holes .............................................................................................................186 Compress ...........................................................................................................186 Load....................................................................................................................186 Save ...................................................................................................................187 Scan View ...........................................................................................................187 Functions for Processing.....................................................................................187 Load....................................................................................................................188 Save ...................................................................................................................188 Functions for Inspect 1 ........................................................................................188
Mesh comparison .......................................................................................................... 188 Fit plane ......................................................................................................................... 189 Fit cone .......................................................................................................................... 190 Fit sphere ....................................................................................................................... 191 Fit dumbbell ................................................................................................................... 192 Fit cylinder...................................................................................................................... 193 Write PTS to ASCII ........................................................................................................ 194 Create ............................................................................................................................ 194 Construct........................................................................................................................ 197 Intersect ......................................................................................................................... 204 Measure ......................................................................................................................... 207 Inspect surface point ...................................................................................................... 210 Make sections ................................................................................................................ 210 LUT attrib ....................................................................................................................... 211 Compare PNT file .......................................................................................................... 212 Coord system 321 .......................................................................................................... 212 Coord system from planes ............................................................................................. 213 Move container .............................................................................................................. 213 Container clear............................................................................................................... 214 Container erase ............................................................................................................. 214 Select intersection ......................................................................................................... 214 Select Shell .................................................................................................................... 215 Change selection ........................................................................................................... 215 Snapshot 3D .................................................................................................................. 215 SOI compensation ......................................................................................................... 216 SOI compare .................................................................................................................. 216 N-Point Align .................................................................................................................. 217 Mesh Align ..................................................................................................................... 218 Mesh Align Extended ..................................................................................................... 219 Sensor Volume and Position ......................................................................................... 220 Smooth Group................................................................................................................ 220 Merge ............................................................................................................................. 221 Mesh Optimization ......................................................................................................... 221 Flip Mesh Normal ........................................................................................................... 222

Inspection ...................................................................................................... 188

9.1 9.2 9.3

9.3.1 9.3.2 9.3.3 9.3.4 9.3.5 9.3.6 9.3.7 9.3.8 9.3.9 9.3.10 9.3.11 9.3.12 9.3.13 9.3.14 9.3.15 9.3.16 9.3.17 9.3.18 9.3.19 9.3.20 9.3.21 9.3.22 9.3.23 9.3.24 9.3.25 9.3.26

9.4
9.4.1 9.4.2 9.4.3 9.4.4 9.4.5 9.4.6 9.4.7 9.4.8

Functions for Inspect 2 ........................................................................................217

Content

9.4.9 9.4.10 9.4.11 9.4.12 9.4.13 9.4.14 9.4.15 9.4.16 9.4.17 9.4.18 9.4.19 9.4.20 9.4.21 9.4.22 9.4.23 9.4.24 9.4.25 9.4.26 9.4.27 9.4.28 9.4.29

Clean Mesh .................................................................................................................... 222 Mesh Outlier Detection .................................................................................................. 223 Visualize Mesh Reliability .............................................................................................. 223 Find Holes In Mesh ........................................................................................................ 223 Fill Holes ........................................................................................................................ 224 Cut Mesh........................................................................................................................ 224 Filter Mesh ..................................................................................................................... 225 MultiVis Dialog ............................................................................................................... 225 Snapshot 3D .................................................................................................................. 225 Edge Merge ................................................................................................................... 226 Edge Fit .......................................................................................................................... 227 Edge Filter...................................................................................................................... 228 Compress NetLine ......................................................................................................... 229 Edge Average ................................................................................................................ 229 Edge Connect ................................................................................................................ 231 Mesh Extend to Edge .................................................................................................... 232 Clean Mesh (all) ............................................................................................................. 233 Mesh Outlier Detection (all) ........................................................................................... 233 Compress Mesh (all) ...................................................................................................... 234 Filter Mesh (all) .............................................................................................................. 234 Save All Meshes (all) ..................................................................................................... 235

10 Tools ............................................................................................................... 236

10.1 Check system .....................................................................................................236
10.1.1 Check calibration ........................................................................................................... 236 10.1.2 VDI 2634 ........................................................................................................................ 237 10.1.3 Log View ........................................................................................................................ 238

10.2

Calibration...........................................................................................................238
Sensor calibration .......................................................................................................... 238 Check calibration ........................................................................................................... 239 Projector calibration ....................................................................................................... 240 Scale calibration............................................................................................................. 241 Set scale ........................................................................................................................ 242

10.2.1 10.2.2 10.2.3 10.2.4 10.2.5

10.3

Photogrammetry .................................................................................................242

10.3.1 Evaluation ...................................................................................................................... 242 10.3.2 Save Reference ............................................................................................................. 242 10.3.3 Load Reference ............................................................................................................. 242

10.4

Feature lines .......................................................................................................243

10.4.1 Load ............................................................................................................................... 243 10.4.2 Feature Lines ................................................................................................................. 243 10.4.3 Save ............................................................................................................................... 244

10.5 10.6 10.7

BRE Export .........................................................................................................244 Temperature .......................................................................................................245 2D Window .........................................................................................................245

10.7.1 Abssensor ...................................................................................................................... 245 10.7.2 Abs Init ........................................................................................................................... 245 10.7.3 Abslimits ......................................................................................................................... 246 10.7.4 Abslight .......................................................................................................................... 247 10.7.5 Abslaser ......................................................................................................................... 247 10.7.6 Abslive ........................................................................................................................... 247 10.7.7 Autoexposure ................................................................................................................. 248 10.7.8 Absbright ........................................................................................................................ 249 10.7.9 Absload .......................................................................................................................... 249 10.7.10 Abssave ......................................................................................................................... 250 10.7.11 Absgrab .......................................................................................................................... 250 10.7.12 Absmask extended ........................................................................................................ 251 10.7.13 Phase enhance .............................................................................................................. 252 10.7.14 Local Phase Correction ................................................................................................. 253 10.7.15 Absfilt ............................................................................................................................. 253 10.7.16 ABS Export .................................................................................................................... 254 10.7.17 AbsSequence................................................................................................................. 255 10.7.18 AbsCalculate .................................................................................................................. 256

Content

10.7.19 Set Cam Settings ........................................................................................................... 256 10.7.20 Cam Synchronisation ..................................................................................................... 257 10.7.21 Show Cam Synchronisation........................................................................................... 257 10.7.22 Synchronsnap ................................................................................................................ 257 10.7.23 Synchronsnap Average ................................................................................................. 258 10.7.24 Load Cam ...................................................................................................................... 258 10.7.25 Init Coord Machine ......................................................................................................... 258 10.7.26 Init Joystick .................................................................................................................... 259 10.7.27 Abs Position ................................................................................................................... 259

11 Support........................................................................................................... 260
11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 Reload layout ......................................................................................................260 Start OPTOCAT Help ..........................................................................................260 Open the OPTOCAT brief manual ......................................................................261 Save Service .......................................................................................................261 Load Service .......................................................................................................261 Zip Service ..........................................................................................................261 Start the OLWizard .............................................................................................262 Remote help .......................................................................................................262

12 Customer........................................................................................................ 263 Appendix A New Colour Coding ......................................................................... 264

A1 Find Index Marks (e.g. Calibration)............................................................................264 A2 IM Live ......................................................................................................................265

Appendix B Extended Measuring Fields ............................................................ 266

B1 Sensor Calibration of special (extended) FOV with 15 calibration positions ...............266 B2 Sensor Calibration of special (extended) FOV with 28 calibration positions (e.g. optoTOP based triTOS-HE L600-1700) ..........................................................................271

Appendix C Edges ................................................................................................ 275

C1 General Information ..................................................................................................275 C2 Initialisation dialogue ................................................................................................276

Safety instructions and general hints

1 Safety instructions and general hints

1.1 Safety instructions
Read all the instructions carefully before using the system the first time. Do not connect any electronic device with power sources of other voltage or frequency as described on the marking label at the rear side of the product. Follow all warnings and instructions marked on the components. Do not remove or connect cables during operation. Do not use a PC non-authorized by Breuckmann GmbH. It can cause problems especially with the firewire components and worst case the sensor can be damaged. There is no guarantee for such damages. Do not use liquid or aerosol cleaners. Use a damp cloth to clean it. Place the devices on stable, flat areas. Secure a safety gap between the device, walls and edges Do not expose the components to rain, moisture or heat. Do not block or cover ventilating openings with cloth or other material. Use the provided power cord or a power-cord with VDE-/UL-/CAS-/PSE-/CCCcertificate. Use the delivered cords to connect the components to each The use of other cords can result in damage of one or several components. Do never change parts of the scanning system into devices we did not deliver. In the case of failure, never remove or open any of the components housings. other.

1.2 General hints for a good measurement

The Sensor is a high-precision optical tool, which has to be transported and handled with outmost carefulness. Avoid collisions and shocks to the sensor! Do not disassemble any parts of the sensor! Do not lose any screws! Do not change the aperture of the projector or the camera lens! Use the appropriate box (part of delivery) for transportation! Keep the temperature of the room steady. Dim the brightness of any light sources (electrical and daylight) to a minimum. Do not use neon light nearby the measurement scene. Avoid direct sun light on sensor and object. Regard the warm-up time. The safety of the data is only secured 30 minutes after power up of the control unit. Reduce the on-times of the projector lamp to a minimum (internal heating, lifetime of the lamp). Avoid movement nearby the sensor during measurement (sources of interference are vibrations, shadows, etc.).

Setting up the system

2 Setting up the system

2.1 System components
Hardware 3D stereoSCAN

smartSCAN -duo

smartSCAN -basic

smartSCAN -HE

optoTOP sensor

optoLINK

Setting up the system

Computer - Laptop

Parallel or USB dongle

parallel dongle

USB dongle

Software CD

Cables

power cord (EU)

Sensor cable with firewire cable (IEEE1394)

RS232 cable

USB cable

Transport box

Halogen bulb

Setting up the system

2.2 Setting up the hardware

2.2.1 Connections stereoSCAN3D and optoLINK

Firewire cable

Sensor cable with fire wire B and laser arm

Laser cable
stereoSCAN
3D

Sensor cable
Sensor cable with fire wire A and laser arm

Serial cable

USB cable

Power cable (EU)

Connections - Sensor cable: - Firewire cable: - Laser cable - Serial cable or USB cable: - Power cable:

stereoSCAN to optoLINK 3D stereoSCAN to PC 3D stereoSCAN optoLINK to PC or laptop by COM 1 or marked USB port optoLINK

Connect all cables with the defined measurement system components (3D scanner, controller, host computer etc.) before switching on any devices. Avoid connecting and disconnecting of cables as long as devices are switched on (hot plug). Otherwise damages of device parts especially of the IEEE1394 camera may happen. Avoid unintentional disconnection of IEEE1394 cable from camera by means of delivered strain relief.

IMPORTANT

For optoLINK II an USB connection to the PC is used instead of the Serial cable.

NOTE

Setting up the system

2.2.2 Connections optoTOP and optoLINK

Sensor cable with firewire arm

Sensor cable

Firewire cable

optoTOP

Projector

Strain-relief

Basler camera

PixelLINK camera

6 Mpixel camera

Power cable (EU)

Serial cable

USB cable

Connections - Sensor cable: - Firewire cable: - Serial cable or USB cable: - Firewire cable: - Power cable:

optoTOP to optoLINK optoTOP to optoLINK optoLINK to PC or laptop by COM 1 or marked USB port optoLINK to PC or laptop optoLINK

IMPORTANT

Setting up the system

2.2.3 Connections smartSCAN3D (SE version) and optoLINK

Sensor cable Trigger adapter + Laser cable

Sensor cable with firewire , trigger and laser arm

Firewire cable
Power cable (EU)

smartSCAN

Connections

Sensor cable

Strain-relief

USB cable Connections - Sensor cable: - Firewire cable: - Trigger and Laser cable - Serial cable or USB cable: - Power cable:

Serial cable

smartSCAN to optoLINK 3D smartSCAN to PC 3D smartSCAN optoLINK to PC or laptop by COM 1 or marked USB port optoLINK

IMPORTANT

Setting up the system

2.2.4 Connections smartSCAN3D-HE and optoLINK

Laser cable

Sensor cable

Sensor cable with fire wire B and laser arm

Firewire cable
smartSCAN -HE
3D

Serial cable

USB cable

Power cable (EU)

Connections - Sensor cable: - Firewire cable: - Laser cable - Serial cable or USB cable: - Power cable:

smartSCAN -HE to optoLINK 3D smartSCAN -HE to PC 3D smartSCAN -HE optoLINK to PC or laptop by COM 1 or marked USB port optoLINK

IMPORTANT

For optoLINK II an USB connection to the PC is used instead of the Serial cable.

NOTE

Setting up the system

2.2.5 Connections on the optoLINK I

Connections for optoTOP

optoLINK control unit

Sensor cable firewire arm

with

Power cable

Serial cable

Connections - Sensor cable: - firewire cable: - Serial cable: - firewire cable: - Power cable:

optoTOP to optoLINK optoTOP to optoLINK optoLINK to PC or laptop by COM 1 optoLINK to PC or laptop optoLINK

IMPORTANT

Setting up the system

Connections for smartSCAN

and stereoSCAN

Sensor cable with two firewire arms Connections - Sensor cable: - firewire cable: - Serial cable: - power cable:

Power cable

Serial cable

smartSCAN or stereoSCAN to optoLINK 3D 3D smartSCAN or stereoSCAN to PC or laptop optoLINK to PC or laptop by COM 1 optoLINK

IMPORTANT

Setting up the system

2.2.6 Connections on the optoLINK II

Connections for smartSCAN , stereoSCAN
3D 3D

and optoTOP

Sensor cable with two firewire arms

Power cable

USB cable

Connections - Sensor cable: - Firewire cable: - USB cable: - Power cable:

optoTOP, smartSCAN or stereoSCAN to optoLINK 3D 3D optoTOP, smartSCAN or stereoSCAN to PC or laptop optoLINK to PC or laptop by COM 1 optoLINK

IMPORTANT

Setting up the system

2.2.7 Connections on the computer

Power connection 230 V

Right: Serial port Left: Parallel port

firewire ports

USB ports

power cord connection

firewire connection

Computer Connections - PC - PC - PC (COM 1) to optoLINK: stereoSCAN: - PC to stereoSCAN: optoTOP: - PC to optoLINK: smartSCAN: - PC to smartSCAN:

serial cable RS232

Power supply, keyboard, mouse, screen USB or parallel port dongle Serial cable or USB cable 2 firewire cables 1 firewire cable 1 or 2 firewire

cables

Setting up the system

2.3 Software installation

2.3.1 Requirements
We recommend to order a host computer together with the measurement system. Then the combination of computer and scanner is well tested. If other computers should be used, please take into account our specifications below. In worst case the use of other computer types and configurations may cause scanner damage. This is really happened!

IMPORTANT

Requirements for a desktop PC for 1.4MP camera: Dell Optiplex 755 Core2Duo Processor with min. 2,33 GHz 2 GB RAM (DDR2) Open GL graphic unit, for example GeForce 8600GT and 256MB firewire (IEEE 1394) card with Texas Instruments chipset, OHCI conform, for camera connection USB port for a dongle 160 GB hard disk VGA Screen 19 with 70 Hz refresh rate or flat screen; resolution at least 1024x768 pixels Windows XP Professional

Requirements for a desktop PC for 5MP / 6,6MP camera: Dell Precision T3400 Core2 Quad Processor with min. 2,5 GHz 8 GB RAM (DDR2) Open GL graphic unit, Nvidia Quadro FX3700 and 512MB 2 firewire (IEEE 1394) cards with Texas Instruments chipset, OHCI conform, for camera connect and 2 firewire Express cards for 5MP systems USB port for a dongle >= 250 GB hard disk VGA Screen 19 with 70 Hz refresh rate or flat screen; resolution at least 1024x768 pixels Windows XP Professional

Setting up the system

2.3.2 Setup 3GB mode

The address space is usually split so that 2 GB of address space is directly accessible to the application and the other 2 GB is only accessible to the Windows executive software. The 3GB mode allocates 3 GB of virtual address space to an application. Edit the Boot.ini copy the entry in the boot.ini file[operating systems] and add the flag /3GB : timeout in [boot loader] As a precaution you should have the choice between the configurations. You should test to take a picture with the BCAM-Viewer. In case of a problem you should add the flag "/USERVA=2700" behind "/3GB".

Example

2.3.3 Installation of OPTOCAT 2009

1. Please connect all cables (sensor cable, serial cable or USB cable and power cable) excepting the firewire cable (see chapter 2.2). 2. Turn on the PC and the system. 3. Be sure that no Basler camera driver is installed, otherwise please de-install the old driver completely. While de-installing this driver please disconnect the cameras. Otherwise the driver will not be de-installed completely.

IMPORTANT

4. For OPTOCAT 2009 installation please insert the OPTOCAT 2009 software CD into the CD drive of your computer. Then start the setup with a double click on the setup.exe. Follow the installation steps. Select Destination and Start Menu Folder

Setting up the system

Install the FirePackage2v24

Setting up the system

Install the Camera Driver (Basler or PixeLINK)

Install COM Server 5. Please close all other programs before you go on with the installation.

Setting up the system

Install Hardlock device driver

Install VS2008Runtime

When this part of the software was installed before, it can be chosen between Repair and Uninstall. Please select Repair. When installing the first time this dialog wont appear.

Setting up the system

Install Windows Privileges 6. Please enter the exact name of the user or the user group.

7. To run OPTOCAT it is necessary to logoff. 8. Connect the dongle to the PC (see chapter 2.2.7). 9. Start the software with a double click on the shortcut OPTOCAT 2009 on your desktop or start the software from the directory: C:\OPTOCAT-FOLDER\ofw32.exe (default).

Setting up the system

2.3.4 Manual driver installation

Camera driver Be sure that there is no old BCAM driver on your computer. Otherwise please uninstall the old driver completely while the camera is disconnected Then start the setup C:\OPTOCAT-FOLDER\Driver\BCAM18SP1\Setup_bcam1394driver1.8SP1LT.exe. Hardlock driver Run the hldrv32.exe with FOLDER\Driver\Hardlock. IPP Library Execute the C:\OPTOCAT-FOLDER\Driver\Intel_IPP_5.1\setup.exe Com driver Execute C:\OPTOCAT-Folder\Driver\Optolink\comsetup.exe Windows Privileges Execute C:\OPTOCAT2009\Driver\SetWindowsPrivileges\SetWindowsPrivileges.exe USB to serial Execute C:\OPTOCAT2009\Driver\usb-to-serial\CDM 2.02.04.exe Gdiplus Please read the information: C:\OPTOCAT2009\Driver\Gdiplus\redist.txt For Windows 2000, Windows Millennium Edition, Windows NT 4.0 and Windows 98, install gdiplus.dll into the private directory of the application not into the system directory. a double click from the folder C:\OPTOCAT-

IMPORTANT

Setting up the system

2.4 Additional software tools

2.4.1 OLWizard
Check program for sensor connection The OLWizard is an useful program to check the connection of the sensor with the computer independent from the cameras and the OPTOCAT software. You find this program in the folder: C:\OPTOCAT-Folder\Tool\OLWizard.

OLWizard window if no sensor is connected. 1. Check the right COM port.

OLWizard window if a sensor is connected.

2. In the second field Baudrate must normally stand 115200 3. In the field Controller click on Board1: Block A 4. Check if the lamps are activated like in the right picture

Setting up the system

2.4.2 BCAM Viewer

Camera check program The BCAM Viewer is a program to check the camera connection independent from the connection between sensor and PC. You find it in the folder: C:\OPTOCAT-FOLDER\Tool\BcamViewer.

BCAM Viewer: no camera is connected

BCAM Viewer if two cameras are connected with showing a life image Turn on the life image with Camera Continuous grab in the main menu. With the sliders above you can change the brightness, shutter, gain and bytes per package.

Setting up the system

2.4.3 XNView
ABS file viewer XNView is a program, which can show the ABS files of the two cameras so that you have a quick overview of your scans. You can download XNView on http://www.xnview.com/.

2.4.4 Remote control

The remote control tool is helpful for difficult support cases. You send an invitation from your computer to our support PC and someone from Breuckmann can access to your PC. The program can be started from C:\ OPTOCAT-FOLDER\BreuckmannRemoteHelp.exe Please make an appointment with Breuckmann GmbH for the remote control help. To send an invitation double click on Internet support.

Setting up the system

2.5 Measurement volume and working distance

For scanning please position the sensor in front of the object. The corresponding working distance depends on the used field of view of the sensor. The sensor works properly within the calibrated standard volume you can see in the sketches below. You can imagine these standard sensor volume as a box with a sensor field of view depending dimension.

2.5.1 stereoSCAN3D

2.5.2 optoTOP

OPTOCAT basics

3 OPTOCAT basics
In this chapter you can find the basics about OPTOCAT. The window structure, general functions and several data formats are explained.

3.1 Starting OPTOCAT

Turn on the sensor and start the software with a double click on the shortcut OPTOCAT 2009 on your desktop. If you dont have a shortcut on your desktop open the following file: <dirOfw>\Ofw32.exe (default: C:\OPTOCAT-FOLDER\Ofw32.exe). The following chapter will explain some general software functions for example how to move a picture and the different views in which you can display at the scans.

3.2 General functions in OPTOCAT

Menu Bar

AOI 1 Toolbar

AOI 2
Variable List

Task Bar

Coordinate System

Mouse Interaction

3D Tree

3D Viewer

Context Menu Icon Bar

Status Line Variable List: You can add more variables if you click in a field in the variable list and write in the variable name. Mouse Interaction: With the flag HELP 3D Viewer mouse button control, in the menu bar, the mouse button informations can be enabled (small / big image) or disabled.

Unit support: OPTOCAT can handle different units, including mm, inches and thousands (of inches). See details below.

NEW FUNCTION

OPTOCAT basics

3.2.1 Change Unit

Unit

Digits

Units can be changed between: mm Inch thou (thousands of inches) Number of shown digits

3.2.2 Movement and marking

LMB Movement in all directions

MMB

Movement in screen layer

RMB

Zoom

Shift + MMB

Zoom window

Alt LMB

Movement in clock or against clock direction

Shift + LMB Ctrl + Shift + LMB

Select Deselect

With the flag HELP 3D Viewer mouse button control, in the menu bar, the mouse button control can be changed between OPTOCAT, Rapidform or Polyworks control settings.

NOTE

OPTOCAT basics

3.2.3 Context menu

Shows the scan in front view (x)

Shows the scan in side view (y)

Shows the scan in upper view (z)

Centres the scan on the screen

Different render and densities visualisation possibilities:

Static view

Flat Flat + Wireframe Smooth Render the data as shaded Render the data as Render the shaded triangles and smoothed triangles. overlays it with a wire triangles. frame

data as shaded

OPTOCAT basics

Wireframe Points Render the data as a wire Render the data as points. frame.

1 Displays point.

each

1/2 triangle Displays each triangle point.

1/4 second Displays each triangle point.

fourth

1/8 Displays each triangle point.

1/100 eighth Displays each hundredth triangle point. Dynamic view

Same 3D rendering options as in the static view above.

To speed up your 3D visualisation use the point and 1/100 display mode in the dynamic view. Different selection modi: Select mode

Line Rectangle Define a selection line by Raise a rectangle holding LMB. holding LMB.

Ellipse by Raise an ellipse or circle by holding LMB.

OPTOCAT basics

Lasso, Polygon Define arbitrary area by Define arbitrary area by holding LMB. clicking LMB, confirm with clicking RMB. Front & Back Face Front Face Back Face Select Visible Only Selects the front and the back faces. Selects only the front faces. Selects only the back faces. Selects only the visible faces. Select all

Select none

Invert selection

Select an area with the LMB. Deselect an area with the LMB. Delete all selected parts. To a given selection all connected triangles are marked.

Add selection Remove selection Erase selection Extend selection

OPTOCAT basics

Select a small area on the With extend selection all object. connected triangles are selected. A given selection becomes smaller. Erode selection

Select an area on the With erode selection the object. selected area becomes smaller. A given selection becomes bigger. Dilate selection

Select an area on the With dilate selection the object. selected area becomes bigger.

OPTOCAT basics

Different vertex colour modi possible.

Vertex colours

Disabled Ambient Each scan has its own Each scan has its own colour definition. colour, which is influenced by the light sources.

Enabled Each scan has its own grey values (respectively colour values).

Material Each scan has its own grey values (respectively colour values), which are influenced by the light sources. Show grid

Shows or hides a grid on the main window.

Grid is displayed.

Grid is not displayed.

OPTOCAT basics

Light options for Ambient and Material vertex colour modi.

Light options

With the light setting you can improve the 3D impression of your object by playing with the light shadow and colour. If you click on the light bulbs in the dialog window you can move them. With clicking on the bulb it is activated and the colour can be set by moving the small rectangle in the colour circle. You can choose up to 4 light bulbs and one ambient light. For each you can define the brightness and specular value with the sliders.

This function hides and shows the coordinate cross.

Coordinate cross

3.3 Data formats

ABS CTR MAT ASC BRE STL PLY VRML DXF Data format to save a single measurement Data format to organize 3D data types and abstract geometry types in the 3D viewer of OPTOCAT. Matrix data format to save 3D linear operations, e.g. the orientation of data sets. ASCII data format to export 3D data point wise (x, y, z coordinate values) without colour information. Data format to export SOI data sets, with colour information Data format to export triangulated data, without colour information Data format to export triangulated data, with colour information Data format to export triangulated data, with colour information Data exchange format AutoCAD, without colour information

OPTOCAT basics

3.4 Brightness adjustment for a scan

For a high quality scan it is necessary to have a good contrast in the scan. This chapter shows which possibilities OPTOCAT offers and how to set up a good brightness adjustment. The contrast in the measurement scene depends on: Surface characteristic of the object Projector brightness Camera offset, gain and shutter values Ambient light conditions

3.4.1 Lookup Tables

In the 3D metrology usually lookup tables (LUT) are used, for the visualisation of the image data. They comprise a series of red, green and blue (RGB) intensities, each normalized to 1. Lookup tables simplify the overview to the image with sharp boundaries between contrasting colours. Most common LUTs are: icon name GREY COLOUR8 GREYSAT GREYRED Colour value 0 64 128 often used for 196 255 camera, phase camera, contrast, graycode, brightness projector brightness camera, contrast, masking

3.4.2 Ambient Light

This is how to check the influences of the ambient light to the measurement. It should be checked one time before starting with the measurement acquisition. 1. Start ABS Bright dialogue. 2. Change LUT to COLOUR 8. 3. Slide down the brightness of the projector to the minimum (0). In the image you can see the influence only from ambient light. 4. Estimate the intensity and constancy of the ambient light. Possible errors: live image is already lighted more than 25%. instable ambient light, live image flashing in the frequency of the ambient light

Although there is no light from the projector lamp, the brightness of the image is about 30% (dark blue, with COLOUR 8 LUT)

Better reduce the ratio of the ambient light to a minimum, so you get a better contrast of the projected patterns during the measurement.

OPTOCAT basics

If necessary: Shade the room as much as possible. Avoid sun light. It is by factors brighter than the projector intensity and cannot be controlled. Prevent neon light, because the frequency of the light can produce phase errors in the measurements. In OPTOCAT available standard shutter values are adapted to avoid errors caused by 50Hz neon light (Flickerless active). Slide down the shutter and gain of the camera.

3.4.3 Brightness Dialog

Brightness dialog for stereo camera systems

Brightness dialog for single camera systems

Changes between showing the first camera picture (1 - left camera), second camera picture (2 - right camera) or both camera pictures (using All). Changes the LUT (color options), different fringe images can be displayed as well. Grab Mode Fast Standard Noise Reduction + Averaging Flickerless Max shutter allowed for a fast acquisition cannot be overstepped. For standard measurement, shutter can be higher than the shutter value for fast measurement. For measurement with noise reduction, shutter can be higher than the shutter value for fast measurement, select the number of phase averaging. Yes: only defined shutter values are possible, they are defined in settings-capture and are optimized for 50Hz neon light flashing (settings for 60 Hz are possible, too) No: all shutter values are allowed Changes the number of grabs (for measurement with different intensity settings). When more than one intensity is used, the sliders for brightness, shutter and gain can be linked to change values in equal steps. Possible Settings: No Linkage, 2 (exposure change of factor 2), 3,4 and 5 Changes the light intensity of the projector. The higher the value the better the contrast of the fringes in the images. The image quality gets worse if you have a low brightness. Changes the camera shutter, main instrument for brightness adjustment. Changes the camera gain, with increasing the gain also the camera noise gets worse. Automatic brightness adjustment (uses both camera pictures)

Exposure Settings Multiple Grabs HDR Link Factor

Brightness

Shutter Gain Auto Exposure Autoexposure

OPTOCAT basics

Correction Sensor Laser Cross Index Marks

Automatic adjusted brightness can be changed into higher or lower values using the slider (e.g. when result is too bright or too dark). Switches the laser on and off. Switches the cross on and off. For objects with indexmarks it is shown whether the marks are detected or not. LUT changes into GREYSAT automatically. Shows the contrast value of the camera or projector. Color coded bar that shows the intensity of instabilities (like movements or changing light conditions in the colors green (still ok) yellow red (not ok)).

Contrast Online Check

For additional information concerning the new Index Marks functionality in Absbright see Appendix A.

NOTE

3.4.4 Brightness Adjustment

1. 2. 3. 4. 5. Start ABS Bright dialogue Choose COLOUR8 or GRAYSAT LUT If necessary reduce the ambient light (see in section 3.4.2) Increase the brightness of the projector lamp with the slide bar to the maximum Neither do overexpose nor underexpose the object. Areas which are too bright as well as too low will be masked out for the 3D calculations!

COLOUR8: Overexposed areas are white and underexposed areas are black coloured. GRAYSAT: Overexposed areas are magenta and underexposed areas are yellow coloured. Image still overexposed: first slide down the gain, if it is not enough also slide down the shutter for the camera. Image still underexposed: slide up the shutter, if it is not enough also slide up the gain for the camera. 1) Do not change the Offset parameter of the camera! 2) With increasing the Gain also the camera noise is increased! 3) Consider that the fast measurement acquisition mode with Basler camera only run up to a Shutter value of 10ms (value depends on the used camera type). 4) Do not change the aperture of the camera nor from the projector to influence the brightness of the measurement scene! The sensor would be de-calibrated!

IMPORTANT

OPTOCAT basics

Examples with GRAYSAT LUT: Overexposed areas are magenta, underexposed ones are yellow coloured. The best adjustment is, if you have little magenta areas in the important image areas. The background is not important, so it does not matter if it is yellow coloured.

Right adjustment: only little magenta areas and a lot of bright grey

Bad adjustment: illumination too bright (magenta)

Bad adjustment: illumination too low (black)

OPTOCAT basics

Examples with COLOUR8 LUT: Overexposed areas are white, underexposed ones are black coloured. The best adjustment is, if you have mainly red, green and yellow areas in the important object areas. The object background is not important!

Right adjustment: only little white areas and a lot of red, green and yellow

Bad adjustment: illumination too bright (white)

Bad adjustment: illumination too low (blue)

OPTOCAT basics

3.4.5 Multiple Exposures

If one intensity/ exposure setting (Standard) is not enough for an optimal illumination of the object, it is possible to adapt up to four different parameter combinations for a measurement. This is helpful for objects with a difficult surface characteristic (slightly reflective objects for example). The scan result is then calculated out of the different exposures average. This is comparable with HDR (High Dynamic Range) - the ability to take a series of different exposures of the same scene and combining them in post processing so basically all the image is properly exposed. 1. Go to the brightness adjustment dialog. 2. Change parameter Multiple Grabs in the Exposure Settings tabulator to the desired number 3. Change in Multiple Grabs to the different exposures and adjust the brightness for all image parts. 4. If possible choose the same projector brightness (63) for each intensity setting and adapt only the shutter and gain parameters. Then each intensity is acquired within one acquisition fringe sequence. If you have different brightness values, for each an additional acquisition fringe sequence has to be executed. That needs more time than the way over the same brightness values. Especially for the optoTOP it is important to choose always the same brightness value because of the heating up of the projection unit during several sequence acquisitions within one measurement.

IMPORTANT

OPTOCAT basics

3.5 Manual Masking

3.5.1 Manual 2D-Masking
Depending on object size and used FOV sometimes the environment of the scan-object is scanned as well. To avoid loading these data in the 3D Viewer and spending time in cutting away this later, it is useful to create a 2D mask. Thereby only the selected area is loaded in the Viewer. In addition thereby the time of loading becomes shorter. For selecting please use the LMB. For reprocessing you can reload the created mask by using the parameter menu.

masking window

Create manual 2D-mask

select all

deselect all

select a rectangle

OPTOCAT basics

deselect a rectangle

select an ellipse

deselect an ellipse

select a freeform area

deselect a freeform area

select a polygon Close the polygon by double click.

deselect a polygon Close the polygon by double click.

OPTOCAT basics

3.5.2 Manual 3D-Masking

For the same purpose as creating a 2D Mask described in section 3.5.1 you also have the possibility to create this data set mask in the 3D. Thereby you are limited in the choice of defining this 3D Mask. Only line and rectangle selection mode support this software functionality.

(a)

Create manual 3D-mask

(a) how to select data to keep

(b) only red selected data are kept

Use the rectangle- or line-selection to define data to keep, only those selections can be recorded. It is not possible to reload lasso, ellipse or polygon selections.

IMPORTANT

OPTOCAT task overview

4 OPTOCAT task overview

This chapter shows an overview of the several macro groups. The main menu is the application task bar. From there you can get to the several submenus. Initialisation Chapter 5 Calibration Chapter 6 Scan Chapter 7 Processing Chapter 8 With the button Home you can get back to the home menu. Inspection Chapter 9 Tools Chapter 10 Support Chapter 11 Customer Chapter 12

With the button Back you can get back to the next menu above.

4.1 Initialisation
Before starting a measurement the current sensor and several measurement parameter have to be initialised. This initialisation can be found in every scan submenu.

4.2 Calibration
After travelling or changing the sensor field of view a re-calibration of the sensor is necessary to be sure that it works correctly. To check whether the calibration is still ok the function check calibration in the macro group Tools/Check system can be used. If the calibration is not good anymore a re-calibration before starting the next measurement project is recommended.

4.3 Scan
In OPTOCAT you have several scanning strategies available. Contour Matching: Single scans can be matched with the help of a significant contour surface of the object. By marking some equal areas in the scans they will be matched together. Index Mark Matching: For an index mark matching project the objects do not need to have a significant contour surface. The object and/or the surrounding of the object will be labelled with index marks. The scans are combined via a successive created reference file with the 3D coordinates of the index marks. Reference Matching: In comparison to the index mark matching the difference is that the reference file of index marks is measured by Photogrammetry. You can use the AICON or OPTOCAT software to create the reference file and start afterwards a Reference matching project for the measurements. Single Scan: This scanning strategy can be used to make single scans. For example to check your parameters before starting the project.

OPTOCAT task overview

Collect Marks: If only the 3D point coordinates of the index marks are needed the Collect Marks project type has to be chosen. Automatic: The automatic menu can be used in combination with a turntable and turn-tilt-table. Only the teach in of the axis for tilt and rotation has to be done. With the definition of the number of scans the angle steps are calculated and all positions are measured automatically. The turntable/turn-tilt-table rotates automatically in calculated angle steps and the measurements are done. A hand-operated mode can also be used. Multi Sensor: The Multi Sensor menu can be used when several scanner are available and they shall be run at the same time (in one project). Metronor: This menu can only be used with a naviSCAN sensor (combination of Breuckmann 3D stereoSCAN scanning system and Metronor portable CMM). While the Metronor DUO system 3D sets up a large working volume, the stereoSCAN precisely and quickly scans areas up to one square meter per shot. Stitching several shots together works seamlessly and without any user interaction through the navigation target mounted to the back of the scanner.

4.4 Processing
In Processing you can find all functions for the post-processing and analysis after finalising the measurements. For example you can merge the data sets into one common triangulated data model, cutting the index marks, filling holes, smoothing and compressing the data set. In addition you have several possibilities to load, save or export the data set in different data formats.

4.5 Inspection
The menu Inspection includes many basic functions for global aligning, measuring, comparing and constructing.

4.6 Tools
The tools submenu offers additional functionalities like: Check system: useful tools to check the functionality of your system. Calibration: extended calibration with several additional functions. Photogrammetry: calculation, opening or saving of a Photogrammetry data set. Feature lines: extraction of feature lines. 2D-Window: user interface for analysing 2D or dynamically created 3D images. BRE Export: saving possibility in special Breuckmann 3D file data format for import in Rapidform, Polyworks or Geomagic software. Temperature: temperature stabilisation for optoTOP systems.

OPTOCAT task overview

4.7 Support
-

Reload Layout: the user interface can be reloaded if something is wrong. Help: the help menu or can be opened. Manual: the manual as PDF document can be opened. Save Service: for support all AOIs can be saved. Load Service: AOIs can be load. Zip Service: a zip file of the AOIs for support can be created and sent to Breuckmann. OLWizard: to check the optoLINK. Remote help: to start the remote control program.

4.8 Customer
The Customer task bar offers the possibility to open demo data from the Breuckmann CD. It is also possible to create special user defined macro buttons.

Initialisation

5 Initialisation

5.1 Project define

For initialising a project an old one can be opened or a new one can be created. Define a save folder and enter a project name. The required folders for running the OPTOCAT 2009 software are created automatically in your project folder.

Change the main save directory Click on the button folder and browse for a save directory. Initialise a new project Enter a new project name in the line init this project. The line below in folder shows the main save directory. Load an old project With the left mouse button an already existing project from the list can be selected. Please do not use blanks or other special characters in the save paths and project names. By clicking the options button a choice of the recent 10 projects appears. Please select the file which has to be loaded.

IMPORTANT INFO

Initialisation

5.2 Project predefines

In the Template the project settings are saved (see chapter 5). For working with an old project the last settings can be loaded automatically. If there does not exist a template a default template from <DIROFW>\JOBS\Templates\Standard.INI can be loaded.

It can be chosen between different ways of handling (pixel-dependent). Template Keep Current Settings: to keep the settings from the project before (for previous existing projects only) Reload Project Settings: to reload the settings from the measurement acquisition (for previous existing projects only) Full: Use of all pixel, needs more time to evaluate Full5MP: Use of all pixel, special template for 5MP Systems Preview: it is only an overview with using each third pixel Preview5MP: Use of each third pixel, special template for 5MP Systems Standard: default, using each second pixel Standard5MP: Use of each second pixel, special template for 5MP Explore Template: Path for using an user defined template. Each *_Parameter.ini file from an arbitrary previous project can be used as a template No: to load a project for processing only Yes: to make additional scans Change Sensor: to change the automatically selected sensor (the last initialized sensor)

Add scans to existing project Sensor

5.3 Scanner initialisation

When pressing Change Sensor (see dialog above) the following dialog will open the choose the right sensor for scanning.

For example: ST816-HE-L-400 for a stereoSCAN large base, measurement field 400 mm diagonal.

with a projector number 816, High End,

Initialisation

5.4 Initialisation dialog

5.4.1 Capture

Expert Mode Capture Type

Averaging for noise reduction Number of Captures

Stability Check

Sensor

Fast: measurement in fast speed Standard: measurement in standard speed (multi exposures mode with choosing only different shutter values) Noise Reduction : to reduce noise by image averaging 2, 4, 8 (default), 16, 32 : number of images for averaging (for noise reduction only) 1 (default): measurement with one intensity 2: average of 2 images with 2 different intensity settings (brightness and/or shutter value) 3: average of 3 images with 3 different intensity settings (brightness and/or shutter value) 4: average of 4 images with 4 different intensity settings (brightness and/or shutter value) ! If possible choose only different shutter values and always the same highest brightness value for the intensity setting ! Yes: start with the first measurement/snap when there are no changes in brightness and no plate movements anymore (stable measurement conditions) No: instabilities (brightness changes or plate movements) will be ignored Change sensor: to change the automatically set sensor

Initialisation

Additional Parameter Admin Mode Stability Check tolerance value for check before starting scan -Tolerance before 5: standard, 1: highest sensitivity, 50: lowest sensitivity Stability Check tolerance value for check after scanning 5: standard, 1: highest sensitivity, 50: lowest sensitivity -Tolerance after Yes (default): opens the brightness dialog box and the user can set the Manual Brightness Setting brightness values manually No: the dialog box does not open and the brightness is set automatically Fix: The scan setting will be read from the template and will not be changed.

Additional Parameter optoTOP Yes: each measurement is done at a stable sensor temperature of 33C Temperature No: measurements could be made at different sensor temperatures stabilisation When you have chosen Stability Check: Yes in the capture initialisation the measurement will not start until the environment is stable, that means the object or sensor are not moving and there are no big changes in the lighting conditions. For more information please scroll to section 6.1.4.1, sub point 7.

INFO

5.4.2 Masking
Depending on the fringe contrast a distinction is drawn between reliable object parts and those, which are excluded from further evaluation. The bad areas are masked out. In the greyred LUT the masked out areas are coloured in red.

Initialisation

Expert Mode Masking Algorithm Masking Reliability

Erosion of Mask

Manual 2D Masking Manual 3D Masking

Standard: (default) recommended Fast: not recommended, only for flat surfaces without edges Standard (default): data with middle quality are not masked out Maximum quality: all data without best quality will be masked out More quality: all data with less quality will be masked out More data: some data with less quality are not masked out The higher the value the bigger the ignored area around pixel with low contrast: 1: only the low contrast pixel is masked out 3: 3x3 pixel area around is masked out (default) 5: 5x5 pixel area around is masked out 7: 7x7 pixel area around is masked out 9: 9x9 pixel area around is masked out 11: 11x11 pixel area around is masked out No: no manual masking Create: you can create your own mask to cut away the background Reload: load the before created manual mask again No: no manual masking Create: you can create your own mask to cut away the background Reload: load the before created manual mask again

Only the selecting mode rectangle can be used for creating a manual 3D-mask. For more informations concerning masking see section 3.5.

IMPORTANT

5.4.3 Triangulation

Initialisation

Expert Mode 2D-Subsampling

3D-Mesh Compression

Input Data (additional field for stereoSCAN)

Sensor Volume of acquisition Radius of 3D-Filter

Depends on the sensor resolution. To speed up the acquisition time for a project, less number of pixel can be used for the evaluation Full Resolution: highest resolution, but needs more time to evaluate Standard: small decimation for a faster evaluation Preview: high decimation for a fast evaluation time To reduce points without losing shape. Highest: compression level for very rough measurements (0,008mm = 0,0003inch) High: compression level for free-form surfaces Standard: compression level for standard objects Low: compression for objects with edges Lowest: only little compression for objects with sharp edges (0,08mm = 0,003inch) Raw data: no compression Select the raw data input source. Stereo: standard used data with high quality Other sources: used to get additional data (e.g. Stereo + Right (20degree), Stereo + Left (10degree), Stereo + Right (20degree) + Left (10degree), Right (20degree), Left (10degree)) To display the sensor volume of current scan. Hide Show Volume Which value suits to the application depends on the object surface. In principle: if there are a lot of sharp edges the kernel should be small, is it more a free-form surface the kernel can be larger. No Filter: no data smooth 1 x Pixelsize: no data smooth 2 x Pixelsize: smooth with averaging two pixels 3 x Pixelsize: smooth with averaging three pixels 4 x Pixelsize: smooth with averaging four pixels 5 x Pixelsize: smooth with averaging five pixels

Additional Parameter Admin Mode Additional Decimation use only every ** pixel for sorting into 3D viewer of Sorting Steps Filter cycles To remove very noisy data choose more than one cycle. 19 Additional Parameter optoTOP Highest: deviations up to the highest level are removed Local Phase High: deviations up to a high level are removed Correction Standard: deviations up to a standard level are removed Low: deviations up to a low level are removed Lowest: deviations up to the lowest level are removed No: no phase correction

Initialisation

5.4.4 Mesh Filter (Only Admin Mode)

This dialogue is still under construction!

NOTE

Radius of 3D-Filter

Filter cycles Smart filter before compress

Smart filter after compress

Maximum change Edge sharpness

Which value suits to the application depends on the object surface. In principle: if there are a lot of sharp edges the kernel should be small, is it more a free-form surface the kernel can be larger. No Filter: no data smooth 1 x Pixelsize: no data smooth 2 x Pixelsize: smooth with averaging two pixels 3 x Pixelsize: smooth with averaging three pixels 4 x Pixelsize: smooth with averaging four pixels 5 x Pixelsize: smooth with averaging five pixels Chose the number of cycles (1 up to 9 cycles; to remove high noisy data use more than 1 cycle) Number of iterations of mesh smart filter before compress is running 0: disable filter before compress Number of iterations of mesh smart filter after compress is running 0: disable filter after compress Maximum change that is allowed to be applied to the model Control the performance on sharp edges 0.1: only smoothening; keeping only sharp edges 0.9: smoothening areas with low curvature; sharpening areas with high curvature

Initialisation

5.4.5 Processing

Expert Mode Reduce Outlier Triangles Remove small parts

Minimum connected Points Align

Reduces flapping triangles at the border of single meshes. Yes/No Deletes small parts (shells) in meshes. Yes: If a part has less points than the defined minimum it will be deleted. No: Nothing will be deleted. Define the minimum number of points in a part in the mesh. If Remove small parts = yes and the part has less than the defined minimum of points it will be deleted. Runs mesh align with shown dialog or without shown dialog. always automatic only interactive on each scan only interactive to realign all scans always interactive

Additional Parameter Admin Mode Outlier Triangles Angle of flapping triangles to remove at the border of a single mesh Angle SubSampling Quantity of used points 1/1: no decimation, every point will be used for the alignment th 1/100: high decimation, only every 100 point is used for a faster evaluation th th Auto: it starts with using every 64 point, in a following step every 4 point is used for the alignment 3.00: max. gap distance (here 3.0mm) between the scans, which are Maximum Distance observed Align Reliability Define align reliability to control which data is used for aligning. Ignore Reliability (Default): all data are used for aligning Further parameter: Lowest, Low, Standard, High, Highest No: search radius equates max. point distance in mm (in Align dialog) Align Adaptive

Initialisation

Search Radius

Align Use Convergence in mm

Yes: adaptive search radius is used, therefore the distance between two meshes is calculated, after iterating the distance is calculated again; by using this parameter the search radius is getting smaller with each iteration No: Convergence is calculated out of a matrix and has no unit. Yes: the convergence is calculated in mm.

5.4.6 Texture

Expert Mode Additional Texture Snap

Color Camera

Reload Texture Stereo Color Source (not for optoTOP)

No: no additional snap of the Texture Environmental Light: additional texture snap with environmental light Manually Switched Light: additional texture snap with manually switched light Radio Switched Light: additional texture snap with radio switched light Sensor Light: additional texture snap with a sensor light External Light: additional texture snap with external light Only available for color systems (smartSCAN/optoTOP). No: black/white camera Yes: color camera No: to reload no texture to the 3D data Yes: to reload texture to the 3D data Choose camera for color mapping Left Camera: choose left camera for colour mapping Right Camera: choose right camera for colour mapping Both Cameras: choose both cameras for colour mapping Its recommended to use the left camera as colour source because of the smaller angle to the projector. This gives a better result.

Initialisation

Generate explorer thumbnail

No: to create no thumbnail from the texture to show it in the explorer Yes: to create a thumbnail from the texture to show it in the explorer

5.4.7 Indexmarks (For Index Mark Matching and Reference Matching only)

Reference File

Appending points to reference

Diameter of Index Mark Diameter of visualized Reference Marks Additional Lamp?

choose a reference file, allowed files: *.pnt, *.obc, *.asc PNT: OPTOCAT format OBC: photogrammetry format ASC: #xyz-format No <space> signs are allowed in string! No: Points which are not captured with photogrammetry will not be added to the reference. Yes: Points which are not captured with photogrammetry will be added to the reference. Size of index mark in mm Indexmarks will be shown in this diameter in the 3D-Viewer No: no special lamp and hardware for additional illumination for measurement of index marks available Yes: special lamp an hardware for additional illumination for measurement of index marks available Do not chance anything in this field, the setting will be defined by the chosen Processing Mode (in flag: Find) No: only meshes are displayed Yes: index marks and meshes are displayed in 3D viewer

Find Indexmarks Interactive ? Load Indexmarks in 3D- View?

Initialisation

5.4.8 Find (For Index Mark Matching and Reference Matching at Admin Mode only)

Processing Mode

Old Dataset

Choose the kind of index mark matching. Automatic: search without interactive reoperation Automatic with Postprocessing: search with interactive reoperation AutoRaster: individual picture analysis of A1, 5 coded marks like on calibration plates have to be available AutoRaster with Postprocessing: individual picture analysis of A1 with interactive reoperation, 5 coded marks like on calibration plates have to be available Coordinate by Mouse: interactive, directly takeover of mouse position Manuel: interactive, select index marks using the mouse Raster: interactive, search of points in a fixed raster Warning of Exists: you will be asked whether you want to overwrite data Append: add dataset Overwrite: dataset will be overwritten

Initialisation

Type of Mark

Selection

Tolerance Point Order

Threshold 3D Median filter

Type of index mark to detect Indexmark Indexmark_C12 Indexmark_C12_neg Indexmark_C12retro Indexmark_C12retro_neg Indexmark_C14 Indexmark_C14_neg Indexmark_C14retro Indexmark_C14retro_neg Indexsphere Use all or only coded marks All Only Encoded Only Black Only Black and Encoded Only White Only White and Encoded Quality of the ellipse fit Point order of index marks Homology Homology Calibration Plate Homology 2 Mixedinverse Numbering Testmode Quality of index marks Filter to find index marks No Kernel 3x3 Kernel 5x5 Kernel 7x7 Kernel 9x9

Initialisation

5.4.9 Reference ( For Index Mark Matching and Reference Matching at Admin Mode only )

Automatic Numbering

Distance Tolerance Maximum Matching Error Min Found Bad Found Percentage Bad Found

Yes: use geometry of points for matching No: use point number for matching Only Point Numbers > 1000: use only coded marks for matching and numbering the uncoded marks distance tolerance for matching tolerance of index mark 0,05- 0,5 mm minimum number of identical points for matching maximum number of deleted points during matching defines how many percent of bad data will be deleted

Initialisation

5.4.10

Edge Detection

Edge Detection can be done in Contour Matching-, Indexmark Matching and Reference Mark Matching Projects. In the Project Initialisation the parameters for Edge Detection can be chosen.

Expert Mode Edge Detection Interactive Reliability Kind of edges to find

Width of used tape Image filter

Angle to sensor Ignore areas smaller than value Smoothing type

Yes: Enable edge detection No: Disable edge detection Yes: Edges which has to be extracted can be chosen manually No: All edges will be extracted automatically Different reliabilities for the edge detection: Highest, High, Standard, Low, Lowest Standard: Edges which achieve the angle criteria and due to a border of a masked area will be detected StandardIgnoreMask: same as standard, but without checking the masking TapelineAll: Edges of tapelines und their middle lines will be detected Tapeline-Border: Only the edges of tapelines will be detected TapelineCenter: Only the middle lines of tapelines will be detected (points on the middle line are defined as geometric mean of opposed edge points) Fill in the width of used tape in mm/inch/thousands of inch (depends on unit settings (see 3.2.1)) No: No 2D filter will be used Kernel kxk: the input pictures will be filtered with a 2D-Median filter, using the filter width k (e.g. noisy pictures) (k can have the value 3, 5, 7 or 9) Fill in the width in degree Fill in a minimum number of pixel which present an edge to be detected (integer value) None: No filtering will be done Average: Edges will be filtered with Average filter

Initialisation

Merging edges automatically Extending meshes to edges

Curvature: Edges will be filtered with curvature based filter Yes: merging will be done No: merging will not be done Yes: Mesh will be extended after merging No: Mesh will not be extended after merging

5.4.11

Information

Expert Mode Date User Company Department Part Part No.

Date of measurement acquisition User name Name of the company Department in the company Part of the measurement acquisition Part number of the measurement acquisition

Initialisation

5.4.12
Expert Mode

Options
Admin Mode

Expert Mode Automatic Backup

Number of Displayed Scans

Yes: before or after some defined functions the container is saved automatically No: the customer is responsible to save the data for very big datasets to reduce the number of visualized datasets to the defined number: all, 1, 2, 4, 8, 16, 32, 64, 128

Admin Mode Capture frequency Color Code of Data Type? Angle of 3D-Filter

50Hz, 60Hz Frequency of the electricity network of your country Yes: color texture image No: black and white texture While filtering a mesh each triangle is tested to its neighborhood triangles and if the angle between this triangle and the average of its neighborhood (Angle of 3D-Filter) is greater than the specified value, then this triangle is not moved, that means the edge at this place is kept. Standard: 45 Preserve edges with an angle above 45 (standard)

Initialisation

5.4.13

Advanced (Only Admin Mode)

Admin Mode 2D-Filtertype

Area of 2D-Filter

Save project parameter? Load variable list? Delete Mesh after sorting Angle of 3D-sorting

No Filter: no smoothing on the 2D data Fourier: for standard applications (only available for optoTOP) Average: The area of filter gives the number of pixels, which are considered in the surrounding to calculate the filter result. Which value suits to the application depends on the object surface. In principle: if there are a lot of sharp edges the kernel should be small, is it more a free-form surface the kernel can be larger. Kernel 3x3 (default) Kernel 5x5, 7x7, 9x9 Kernel 11x11 (only for free form surfaces) Kernel 13x13 Kernel 15x15 (only for flat surfaces) Yes: parameters are saved No: parameters are not saved Yes: variable list is loaded No: variable list is not loaded No (default); Yes Click yes to merge a big data set. While calculating a mesh from a scanning, the normal direction of each created triangle is tested against the viewing direction. If the angle between these two directions is greater than the specified value (Angle of 3D-sorting) the triangle will not be created. Put in values in the range between 70 and 85. Default: 80 degree

Initialisation

5.4.14

Template (for task Parameter only)

Expert Mode Change Template

to change the Initialisation Template

Calibration

6. Calibration
The calibration strategy of OPTOCAT uses a model based calibration approach. Parameters concerning the sensor hardware setup with camera, projection unit and lenses are determined within this calibration procedure. Please check the calibration of the sensor system before each measurement project. The system accuracy depends considerably on its calibration. If the sensor system is not calibrated correctly the expected results might not be achieved. In the worst case the results do not match together. In addition it is really necessary to recalibrate the sensor after every demounting of any components, especially after changing the FOV of the sensor.

IMPORTANT

6.1 Calibration stereoSCAN3D

6.1.3

6.1.4

6.1.5

6.1.6

6.1.7

6.1.1 Changing the Field of View of a Sensor

The following explanation is based on the sensor type stereoSCAN . It is assumed that a standard measurement system contains a sensor with different sets of lenses and corresponding calibration plates. The sensor and calibration plate are positioned manually. According to the application task decide which FOV is required. To change the FOV of a sensor first of all the hardware has to be adapted. The rebuilding of the different FOV is realised by: changing of the camera positions (inner or outer position) using of the suitable set of lenses. After changing the FOV of the sensor it is necessary to recalibrate the sensor. Please refer to the data sheet of your system for details of the given configuration and characteristics of the desired FOV.
3D

IMPORTANT

6.1.1.1 Changing Camera Positions

(a) Camera positions outside for large FOV.

(b) Camera positions inside for small FOV.

Figure: Depending on desired FOV choose the inside or outside positions of the cameras. Switch off the computer and optoLINK before changing the camera positions! If not the projector and/or the camera can be damaged!

IMPORTANT

Calibration

1. Switch off the computer 2. Setup the sensor with the 3/8 adapter angle on the tripod. Please be sure that the system is fixed correctly. 3. Disconnect all cables from the sensor 4. Choose the right camera positions (inside or outside) 5. Put the tripod with horizontally orientated base in front of the calibration plate. The height of the lenses should be in the centre of the calibration plate.

(a) Loosen the screws of the camera.

(b) One at the top and one at the bottom of the camera.

(c) Take off the camera.

(d) Put the camera to the inner position.

(e) Fasten the two screws again.

(f) Do the same with the other camera. On the picture you see the small measurement field.

Figure: Depending on desired FOV choose the inside or outside positions of the cameras. Regard that after changing the camera positions and/or the set of lenses the recalibration of the sensor is essential before starting a new measurement project!

IMPORTANT

Calibration

6.1.1.2

Changing a Set of Lenses

To simplify the setup and calibration of a FOV, each has its own special set of lenses. The lenses are delivered with a factory-made setting for the aperture and depths of focus. This setting is optimized for the corresponding FOV and guarantees a sufficient sharpness in the complete measurement volume. It is not allowed to change the focus or the aperture of the lenses. With changes of the settings the quality of the FOV cannot be guaranteed and the warranty expires!

IMPORTANT

Each lens has one label. Lenses for the camera are marked with CR for camera right or CL for camera left. Please regard that this right and left is for standing behind the sensor and not in front of! Lenses for the projector unit are marked with a P. The letter in the middle gives the position of the cameras. L for large distance (outside position for the cameras), and S for small (inside positions). The number gives the size of the FOV in cm. See the figures with an example. The corresponding lenses only have to be attached on the cameras and the projector.

(a) Labels for small 6 cm FOV.

(b) Labels for large 25 cm FOV.

(c) Labels for large 40 cm FOV.

Figure: Depending on desired FOV choose the right lenses set for the corresponding sensor. There is one set of lenses for every sensor field of view. The focus setting of all lenses is done (pre-defined focus setting), thus after changing the lenses set a re-adjustment of focus is not necessary. In the event that the fixation of focus setting is opened, the pre-setting done in our laboratory is lost!

IMPORTANT

6.1.2 Preparations
Connect the sensor, optoLINK and computer and switch on all devices. Start OPTOCAT and click on icon Calibration. Depending on the desired FOV setup the measurement scene with the right calibration plate in front of the sensor and decrease the environmental brightness. Connect all cables with the defined measurement system components (3D scanner, controller, host computer etc.) before switching on devices. Avoid connecting and disconnecting of cables as long as devices are switched on (hot plug). Otherwise damages of device parts especially of the IEEE1394 camera may happen. Avoid unintentional disconnection of IEEE1394 cable from camera by means of delivered strain relief.

IMPORTANT

Calibration

6.1.2.1 Identify the Calibration Plate

To each FOV there is a corresponding size of the calibration plate. Refer to the table in the data sheet to find the suitable plate for your FOV. The right size of the calibration plate can be identified by its name. Identification: Example: PlateType-PlateNo_FieldOfView 1036_100

(a) Different sizes of calibration (b) Calibration plate with (c) Touch the plate only on its plates for different FOV. identification number at the bottom frame and not on the targets. left corner.

Figure: Identification and handling of the calibration plate. Do not touch the index marks on the calibration plate! The marks are quite sensitive. Finger tips on the plate will cause shiny areas. Therefore handle the plate only on its frame and use the provided gloves!

IMPORTANT

The calibration plate has to be parallel to the sensor in the centre of the measurement volume (working distance). Use the template with scales for the right calibration positions. The stereoSCAN and the calibration plate should have been in the similar tempered environment for 24 hours before the calibration.
3D

IMPORTANT

6.1.2.2 Positioning of the Sensor

Place the tripod on a stable, flat surface. Choose a suitable height for the legs and adjust the spirit levels, when available, so that they are in balance. Setup the sensor with the 3/8 adapter angle on the tripod. Please be sure that the system is fixed correctly. Control the adjustment of the sensor with the integrated spirit level in the holder (figure (a)). The distance of the sensor to the calibration plate should be the working distance of the FOV (see the data sheet for the value of the operating distance). Control that the sensor is parallel to the calibration plate (figure (b)). Adjust the height of the sensor so that the lenses are approximately at the same height of the centre circle of calibration plate (figure (c)).

(a) Control the adjustment of (b) Set up the sensor parallel (c) Adjust the height and the working the sensor with the spirit level. to the calibration plate. distance to the calibration plate.

Figure: Sensor orientation for calibration.

Calibration

If you do a re-calibration without changing the camera positions, the right height and distance of the sensor can be controlled with the adjustment lasers provided that they were right adapted before. They have to be oriented approximately horizontally to the calibration plate and intersect each other. Do not trust in the position of the laser pointers after changing the FOV, because they still are setup for the previous one! Instead you can use the live image for the setup.

IMPORTANT

6.1.3 Adjust Sensor

After preparation of the hardware the software provides a tool with the function Adjust Sensor 3D to adjust the exact operating distance. The right operating distance for the stereoSCAN is where the optical axes of both cameras intersects each other. An exact positioning of the sensor is essential before starting the calibration process, because the first calibration position gives the position of the centre of the coordinate system. Based on the first position the following calibration positions were orientated. For a successful calibration it is necessary to have a sufficient sharpness in the complete measurement volume. The lenses are delivered with a factory-made setting for the aperture and depths of focus. This setting is optimized for the corresponding FOV and guarantees a sufficient sharpness in the complete measurement volume. 1. Start the adjustment of the sensor by clicking on the icon shown above. 2. Choose the Scanner Serial Number and decide if you want to Restore presets or not. Example for nomenclature ST816-HE-L-425: 3D - ST816: stereoSCAN with the projector number 816; - HE means High End-Scanner L on the large base (means outside camera positions); - with the measurement field diagonal of 425mm.

Scanner Serial Number Restore presets

Select the scanner which you want to calibrate. Be sure that you select also the right measurement field. No: presets are not reinitialised. Yes: (standard) presets are initialised.

3. Absbright-Dialogue: In this function you can adjust the exact operating distance. Click on the button Cross on. With the both live images of the camera you can set the position of the calibration plate in the right way. Both camera views should be symmetric to the displayed crosses.

Calibration

Troubleshooting: - Focus of the camera and the projector is not sharp - Operating distance is completely different as written in the data sheet - The displayed size of the calibration plate is wrong Possible reasons for such problems: - A wrong set of lenses is used or only single lenses were exchanged - The wrong camera positions are used (inside or outside positions), - A wrong calibration plate was taken

IMPORTANT

4. Adjust of laser pointers: After adjustment of the exact operating distance the laser pointers have to be readjusted. Switch on the laser pointer pair: Click in the small box in front of Laser in the Absbright dialogue Release the laser fitting of both lasers with the wider diameter side of the adjustment tool. With the smaller diameter of the tool you can adjust the laser so that the laser points intersect in the centre of the measurement volume. That is when the laser points and the centre circle are at the same position on the calibration plate. Fix the laser fitting of both lasers again with the wider tool side.

Do not use the optoTOP laser adjustment tool made of aluminium to adjust the stereoSCAN laser pointers! This could damage the lasers! Use only the provided displayed one, made of synthetic material.

IMPORTANT

(a) Laser adjustment tool for (b) Release and fix the (c) Adjust the laser to the (d) Pointers intersect each other stereoSCAN. laser fitting. coded mark in the centre. in the FOV centre.

Figure: Laser adjustment for stereoSCAN. Side with wider diameter for releasing respectively fixing of the laser fitting (figure b). The other side with the smaller diameter for the adjustment (figure c).

Calibration

5. Final Check Check ones more if all sensor components with camera, projector and all lenses are fixed. In addition check that the calibration assembly as well as the sensor position is stable. The sensor has to be: parallel in working distance and in the height of the centre calibration target

of the calibration plate. Please check that you select the appropriate calibration plate for your measurement field. It is very important that all sensor components are fixed. Otherwise they can move during a measurement and the calibration will not be valid.

IMPORTANT

It is useful to calibrate the system under the same conditions as we recommend during measurements. Dim the environmental brightness to a minimum so that the contrast of the projection unit is sufficient. In order to get the best condition for scanning, operate 3D the calibration in the ambient temperature in which the stereoSCAN shall work later. Also let the sensor warm up for about half an hour before you start.

6.1.4 Sensor Calibration

With the calibration process the calibration plate is measured in different positions over the complete sensor measurement volume. In each position the targets are detected and set into correlation to the referenced target information. The positions of the plate defines the calibrated volume of the sensor. Therefore the complete possible measurement volume of the used FOV should be used. In the following figure you can find a simplified model of the measurement volume with the working distance in the centre (zero level), the diagonal of the FOV and the effective depth of field.

(a) Simplified 3D model of the measurement volume

(b) Calibration setup of first position.

Figure: First plate position in the working distance defines the coordinate system of the sensor. The first position of the calibration plate defines the coordinate system of the sensor. The centre index mark is the zero point, horizontally right is the x axis and vertical up is the y axis. Perpendicular to the calibration plate in direction to the sensor is the z axis.

IMPORTANT

Calibration

Calibration positions: Diagonal: -1 -2/3 -1/3 working distance +1/3 +2/3 +1 2. position 3. position 4. position 1. position 5. position 6. position 7. position 1. position 2. position

In the standard calibration process 9 plate positions are measured consecutively. Seven parallel moved from the farthest to the nearest distance to the sensor. Finally two positions again in the working distance but with the plate set into a diagonal orientation. For the extended measuring field HE-L-950 there are additional calibration positions needed, because the calibration plate do not cover the complete sensor view in the farthest position. Please refer to appendix B for details. Three different calibration modes are available for the stereoSCAN : stereo calibration mode projector calibration mode stereo + projector calibration mode
3D

INFO

By default the stereo mode is used. Thereby the calibration plate positions are acquired by camera snaps. The data evaluation is only possible for areas in the FOV which are seen from both camera views at the same time. With the projector calibration mode the projection unit will be calibrated inclusively. You have the possibility to evaluate not only the stereo information you can use also the additional information of areas in the FOV which are seen only from one (or the other camera view) and of the illumination area of the projector (optoTOP principle). Therefore the calibration plate positions have to be acquired by a complete 3D measurement sequence. While doing a measurement the projector will be re-calibrated online (same way with smartSCAN-HE) when a combined calibration of stereo + projector was done at the beginning. In principal the macro process is the same for both calibration modes. In the following we describe the procedure therefore in detail only for the stereo mode. Differences to the projector mode are remarked. Do not forget to finish all preparations mentioned in the sections before.

IMPORTANT

Calibration

6.1.4.1 Calibration Mode (default)

1. Initialise a calibration project. Select the directory path and a name.

Change the main save directory Click on the button folder and browse for a save directory. Initialise a new project Enter a new project name in the line init this project. It is useful to choose a name which indicates the sensor type, the FOV and the number of the calibration. 3D For example: ST816-HE-L-400-cal01 means: it is the first calibration of the stereoSCAN sensor ST816 with the measuring field L-400 This numbering of calibrations gives a history to the quality of the sensor calibrations. The line below in folder shows the main save directory. Continue with OK. Use only letters a z and numbers 09. Also the hyphen ''-'' and underscore ''_ are allowed. Do not use any other special character or blanks in the name! We recommend to define always a subfolder in the OPTOCAT subdirectory SENSOR for each new calibration file set. So previous calibrations are not lost and in case of problems it is easier to find the reason for failing.

IMPORTANT

Initialise the sensor. Select the used sensor and the desired sensor mode.

Scanner Serial Number Mode

Select the scanner which you want to re-calibrate. Be sure that you select also the right measurement field. Scan: Choose scan if you want to make measurements. Load: Is only available if the initialised calibration project contains previous measured data to evaluate.

Calibration

Choose calibration mode for stereoSCAN.

Mode

Extended parameters

Stereo: stereo calibration with camera snaps Projector: projector calibration with complete 3D measurement sequence Stereo+Projector: (default) stereo calibration and projector calibration are done in the same calibration procedure No: (default) to use the pre-defined calibration plate Yes: to define a calibration plate and additional parameters by your own

For projector calibration mode no extended parameters are available!

INFO

4. Optionally if extended parameters set to YES: Choose extended initialisation parameters.

PNT file name of plate Only stereo: type of marks Take limits from corpus

Enter the path and name of the used calibration plate (*.pnt file extension). All: all marks are used for evaluation. Only encoded: only the encoded marks are used for evaluation. Yes: the limits will be kept by -110110 (in case FOV 400) No: the user can choose between limits of plate position and corpus

Calibration

5. Check the used calibration plate number.

6. Measurement acquisition of the first calibration plate position.

Follow the instruction and place the calibration plate in the position requested. All instructions are with images to simplify the positioning of the calibration plate.

7. The ABSBRIGHT dialogue is opened and the camera live images are shown to set up the exposure for the scan (measurement). Adapt Brightness (or Shutter) to a value, so that the calibration plate is illuminated sufficiently. With GREYSAT LUT just no or only little magenta points should be displayed. If calibration marks appear yellow then there is too less exposure. But dont care about yellow appearance of black background of calibration marks.

Calibration

The camera snaps (or 3D measurements) will only be done when the measurement conditions are stable, that means that there are no plate- or sensor-movements or any brightness changes. The conditions are stable when the red marked bar shows no colour or only green. When the bar is yellow or red, the sensor isnt stable. To see this coloured bar please tick the little box in front of Onlinecheck.

IMPORTANT

Continue with OK when the conditions are stable. 8. When the conditions are not stable a sandglass and the information Sensor not stable appears in lower part of the screen. The measurement doesnt start. If the environment stabilizes the measurement will be done. If not, then after 20 seconds the following window appears. You have to decide whether you want continue the calibration in spite of shaking (Ignore) or whether you want to cancel the calibration and restart when the environment is stable (repeat). It is also possible to increase the tolerance for the stability, to disable the Stability Check or to get more information about possible reasons.

When pressing the button More information the following will appear. Read the information and press OK or Cancel.

Calibration

9. In a stable environment the camera snaps are done (only for stereo calibration mode!), the targets are detected (detected points are green) and shown for a short time.

Since OPTOCAT Version 2009 the colour coding has changed. See Appendix A for detailed information about the new colours.

IMPORTANT

For projector calibration mode instead of the snaps a complete 3D measurement is done and there are no visual detections in comparison to the stereo calibration mode.

INFO

10. Then the acquisition of the next positions follow. Steps 6 to 9 are repeated for all seven parallel and the two diagonal calibration plate positions. Acquire the images at every position. Follow the position numbers. Very important is that the first position is done in the working distance of the sensor. For the extended measuring field HE-L-950 there are additional calibration positions needed, because the calibration plate do not cover the complete sensor view in the farthest position. Please refer to Appendix B for details.

IMPORTANT INFO

11. After all positions are acquired the calculation of the calibration parameters is started automatically. The calibration marks are analysed and the calibration parameters are checked.

12. Only for stereo calibration mode!: If you have calibrated more than the predefined standard measurement volume (farthest and nearest calibration plate position to the sensor), you have to choose if you would like to extend the measurement volume to the real calibrated boundaries. We recommend to use the predefined standard values. If the calibrated volume is smaller than predefined, the volume is automatically reduced to the real calibrated boundaries.

Calibration

13. You get information about the status of the calibration.

Finally you have to choose whether or not to activate the new calibration. Yes All necessary calibration results will be automatically copied into the SENSOR directory of OPTOCAT. Afterwards the new sensor files are initialised. You get the information message that the new calibration is active. With NO the previous calibration file is still active. You also have the possibility to activate the new calibration files later.

If you do not activate the calibration you still work with the old calibration.

IMPORTANT

14. If you choose to activate the calibration an information window appears, that the new calibration is initialised.

Calibration

6.1.4.2 Projector Calibration

Because the procedure is the same as for the stereo calibration mode, please refer to the section before. Differences to the projector mode are remarked.

6.1.5 Visualisation

With this function you can check the calibration directly after making a new calibration. All measured points are displayed colour coded depending on the deviations to the photogrammetric determined positions. Are the targets chiefly green with only a few yellow and red ones in the border area the result is OK. Are the deviations very large (a lot of red targets) it is better to create a new calibration and to check all settings of the sensor again. Please check all planes of the calibration separately by activating of the different planes in the tree of the 3D-Viewer. Figure: Example of the deviation of detected targets to the photogrammetric determined positions.

The visualisation of the target deviations can be done for each acquired calibration position.

IMPORTANT

If there are very high deviations from the calibration plate to the reference file (a lot of red points), please check: the used camera positions, respectively sensor base. the used set of lenses. the used calibration plate. the sensor adjustment

6.1.6 Phase Correction

The phase correction is not necessary for stereoSCAN . You can only use the phase correction macro if you measure with an optoTOP system (or smartSCAN-SE).

Calibration

6.1.7 Fast Grab Delay

Recently we noticed that for continuous mode of acquisition (FAST mode) the timing between camera and projector may differ from computer to computer. The timing may affect the data quality in the picture edges. These effects can be avoided by an adjustment procedure for the Fast Grab Delay (=FGD). This adjustment has to be carried out only one time for certain scanner-computer-combination.

6.1.7.1 Description of the Effect

The effect can be fixed with a single 3D measurement in OPTOCAT. If there are any ripples either on top or bottom (or respectively left or right) of the 3D camera image the FGD has to be adjusted. See the following pictures: on the left the ribbles are on the top, on the right they are at the bottom.

(a) A3 Contrast

(b) A3 Contrast

Figure: Choose image A3 out of the AOI list above the camera pictures to get the contrast information of the measurement.

(a) Measurement displayed in the 3D Viewer.

(b) Detail in the 3D Viewer.

Figure: Wrong value for the FGD may affect the quality of the 3D data.

Calibration

6.1.7.2 Adjustment of the Fast Grab Delay

1. Position a white plane in the centre of the measuring volume. Press the button Fast Grab Delay in submenu Calibration. 2. Choose the Scanner Serial Number and decide if you want to Restore presets or not.

Scanner Serial Number Restore Presets

Select the used scanner No: presets are not reinitialised Yes: (standard) presets are initialised

3. A live image dialogue is opened. Adjust the right brightness so, that there are just no magenta parts displayed.

4. The first suggested value Fastgrabdelay was found out experimentally, which was read out of the sensor file. The next two values are the range and the steps, in which the Fastgrabdelay is tested. That means in steps of 2 you go from 90 till 110 (90,92,94,,106,108,110). For each setting a measurement will be done automatically.

Calibration

5. Next the results are shown for each measurement. The black more or less extended areas into the green, show that the timing between projector grid and camera snap is not suitable. The camera snap acquire a wrong projector grid part.

(a) FGD value 90

(a) FGD value 92

(a) FGD values 94-104

(a) FGD value 106

(a) FGD value 108

(a) FGD value 110

Figure: Displayed measurements for the different FGD values. The black coloured areas are a sign for errors in the 3D data, the green coloured areas are ok. This description is made for scanners with 1.4 MP camera Basler-A102f/fc or PixeLINK PL-A633/654. In case of 6.6 MP camera PixeLINK PL-A781 the green/black pictures appear rotated by 90.

IMPORTANT

6. A text file with two column is automatically opened. The first column shows the value for the FGD, the second one is a summarized pixel value, which count all good green parts of the measurement.

These values are examples and depend on the environmental light conditions. The highest and thus the best values are given with a FGD from 94 to 104. So in this example the average for FGD is about 100.

7. Set the new value for the FGD (100 in our example) depending on your results from the measurements before. The new value for the FGD is replaced automatically in all files needed.

Calibration

6.2 Calibration smartSCAN 3D

6.2.4.1 6.2.5.1

6.2.4.2 6.2.5.2

0 6.2.5.3

6.2.4.4 6.2.5.4

6.2.4.5 6.2.5.5
3D

Breuckmann produces different kinds of smartSCAN overview about the different sensor types.

systems. The following table will give an

smartSCAN SE-version 3D smartSCAN as two camera and one camera system

3D3D-

HE-version 3D-HE smartSCAN only as two camera system

smartSCAN

duo

smartSCAN

basic

Section 6.2.1 6.2.3 are valid for the SE- and HE-version of smartSCAN. Section 6.2.4.1 6.2.4.5 are valid for the two camera version of the SE-version, 3D3D-HE called smartSCAN duo as well as the smartSCAN . Section 6.2.5.1 6.2.5.5 are only valid for the one camera version of the 3D 3DsmartSCAN , called smartSCAN basic.

NOTE

6.2.1 Changing the Field of View of a Sensor

The following explanation is based on the sensor type smartSCAN . It is assumed that a standard measurement system contains a sensor with different sets of lenses and corresponding calibration plates. The sensor and calibration plate are positioned manually. According to the application task decide which FOV is required. To change the FOV of a sensor first of all the hardware has to be adapted. The rebuilding of the different FOV is realised only by changing the set of lenses. There only exists one base for all FOVs. 3D It isnt possible to change camera positions as is the case with a stereoSCAN . After changing the FOV of the sensor it is necessary to recalibrate the sensor. Please refer to the data sheet of your system for details of the given configuration and characteristics of the desired FOV.
3D

IMPORTANT

Calibration

6.2.1.1 Changing a Set of Lenses

IMPORTANT

Each lens has one label. Lenses for the camera are marked with CR for camera right or CL for camera left. Please regard that this right and left is for standing behind the sensor and not in front of! Lenses for the projector unit are marked with a P. The numbers next to CL, CR and P give the size of the FOV in cm. See the figures with an example. The corresponding lenses only have to be attached on the cameras and the projector.

Labels for 22 cm FOV.

Labels for 9 cm FOV.

Figure: Depending on desired FOV choose the right set of lenses for the corresponding sensor.

There is one set of lenses for every sensor field of view. The focus setting of all lenses is done (pre-defined focus setting), thus after changing the lenses set a re-adjustment of focus is not necessary. In the event that the fixation of focus setting is opened, the pre-setting done in our laboratory is lost!

IMPORTANT

6.2.2 Preparations
Connect the sensor, optoLINK and computer and switch on all devices. Start OPTOCAT and click on icon Calibration. Depending on the desired FOV setup the measurement scene with the right calibration plate in front of the sensor and decrease the environmental brightness. Connect all cables with the defined measurement system components (3D scanner, controller, host computer etc.) before switching on devices. Avoid connecting and disconnecting of cables as long as devices are switched on (hot plug). Otherwise damages of device parts especially of the IEEE1394 camera may happen. Avoid unintentional disconnection of IEEE1394 cable from camera by means of delivered strain relief.

IMPORTANT

Calibration

6.2.2.1 Identify the Calibration Plate

To each FOV there is a corresponding size of the calibration plate. Refer to the table in the data sheet to find the suitable plate for your FOV. The right size of the calibration plate can be identified by its name. The right size of the calibration plate can be identified by its name. Identification: PlateType-PlateNo_FieldOfView Example: 1036_100

(a) Different sizes of calibration (b) Calibration plate with (c) Touch the plate only on its plates for different FOV. identification number at the bottom frame and not on the targets. left corner.

Figure: Identification and handling of the calibration plate.

Do not touch the index marks on the calibration plate! The marks are quite sensitive. Finger tips on the plate will cause shiny areas. Therefore handle the plate only on its frame and use the provided gloves!

IMPORTANT

The calibration plate has to be parallel to the sensor in the centre of the measurement volume (working distance). Use the template with scales for the right calibration positions. The smartSCAN 3D and the calibration plate should have been in the similar tempered environment for 24 hours before the calibration.

IMPORTANT

6.2.2.2 Positioning of the Sensor

Place the tripod on a stable, flat surface. Choose a suitable height for the legs and take a spirit level to level so that they are in balance. Setup the sensor with the 3/8 adapter angle on the tripod. Take a spirit level or another tool and adjust the level so that the sensor is in balance. Please be sure that the system is fixed correctly. The distance of the sensor to the calibration plate should be the working distance of the FOV (see the data sheet for the value of the operating distance). Control that the sensor is parallel to the calibration plate (figure (a)). Adjust the height of the sensor so that the lenses are approximately at the same height of the centre circle of calibration plate (figure (b)).

There is only one sensor base for all fields of view. Please do not open any screws on the sensor base and change the configuration of the base. The adjustment of the base inclusively the adjustment of the cameras are settings which were done in our laboratory. When calibrating a sensor without changing the camera positions, the right sensor height as well as the right working distance can be checked with the laser pointers. They have do to be approximately horizontal to the calibration plate and have to intersect each other. After changing the camera positions please do not trust the laser pointer any-

IMPORTANT

INFO

Calibration

more, because the adjustment of the lasers still corresponds to the previous FOV! Instead of the lasers, the live image can be used for adjusting the sensor and the calibration plate.

Set up the sensor parallel to the (Adjust the height and the working calibration plate. distance to the calibration plate.

Figure: Sensor orientation for calibration. If you do a re-calibration the right height and distance of the sensor can be controlled with the adjustment lasers provided that they were right adapted before. They have to be oriented approximately horizontally to the calibration plate and intersect each other.

IMPORTANT

6.2.3 Sensor configuration and calibration strategy for smartSCAN3D

and a There are two versions of smartSCAN . There is the SE version called smartSCAN 3D-HE . Both systems differ for example in type of lenses, HE (HighEnd) version called smartSCAN 3D camera type and evaluation strategy. The smartSCAN (SE-version) is available as one 3D 3D camera system (smartSCAN -basic) and two camera system (smartSCAN -duo). The 3D smartSCAN -duo system is calibrated as stereo system, as optoTOP with 10 triangulation 3D angle and optoTOP with 20 triangulation angle. The smartSCAN -basic is calibrated as an optoTOP with 20 triangulation angle. 3D-HE is only available as two camera system. The calibration and evaluation The smartSCAN 3D strategy is the same as in case of a stereoSCAN . When only calibrating in stereo mode, calibration plate positions are acquired by camera snaps. The data evaluation is only possible for areas in the FOV which are seen from both camera views at the same time. When calibrating in the combined stereo + projector mode the calibration plate positions have to be acquired by a complete 3D measurement sequence. Then it is possible to evaluate not only the stereo information, the additional information of areas in the FOV which are seen only from one (or the other camera view) and of the illumination area of the projector (optoTOP principle) are evaluated as well. While doing a measurement the projector will be re-calibrated online 3D-HE ) when a combined calibration of stereo + projector was done (same way with smartSCAN at the beginning.
3D 3D

Calibration

6.2.4 smartSCAN3D-duo and smartSCAN3D-HE

6.2.4.1 Adjust Sensor

For the smartSCAN (SE-version) all FOVs are adapted for one working distance about a special software feature. In some cases it occurs that the cross is not exactly in the middle, 3D because you have a fixed working distance. This strategy is different to stereoSCAN . An exact positioning of the sensor is essential before starting the calibration process, because the first calibration position gives the position of the centre of the coordinate system. Based on the first position the following calibration positions were orientated. Note that in comparison to the SE-version all FOVs of the smartSCAN have different working distances. Use the crosshairs to find the right working distance.
3D-HE

IMPORTANT

For a successful calibration it is necessary to have a sufficient sharpness in the complete measurement volume. The lenses are delivered with a factory-made setting for the aperture and depths of focus. This setting is optimized for the corresponding FOV and guarantees a sufficient sharpness in the complete measurement volume. 1. Start the adjustment of the sensor by clicking on the icon shown above. 2. Choose the Scanner Serial Number and decide if you want to Restore presets or not. Example for nomenclature SM1046-SE-300: 3D - smartSCAN with the projector number 1046 and a measurement field diagonal of 300mm.

Example for nomenclature SM2000-HE5600: 3D-HE - smartSCAN with the projector number 2000, 5 megapixel cameras and a measurement field diagonal of 600mm.

Scanner Serial Number Restore presets

Select the scanner which you want to calibrate. Be sure that you select also the right measurement field. No: presets are not reinitialised. Yes: (standard) presets are initialised.

3. Absbright-Dialogue: In this function you can adjust the exact operating distance. Click on the button Cross. With the both live images of the camera you can set the position of the calibration plate in the right way. Dont worry that in some FOVs the cross in xdirection is not exactly in the middle. In this case it only has to be on the same position in both pictures.

Calibration

IMPORTANT

Adjust of laser pointers: After adjustment of the exact operating distance the laser pointers have to be readjusted. Switch on the laser pointer pair: Click in the small box in front of Laser in the Absbright dialogue. With the smaller diameter of the tool you can adjust the laser so that the laser points intersect in the centre of the measurement volume. That is when the laser points and the centre circle are at the same position on the calibration plate. When the lasers cant be moved (or only rough-running) the laser fitting of both lasers can be untighten a little bit with the wider diameter side of the adjustment tool. Fix the laser fitting of both lasers again with the wider tool side.

Do not use the optoTOP laser adjustment tool made of aluminium to adjust the smartSCAN laser pointers! This could damage the lasers! Use only the provided displayed one, made of synthetic material.

IMPORTANT

(a) Laser adjustment tool for (b) Adjust the laser to the coded (c) Pointers intersect each other in the FOV smartSCAN. mark in the centre. centre.

Figure: Laser adjustment for smartSCAN. Side with the smaller diameter for the adjustment (figure b). 5. Final Check Check ones more if all sensor components with camera, projector and all lenses are fixed. In addition check that the calibration assembly as well as the sensor position is stable. The sensor has to be:

Calibration

parallel in working distance and in the height of the centre calibration target

IMPORTANT

It is useful to calibrate the system under the same conditions as we recommend during measurements. Dim the environmental brightness to a minimum so that the contrast of the projection unit is sufficient. In order to get the best condition for scanning, operate the 3D calibration in the ambient temperature in which the smartSCAN shall work later. Also let the sensor warm up for about half an hour before you start.

6.2.4.2 Sensor Calibration

Please scroll to section 6.1.4. In comparison to a stereoSCAN you cant choose between stereo calibration3D and projector calibration-mode using a smartSCAN (SE-version). You have to calibrate the sensor in the merged stereo + projector calibration mode. That means that the calibration plate positions are not acquired by camera snaps but a complete 3D measurement sequence. 3D-HE Using the smartSCAN (HE-version) there is the possibility to choose between stereo calibration-, projector calibration- and combined stereo+projector calibration mode. When doing a combined calibration (stereo+projector) the projector will be recalibrated automatically while doing a scan project. But in principal the macro process is the same for all calibration modes. Using the SE-version, in comparison to a stereoSCAN calibration, two monooptoTOP output files and one stereo output file instead of only one stereo output file will result from calibration. Using the HE-version one stereo output file will result from calibration 3D (stereoSCAN principle).
3D 3D

IMPORTANT

INFO

6.2.4.3 Visualisation

Please refer to the stereoSCAN

visualisation in section 6.1.5.

Only the stereo calibration result is visualised.

INFO

Calibration

6.2.4.4 Phase Correction

In comparison to a stereoSCAN and a smartSCAN you can do a phase correction with a 3D smartSCAN sensor (SE-version). For further information, please scroll to section 6.3.7 and see the phase correction for an optoTOP. The phase correction has to take place for each of the two optoTOPs of the 3D smartSCAN , not for the stereo system. That means in comparison to an optoTOP sensor the phase correction has to be done twice.

3D-HE

INFO

6.2.4.5 Fast Grab Delay

Please scroll to section 6.1.7. The process is the same like for a stereoSCAN .

Calibration

6.2.5 smartSCAN3D-basic
The smartSCAN -basic is only available as SE-version.
3D

6.2.5.1

Adjust Sensor

The adjustment is the same as with an optoTOP system. Please scroll to section 6.3.4.

6.2.5.2

Sensor Calibration

Please scroll to section 6.1.4.

6.2.5.3

Visualisation

Please refer to the stereoSCAN

visualisation in section 6.1.5.

6.2.5.4

Phase Correction

In comparison to a stereoSCAN you can do a phase correction with a smartSCAN -basic. For further information, please scroll to section 6.3.7 and see the phase correction for an optoTOP.

6.2.5.5

Fast Grab Delay

Please scroll to section 6.1.7. The process is the same like for a stereoSCAN .

Calibration

6.3 Calibration optoTOP

6.3.4

6.3.5

6.3.6

6.3.7

6.3.8

It is very important to check the calibration of the sensor system before each new project because the system accuracy depends considerably on its calibration. If the sensor is not calibrated correctly the expected results might not be achieved!

6.3.1 Changing the Sensor Field of View

The following explanation is based on the sensor type optoTOP-HE. It is assumed that a standard measurement system contains a tripod, a sensor with different sets of lenses and a suitable calibration plate is available. The sensor and calibration plate are positioned manually. According to the application task decide which FOV is required and choose the corresponding components of angles, sensor base and set of lenses. Please refer to the data sheet of your system for details of the given configuration and characteristics of the desired FOV.

IMPORTANT

To change the FOV of a sensor first of all the hardware has to be adapted. If necessary change the sensor base and the set of lenses of camera and projector.

6.3.1.1 Changing the Sensor Base

Switch off the computer and optoLINK before changing the sensor base! If not the projector and/or the camera can be damaged! Switch off the computer and optoLINK. Disconnect all cables from the sensor. Choose the right sensor base consisting of carbon-fibre tube and block holder. Please check that the tube is fixed and cannot be moved in the holder. If it can be moved fix it. Setup the sensor base with the 3/8'' adapter on the tripod. Put the tripod with horizontally orientated base in front of the calibration plate. The height of the base should be nearly the same like the height of the centre of the calibration plate. (Non-standard system:) Fix the corresponding triangulation angles on camera and projector. Set provisionally camera and projector on the sensor base. Camera and projector should be oriented horizontally to the calibration plate. If you are behind the sensor base the camera is on the left side and the projector unit is on the right! Regard also that after changing the sensor base the readjustment and calibration of the sensor is essential.

IMPORTANT

Calibration

Marks comply.

Marks not comply.

Figure: Marks on sensor base and triangulation angles to simplify the provisionally fixing. They help only for a rough pre-orientation and can drift in the fine positioning of the sensor adjustment! These marks were adapted for delivery calibration. But in many cases of loosing the screw and turning the base, the marks are no more valid.

IMPORTANT

6.3.1.2 Changing a Set of Lenses

To simplify the setup and calibration of standard and extended FOVs, each of them has its own special set of lenses. The lenses will be delivered with a factory-made setting for the aperture and depths of focus. This setting is optimized for the corresponding FOV and guarantees a sufficient sharpness in the complete measurement volume. There is one set of lenses for every sensor field of view. The focus setting of all lenses is done (pre-defined focus setting), thus after changing the lenses set a re-adjustment of focus is not necessary It is not allowed to change the focus or the aperture of the lenses. With changes of these settings the quality of the FOV can not be guaranteed and the warranty expires!

IMPORTANT

Lenses for the camera are marked with a C. Lenses for the projector unit are marked with a P. The number on the marks are equivalent to the diagonal of FOV in centimetres. The lenses only have to be attached on camera and projector and a re-calibration of the sensor is required. (See also the data sheet for the required setting of the aperture.)

Labels for Camera and Projector lens

Labels for aperture and focus setting

Figure: Identification of the lenses

Calibration

Example: In figure (b) a lens is given with two marks (black and white) with number 60. This 60 is equivalent to a FOV of 600 image diagonal.
-

White Number on Black Ground: focus setting Black Number on White Ground: aperture setting (with small dash).

Check: The black label has to be on top of fixed lens, otherwise focus setting had been changed and factory setting is lost!

IMPORTANT

(Remark: During Adjust Sensor procedure factory setting of focus can be restored: Open screw of focus setting and change focus till label is on top of lens and projected pattern looks sharp on calibration plate (case projector lens) or picture of calibration plate on screen looks sharp (case camera lens))

6.3.1.3 Changing Customized FOV

This section is only for customized FOVs or former configurations of the optoTOP produced until 2004.

IMPORTANT

For these special systems changing the FOV is realized by changing the aperture and focus settings of the projector and camera lenses. In this case there is more than one FOV labelled on one lens. So a readjustment of lens aperture and focus must be done. The number on the marks are equivalent to the diagonal of FOV in centimetres (very old systems have a letter instead of numbers). Set projector and camera aperture to the defined values. Afterwards the focus of the camera and projector lenses have to be readjusted. For adjusting the focus the white sign on black ground must be on top of the lens and lens must reproduce sharp stripes on the calibration plate or rather the camera picture has to be sharp in the Absbright on the computer monitor.

IMPORTANT

Remark: During Adjust Sensor procedure factory setting of focus will be set: Open screw of focus setting and change focus till label is on top of lens and projected pattern looks sharp on calibration plate (case projector lens) or picture of calibration plate on screen looks sharp (case camera lens))

6.3.2 Preparations
Connect the sensor, optoLINK and computer and switch on all devices. Start OPTOCAT and click on icon Calibration. Decrease the environmental brightness as much as possible to achieve the best results. Depending on the desired FOV setup the measurement scene with the right calibration plate in front of the sensor. In order to get the best condition for scanning operate the calibration in the ambient temperature in which the optoTOP shall work later. Also let the sensor warm up for about half an hour before you start. The optoTOP and the calibration plate should have been in the similar tempered environment for 24 hours before the calibration.

IMPORTANT

Calibration

6.3.3 Identification of Calibration Plates

(a) Different sizes of calibration (b) Calibration plate with (c) Touch the plate only on its plates for different FOV. identification number at the bottom frame and not on the targets. left corner.

IMPORTANT

The calibration plate has to be parallel to the sensor in the centre of the measurement volume (zero plane). Use the template with scales for the right calibration positions. The optoTOP and the calibration plate should have been in the similar tempered environment for 24 hours before the calibration.

IMPORTANT

6.3.3.1 Sensor Positioning

Especially with the smaller FOV the orientation between sensor and calibration plate is sensitive and seems to be complicated. In the following steps the procedure of orientation is split into small single steps. Place the tripod on a stable, flat surface. Choose a suitable height for the legs and take a spirit level to level so that they are in balance. Tighten the sensor on top of the tripod. Take a spirit level or another tool and adjust the level so that the sensor is in balance. Adjust the height of the sensor so that it is approximately at the same height of the centre circle of calibration plate (figure (a)). Use a pocket rule to measure the distance of the centre circle to the bottom and the distance of the centre of the sensor base (half of base diameter or position of the adjustment lasers) to the bottom (or place tripod with sensor close to calibration plate to set sensor heights to level of centre calibration mark). The distance of the sensor to the calibration plate should be roughly the working distance of the FOV (see the data sheet for the value of the working distance). Control that the sensor bar is parallel to the calibration plate (figure (b)+(c)).

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Calibration

(a) Adjust the height and the (b) Set up the sensor base (c) Set up the sensor base parallel to working distance to the calibration parallel to the calibration mark the calibration plate. plate. lines (horizontally)

Figure: optoTOP sensor orientation.

Case: Calibration without a sensor base change: If the lasers are oriented approximately horizontally to the calibration plate, then the right height of the sensor can be controlled with the adjustment lasers

IMPORTANT

If the adjustment lasers are switched off they can be switched on with the ABSLASER function in submenu Tools - 2D Window. You can also use the Metrology menu out of the toolbar.

6.3.4 Adjust Sensor

For a successful calibration it is necessary to have a sufficient picture sharpness in the complete measurement volume. In any case the focus of camera and projector lenses are already pre-adjusted. Start the adjustment of the sensor by clicking on the icon shown above. Adjustment Re-Calibration: For a re-calibration without sensor base or lenses change the adjustment only has to be checked. Adjustment Standard and Extended FOV: If you have changed the set of lenses it is necessary to check the focus of camera and projector lenses exactly. Because it may occur that the false lens set is used or the lenses are not fixed in the right way. If you have changed also the sensor base a readjustment of the whole sensor is essential. Only then it can be guaranteed that orientation of the camera and projector view are optimal adjusted! Adjustment Customized FOV: For changing an FOV of a former configuration of the optoTOP (produced until 2004) or a special customized setup a readjustment of the whole sensor is essential. Only then it can be guaranteed that the focus of the lenses as well as the orientation of the camera and projector view are optimal adjusted! This section describes the adjustment for a re-calibration of a standard or extended FOV. Most sections are also valid for the customized FOV and make references to the corresponding additional information for setting the lenses focus.

IMPORTANT

Calibration

101

1. Initialise the used sensor and restore the presets.

Scanner Serial Number Restore presets

Select the scanner which you want to calibrate. Be sure that you select also the right measurement field. No: presets are not reinitialised. Yes: presets are initialised (recommended).

2. Position the sensor.

If you have not adjusted the sensor and calibration plate yet, please refer to the preparations section for details before continuing. The sensor has to be: parallel in working distance (see the data sheet for the right value) and in the height of the centre calibration target of the calibration plate.

Continue with OK. 3. Set the projector brightness. The projector light is switched on and illuminates the calibration plate. The camera live image is displayed in the GREYSAT LUT. With restored presets the Shutter is set to maximum time for fast acquisition (e.g. Basler A102f: 10 ms), Gain is prepared and Offset should be minimum. Brightness is normally set to a value between 40 and 50. Adapt Brightness or Shutter to a value, so that the calibration plate is illuminated sufficiently. With GREYSAT LUT just no or only little magenta points should be displayed. If calibration marks appear yellow then there is too less exposure. But dont care about yellow appearance of black background of calibration marks. Continue with OK.

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Calibration

4. Check the projector focus. The projector light is switched on and a fringe pattern is seen on the calibration plate. Check on the calibration plate directly if the projected fringe pattern is (nearly) sharp. If not, please ensure that the lens fit to the desired FOV and that it is marked with a 'P' for projector. Additionally you can check if the lens is really fixed and cannot be moved. Control that the label with the white number on black ground is on top of the lens. Continue with OK. Look directly to calibration plate and not at the screen while checking projector lens focus!

IMPORTANT

5. Check the camera focus. The projector light is switched on and the camera live image is displayed. Check on the computer screen if the camera image is sharp. If not, please ensure that the lens fit to the desired FOV and that it is marked with a ''C'' for camera. Additionally you can check if the lens is really fixed and cannot be moved. Control that the label with the white number on black ground is on top of the lens. Look at the screen for checking the camera lens focus!

IMPORTANT

Adjust tilt of projector.

Do not change any adjustment of the projector tilt if it is not necessary. It is only necessary after a sensor base change.

IMPORTANT

Calibration

103

Look to the calibration plate! Rotate the projector around the base axis to optimize the projector view position to the plate. The middle marks on the right (and left) side of the projected fringe pattern should be in the height of the central coded mark of the calibration plate. Finally fix the screw of the projector angle part and continue with OK. (Older fringe patterns do not have such middle marks. In this case use upper and lower edge of pattern to adjust orientation to calibration plate.)

Adjust tilt of camera.

Do not change any adjustment of the camera tilt if it is not necessary. It is only necessary after a sensor base change.

IMPORTANT

Look to the screen! A white centre cross is seen in the camera live image. Rotate the camera around the base axis to hit the central calibration circle with the horizontal line. (Horizontally shift of cross against central mark is not important yet.) Finally fix the screw of the camera angle part and continue with OK. A test measurement is done.

Alternative to point 6 and 7: If there are dashes on the base bar that fit with projector and camera (see section 6.3.1.1) both steps can be done by rotating base bar on tripod, so that camera cross fits centre mark. 8. Re-adjust tilt of projector. The contrast image of the test measurement is displayed.

If there is a dark stripe or a comb like structure at the bottom or the top of the image then this can be an edge effect of the projector. Stop the macro process with ESC key. If the orientation of camera and projector was corrected the timing between camera snaps and projector pattern movement during continuous mode of acquisition has be adapted (has be done one time for every FOV with a new computer configuration). For that, set the Fast Grab Delay like described in chapter 6.1.7 Fast Grab Delay. Afterwards restart the macro Adjust Sensor. If there are no deviations continue with OK.

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Calibration

9. Re-Adjust sensor-to-plate position. Till now the positioning of the sensor to the plate was done roughly. Now a fine positioning is done. The projector light is switched on and the camera live image is displayed. For an easy positioning of the sensor to the calibration plate a centre cross with the dark/bright edge of the projector pattern is displayed. Sensor-to-Plate distance (Coordinate Z, perpendicular to sensor base): The first step is setting the sensor exact in the working distance in front of the calibration plate. This is when the dark/bright edge is in the middle of the camera image and meets the vertical line of the shown cross. Otherwise sensor is too close or too far away from calibration plate. Sensor-to-Plate shift (Coordinate X, sensor base axis): In the second step the centre calibration mark on plate should meet the cross centre. This can be reached by shifting sensor in base direction. Often these two steps are part of an iterative process to finish this point.

Try to keep the parallel orientation of the sensor to the calibration plate. Continue with OK.

IMPORTANT

10. Adjust laser pointers. Check if the adjustment lasers intersect in the centre of the cross which hit the centre calibration mark as well as the dark/bright edge.

After changing the FOV of a sensor it is necessary to re-adjust the laser pointers. In the following it is assumed that the sensor and calibration plate is still positioned as described for the sensor adjustment.

Calibration

105

Figure: Laser adjustment tool. One side for releasing respectively fixing of laser fitting. The other side for laser adjustment. a. b. c. Switch on the laser pointers. Release the laser fitting of both lasers. Adjust them so that laser points intersect in the centre of the measurement volume. That is when the laser points, the dark/bright edge and the centre circle are all at the same position. d. Fix the laser fitting of both lasers.

(a) Release and fixing of laser fitting.

(b) Laser adjustment.

Figure: Adjustment of the lasers so that the pointers intersect each other in the middle of the measurement volume. 11. Final check. Check ones more if all sensor components are fixed and the calibration assembly as well as the sensor position is stable. Continue with OK.

It is very important that all sensor components are fixed. If not they can move during a measurement and as a result the data are not valid.

IMPORTANT

106

Calibration

6.3.5 Sensor Calibration

Simplified 3D model of the measurement volume

Calibration setup of first position.

Figure: First plate position in the working distance defines the coordinate system of the sensor.

The first position of the calibration plate defines the coordinate system of the sensor. The centre index mark is the zero point, horizontally right is the x axis and vertical up is the y axis. Perpendicular to the calibration plate in direction to the sensor is the z axis.

IMPORTANT

After initialising of the calibration and measuring the first position you are requested to move the calibration plate for the second position. To ease the handling you can use the provided calibration template, which helps with the positioning of the plate. Calibration positions: Diagonal: -1 -2/3 -1/3 working distance +1/3 +2/3 +1 2nd position 8th position 3rd position 9th position 4th position 1st position 5th position 6th position 7th position

Calibration

107

In the standard calibration process 9 plate positions are measured consecutively. Seven parallel moved from the farthest to the nearest distance to the sensor. Finally two positions again in the working distance but with the plate set into a diagonal orientation. Special FOV sizes (bigger 800 mm or smaller calibration plates than the sensor FOV) may require scans of additional positions to fit the whole FOV with the calibration plate (see data sheet of sensor). Do not forget to finish all preparations mentioned in the previous sections, before starting with the calibration procedure.

IMPORTANT

1. Initialise a calibration project. Select the directory path and a name.

Change the main save directory Click on the button folder and browse for a save directory. Initialise a new project Enter a new project name in the line init this project. It is useful to choose a name which indicates the sensor type, the FOV and the number of the calibration. For example: OT855-08HE-L100-100 means: it is the eighth calibration of sensor OT855 with FOV of 100 on a base 100. This gives a history to the quality of the sensor calibrations. The line below in folder shows the main save directory. Continue with OK . Use only letters a z and numbers 09. Also the hyphen ''-'' and underscore ''_'' are allowed. Do not use any other special character or blanks in the name! We recommend to define always a subfolder in the OPTOCAT subdirectory SENSOR for each new calibration file set. So previous calibrations are not lost and in case of problems it is easier to find the reason for failing. 2. Initialise the sensor. Select the used sensor and the desired project mode.

IMPORTANT

108

Calibration

Scanner Serial Number Mode

Select the scanner which you want to calibrate. Be sure that you select also the right measurement field (FOV). Scan: Choose scan if you want to make measurements. Load: Is only available if the initialised calibration project contains previous measured data to evaluate.

3. Temperature Stabilisation For optoTOP-HE you have the possibility to use the temperature stabilization. With using the stabilisation each measurement is acquired at the same internal sensor temperature checked in the projector.

Temperature stabilization Manual Brightness Setting Extended parameters

Yes: For data acquisition at a constant temperature. No: Stabilisation is switched off. Yes: Brightness needs to be adjusted manually for each scan. No: Intensity will be set automatically. Yes: Calibration plate can be chosen interactively. No: Predefined calibration plate is used.

Temperature stabilization is standard for systems produced since December 2004. Systems produced before has to be adjusted in hard- and software that this feature can be used. Please contact Breuckmann GmbH for details of an upgrade.

IMPORTANT

4. Optionally if extended parameters set to YES: Choose extended initialisation parameters.

PNT File Name of Plate Only Stereo: Type of Marks Take limits from corpus

Enter the path and name of file for the used calibration plate (*.pnt file extension). All: coded and not coded will be evaluated Only Encoded: only coded marks will be evaluated Yes: the limits will be kept by -2020 (FOV 100) No: user can choose between limits of plate positions and corpus

Calibration

109

5. Optionally if an old calibration plate is used, it is needed to specify further details to identify the marks on the calibration plate (*.dat file).

Type of calibration plate

DAT file name of plate

Indexmark C12: plate with many non coded and 5 encoded marks. Raster: white plate with only non coded marks. Select the *.dat file for the calibration plate. (Only for old raster calibration plate type)

6. Check the used calibration plate number.

If the given calibration plate file number does not fit with the number on the calibration plate then quit procedure with ESC, look for the right file and/or plate and repeat initialisation.

IMPORTANT
With continuing with the wrong calibration plate or reference file, the calibration could be successful but the scaling of measured 3D data is wrong! The reason is similar to the effect to use a wrong scaling bar in a photogrammetry project. 7. Measurement acquisition of the first calibration plate position.

Follow the instruction and place the calibration plate in the position requested. All instructions are with images to simplify the repositioning of the calibration plate.

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Calibration

8. The ABSBRIGHT dialogue is opened and the camera live image is shown to set up the exposure for the scan. Adapt Brightness (or Shutter) to a value, so that the calibration plate is illuminated sufficiently. With GREYSAT LUT just no or only little magenta points should be displayed. If calibration marks appear yellow then there is too less exposure. But dont care about yellow appearance of black background of calibration marks. Continue with OK.

When the measurement doesnt start after pressing OK, its because the environment isnt stabilized. For more informations please scroll to section 6.1.4, sub point 7. 9. Optionally: If temperature stabilisation is used the current sensor temperature is displayed. A small waiting time for heating up or cooling down of the sensor could be possible.

10. The measurement of the current calibration plate position is done, the targets are detected and saved.

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Since OPTOCAT Version 2009 the colour coding has changed. See Appendix A for detailed information about the new colours.

IMPORTANT

11. Then the acquisition of the next positions follow. Steps 6 to 8 are repeated for all seven parallel and the two diagonal calibration plate positions. Make a scan at every position. Follow the position numbers. Very important is that the first position is in the working distance of the sensor since it defines the coordinate system.

IMPORTANT

12. After all positions are acquired start the evaluation of the calibration parameters. The calibration marks are analysed and the calibration parameters are calculated.

13. If you have calibrated more depth than the predefined standard measurement volume (farthest and nearest calibration plate position to the sensor), you have to choose if you would like to extend the measurement volume to the real calibrated boundaries. We recommend to use the predefined standard values. If the calibrated volume is smaller than defined, the volume is automatically reduced to the real calibrated boundaries.

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Calibration

14. You get an information about the status of the calibration.

15. Finally you have to choose whether or not to activate the new calibration.

Yes

All necessary calibration results will be automatically copied into the SENSOR directory of OPTOCAT. Afterwards the new sensor files are initialised. You get the information message that the new calibration is active. With NO the previous calibration file is still active. You also have the possibility to activate the new calibration files later.

If you do not activate the calibration you still work with the old calibration. After about each 10 calibration it is recommendable to check the fringe pattern adjustment of the projector. Please refer to section 6.3.7.
th

IMPORTANT

16. If you choose to activate the calibration an information window appears, that the new calibration is initialised.

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113

6.3.6 Visualisation

Please refer to the stereoSCAN visualisation in section 6.1.5.

6.3.7 Phase Correction

The Phase Correction procedure is only valid for one-camera-systems like optoTOP and the 3D smartSCAN (SE version). th From time to time (about each 10 calibration procedure) it is recommended to make a phase correction to check the adjustment of the fringe pattern and to update the currently used data of correction. It is suggested to do it after a calibration of the sensor. Systematic phase deviations of the projector fringe pattern are detected. These phase deviations are saved and will be considered in the sensor calibration file. So possibly phase errors will be well-corrected in the measurements. The phase correction is based on the phase image of a measurement on a white plane, e.g. cardboard or paper. It should satisfy following criteria: Greater than the field of view of the camera Contain no holes or steps Homogeneous in colour, not shiny No need to be white, but bright and soft

Do not use the calibration plate, it is improper because of the colour edge between marks and background. If you do not have a qualified cardboard, use a suitable area on the wall. The phase correction feature for OfW 2009 is still under construction! It will be implemented next. Up to now it is not possible to do the phase correction procedure.

IMPORTANT IMPORTANT

6.3.8 Fast Grab Delay

Please refer to the stereoSCAN
3D

fast grab delay in section 6.1.7 Fast Grab Delay.

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7 Scan

7.1

7.2

7.3

7.4

7.5

7.6

7.7

7.8

The scan group offers you several possibilities of measurement types. Contour matching The single scans are matched together with the help of a significant contour geometry of the object (curvatures, edges). Otherwise you need some auxiliary objects to assure the matching of different scans. The single scans are matched with the help of non-coded marks. So the object does not need a significant contour geometry. The single scans are matched with the help of non-coded and/or coded marks, which are referenced by a photogrammetry dataset. With a single measurement you can check your scenery before you start a measurement project. In this menu you will only get the 3D coordinates of non-coded and/or coded marks. The automatic menu can be used in combination with a turntable and a turn-tilt-table. You only have to take a measurement for defining the axis of rotation and you have to define the number of scans you want to take. The turntable rotates automatically in calculated angle steps and the measurements are done. You also can use the menu in a hand-operated mode. The Multi Sensor menu can be used when several scanner are available and they shall be run at the same time (in one project). Support for the naviSCAN system: The sensor position can be measured very precisely by an optical tracking system from Metronor. The new Scan group Metronor gives access to this combined measurement. No indexmarks or photogrammetry is required to get an automatic alignment of the measurements with high accuracy.

Index mark matching

Reference matching

Single scan

Collect Marks

Automatic

Multi Sensor

Metronor

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7.1 Contour matching

7.1.2

7.1.3

7.1.4

7.1.5

7.1.6

7.1.7

7.1.8

7.1.9

7.1.10

Contour matching is a simple way to measure objects with significant contour geometry (free form, edges, curvatures). Here is a short overview about the main characteristics.
-

Only object with significant contour geometry (free form, edges, curvatures) can be measured. For objects without significant contour geometry (spheres, planes) you need auxiliary objects in the measurement scene to define an explicit orientation. For contour matching no index marks, spheres or reference photogrammetry data set are necessary. The object is successively measured patch by patch. Each following measurement needs sufficient overlapping areas to provide the matching procedure. The overall accuracy heavily depends on the number and positions of the single views as well as on the area of overlap to each other. A concluding fine alignment is recommended to optimize all single measurements at the end. For contour matching the orientation of the world coordinate system is defined by the view of the first measurement of the project.

7.1.1 Preparation of the measurement

For objects with significant geometry no special preparation is necessary. For objects without significant geometry position the auxiliary objects in the measurement scene.

Significant geometry object.

Auxiliary object.

Measurement scene.

7.1.2 Initialisation

See chapter 5. When you have chosen Check Stability: Yes in the capture initialisation the measurement will not start until the environment is stable, that means the object or sensor are not moving and there are no big changes in the lighting conditions. For more informations please scroll to section 6.1.4.1, sub point 7.

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7.1.3 Scan

Within the scan procedure several steps are executed. Some of them are automatically others need the interaction of the user. Because the first measurement defines the coordinate system of the object, the procedure is slightly different. No Pre-alignment and Contour Alignment (step 7. & 8.) are done for the first scan. Acquisition steps for the scan procedure 1. Move the sensor and/or object to the desired acquisition position within the optimal distance 2. Adjust the brightness 3. Measurement acquisition (automatic) 4. Possibly: Definition of a 2D mask 5. Calculation of 3D data (automatic) 6. Possibly: Definition of a 3D mask 7. Pre-alignment with marking 3 object positions 8. Contour Alignment 9. Measurement result is displayed in the 3D viewer (automatic) Move the sensor and/or object to the desired acquisition position With the laser pointer pair set up the sensor position into the right measurement distance. With the cross in the brightness dialogue you can check if you are in the optimal distance. Not for the first, but for all following patches: Ensure enough overlapping areas in each successively measured patch. Change the camera view so that the new view contains at least one third to a half of the measurement before. Regard that the quality of the alignment result depends heavily on the area of overlap.

First view. Adjust the brightness

Following view.

Refer to chapter 3.4 for details. With OK the measurement is started. The scan is saved as a *.ABS file in the initialised project folder.

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7.1.4 Pre-align

Select the number of the scan in your 3D tree, which you want to re-align.

To ease finding similar object points, move both views so that they are orientated in the same way. With CTRL + LMB mark three similar points in both windows in the same order. They will be marked with same coloured pins. Check your pin setting by ticking Preview. When the result is not OK, please remove the pins and set them again. Then, confirm your pin setting with OK button. Both scans have the same colour. To see the real texture tick Texture. Then, set pins at similar points to align the scans.

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To ease the finding the background can be lighted up by ticking Bright.

To check the alignment tick Preview. Then, press OK button.

Choose characteristically points beside an edge or a dent for positioning the pins. Set the pins not in one direction, choose an asymmetric distribution. Pins can be set only on the data, not in space! The last pin which is set on a false position can be removed with button Remove Last. All current pins can be deleted with button Remove All. The display colour of the previous and new measured patch can be switched with button Texture. The result of the pre-alignment can be checked with Preview. With CTRL + RMB you can switch to the material colour.

INFO

7.1.5 Align

After the acquisition of the scans (during scan-process) a final fine alignment should be started to optimize the matching of the single patches. In the process of aligning the first scan will be locked for a short time and all other captured scans are aligned on this first scan.

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3D view alignment dialog Subsampling Quantity of used points 1/1: no decimation, every point will be used for the alignment th 1/100: high decimation, only every 100 point is used for a faster evaluation th Auto: it starts with using every 64 point, in a following step every th 4 point is used for the alignment Max. gap distance (here 0.77mm) between the scans, which are observed. Number of Iterations No: the whole available 3D-data is used for the alignment Yes: the alignment works only on the selected areas No: 3D-view update during alignment Yes: 3D-view update during align process (occupies capacity)

Search Range max. Iterations Only Selection 3D View Update

Fine alignment dialog

Detail view after the fine alignment. All scans should be marked with OK.

Standard view of the result

Graphic view of the result

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Object before the fine alignment.

Object after fine alignment

After the fine alignment the datasets intersect each other much better. That means they match well together.

7.1.6 Processing

Automatic change to the taskbar processing. See chapter 8 for information about processing.

7.1.7 Parameter

This function changes the parameters without initialising a project, for a quicker change of parameters. See chapter 5.4.

7.1.8 Brightness

To check the scenery and the brightness settings the brightness dialog can be opened. For more details see chapter 3.4.

Brightness adjustment: only little white areas (light reflections) on the main image parts.

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7.1.9 Load

If a measuring project is already existing this window will open when the button Load is pressed.

Process Abs

Process 3D Container

Open Result

Open Single File

Import

Special

load *.ABS and calculate 3D data Project Parameter: edit project parameter Execution: load/ complete reprocessing/ Load, optimize Align, Merge Project Parameter: edit project parameter Loading Container: load a container Manual Realign: Yes/ No Processing: Optimize Align/ Optimize Align and Merge 3D Backup Container (Ctr): load the project container automatically Mesh result (STL/PLY): Load the merge result (STL or PLY file) automatically Index of scan: enter the scan number which should be opened Reload Matrix: Yes/No Open: Raw data (ABS) / Breuckmann Raster (BRE) / 3D Container (Ctr) / Matrix (Mat) Raw data (Abs): load *.ABS file ASCII: load an ASCII file Index marks: load the point data of the index marks Points: load point data Reference points: load points from a reference point dataset 3D Container (Ctr): load container Mesh result (STL/PLY): load a *.STL /*.PLY file BRE: load a *.BRE file Project: initialise a project Template: load a template Demo data: load demo data Sensor (Cam): load a *.cam file Edges: load edges data Edges Container: load an edges container Fringe analyse (SDF): load a *.SDF file Special Mesh VRML: load a *.VRML file

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If you have a project without data and you press the button Load you will see this window.

New (since OPTOCAT 2007R3): Drag and Drop Function Container, ABS files, STL and PLY files can be dragged directly from a measurement project in the Explorer into OPTOCAT. Drag ABS files into AOI window and CTR, STL or PLY files in the 3D viewer.

IMPORTANT

Drag ABS file from project folder in OPTOCAT. Drop file in AOI window.

Drag CTR file from project folder in OPTOCAT. Drop file in 3D window. An Import folder including the dragged file will appear in the 3D tree.

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7.1.10

Save

Save dialog opens. Below all possible file format for saving.

Save

ABS: ASCII: BRE: CAD: CTR manually: browse for a save directory and select a name. CTR single: the container will be saved automatically Edges CTR: save the edges as container Edges export: export edges data Feature lines: save feature lines MAT all: all MAT are saved Matrix: save a matrix Points: save point data Reference points: save reference point data SDF: save a *.SDF file Section: save a section STL/PLY: save data as STL or PLY VRML: save data as *.vrml Save ABS as BRE Save ABS as PLY Save colour from ABS

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7.2 Index mark matching

7.2.2

7.2.3

7.2.4

7.2.5

7.2.6

7.2.7

7.2.8

7.2.9

7.2.10

The measurement type index mark matching works with non-coded marks to match the single data sets together. Here the main characteristics are described for a short overview.
-

There is no limitation regarding the object geometry. All surfaces such as free form, edges, curvatures, spheres or planes can be measured. The object and/or measurement scene have to be prepared with non-coded targets. It is not necessary to know the spatial position of the non-coded targets before starting with the measurements (no photogrammetry necessary). The orientation of different views result automatically by the positions of the targets (no pre-alignment necessary). The automatic matching process is only possible if the views overlap regarding the index marks. That means every new view must contain at least 3 index marks measured and saved before. No interactive step to define similar points like in the contour matching is necessary. The reference data set with the spatial position of the non-coded targets is created successively with each new measurement. The overall accuracy heavily depends on the number and positions of the index marks as well as on the area of overlap of the single views. A concluding fine alignment is recommended to optimize all single measurements at the end. For index mark matching the orientation of the world coordinate system is defined by the view of the first measurement of the project.

7.2.1 Preparation of the measurement

Following some advices to set up the measurement scene for an index mark matching project:
-

The targets should be randomly distributed without symmetries. The number and size of the targets depends on the FOV. It is possible to use targets of different sizes at the same time. For an optimization of the matching procedure in every measurement approximately 57 index marks should be seen. If necessary to use an anti reflex spray, treat the object surface before the non-coded targets are fixed! Fix the targets on the object and/or direct object surrounding.

Do not change the spatial position of the index marks during the entire measurement procedure. It is very important that the distances and positions relatively between the index marks as well as to the object do not change!

IMPORTANT

According to the used FOV following sizes of the non-coded targets are recommended: FOV 30 - 325 375 - 425 600 - 1050 Target [mm] 4 8 12

There are different kinds of targets on the market. For example there are white or retro reflective targets, available on adhesive films or small magnets. If possible use magnetic noncoded targets, thus you have less effort to stick on and remove them from the object after the measurements are done! Retro reflective targets only can be used with an additional LED lighting.

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7.2.2 Initialisation

For all initialisations see chapter 5. Additionally to the standard settings you are asked for the type, the radius and the tolerance of the index marks on your object. Therefore see section 5.4.8. When you have chosen Check Stability: Yes in the capture initialisation the measurement will not start until the environment is stable, that means the object or sensor are not moving and there are no big changes in the lighting conditions. For more informations please scroll to section 6.1.4.1, sub point 7.

INFO

7.2.3 Scan

Acquisition steps for the scan procedure 1. Move the sensor and/or object to the desired acquisition position within the optimal distance 2. Adjust the brightness 3. Measurement acquisition (automatic) 4. Possibly: Definition of a 2D mask 5. Index mark detection 6. Calculation of 3D data (automatic) 7. Possibly: Definition of a 3D mask 8. Matching of the data set by index marks 9. Constrained Alignment 10. Measurement result is displayed in the 3D viewer (automatic)

Move the sensor and/or object to the desired acquisition position With the laser pointer pair set up the sensor position into the right measurement distance. With the cross in the brightness dialogue you can check if you are in the optimal distance. Not for the first, but for all following patches: Ensure enough overlapping areas and index marks in each successively measured patch. Change the camera view so that the new view contains at least 3 previous measured targets. Regard that the quality of the alignment result depends heavily on the area of overlap.

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First view

Following view

The automatic matching process is only possible if the views overlap regarding the index marks. Every new view must contain at least 3 previous measured index marks. For an optimization of the matching procedure approximately 5-7 index marks should be seen! Adjust the brightness

IMPORTANT

With using index marks it is maybe necessary to work with different exposures if the object and target brightness is too different. All exposures are used for the object acquisition. In addition the first intensity setting is used for the index mark detection. Refer to chapter 3.4 for details of the brightness setting possibilities. With OK the measurement is started. The scan is saved as a *.ABS file in the initialised project folder.

Brightness adjustment (GraySAT LUT): only little pink areas on the main image parts, the targets are well illuminated. Index mark detection After the measurement is done the targets are detected, the 3D data calculated and matched to the pervious measured data sets. The result is displayed in the 3D viewer. If you would like to interact into the index mark detection and select additional index marks manually you have to set parameter Find IM interactive in the Indexmarks initialisation to YES.

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7.2.4 Align

After the acquisition of all scans you should make a fine alignment. This is a constrained alignment, which considers the index mark positions from the successive created reference file and the object contour.

Constrained alignment dialog

After aligning all scans, they should be marked with OK.

Standard view of the result

Graphic view of the result

Object before constrained alignment

Object after constrained alignment

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7.2.5 Processing

Automatic change to the macro group processing. See chapter 8.

7.2.6 Parameter

Additionally to the standard settings you have the possibility to define the index marks parameters, see chapter 5.4.7.

7.2.7 Brightness

To check the scenery and the brightness you can do a preview. With using index marks it is maybe necessary to work with different exposures if the object and target brightness is too different. All exposures are used for the object acquisition. In addition the first intensity setting is used for the index mark detection. For the brightness adjustment please see chapter 3.4.

Brightness adjustment: only little white areas (light reflections) on the main image parts.

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7.2.8 Optimize PNT

With optimize PNT the successive created reference data set (default with number 1) can be optimized regarding the targets positions. After the optimization process the index marks are reloaded automatically.

Start index End index Exclude Reference data set (default: 1)

Enter the start image number Enter the end image number If you want to exclude an image enter the image numbers with a semicolon between the numbers or a range of numbers (e.g. 2-4;6) Reference for joint coordinate system

7.2.9 Load

See chapter 7.1.9.

7.2.10

Save

See chapter 7.1.10.

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7.3 Reference matching

7.3.2

7.3.3

7.3.5

7.3.6

7.3.7

7.3.8

7.3.9

7.3.10

For the measurement type Reference matching a previous measured reference file is used for the automatic matching of the single data sets. Here the main characteristics are described for a short overview.
-

There is no limitation regarding the object geometry. All surfaces such as free form, edges, curvatures, spheres or planes can be measured. Reference matching is often used for the acquisition of very large objects to guarantee the dimensional accuracy of the measurements. The object and/or measurement scene have to be prepared with non-coded and coded targets. It is necessary to know the spatial position of the non-coded (and coded) targets before starting with the 3D surface measurements. The orientation of different views result automatically by the positions of the targets. The automatic matching process is only possible if the views contain at least 3 targets which fit with the targets saved in the reference file. No interactive step to define similar points like in the contour matching is necessary. Overlapping areas regarding the measurement before are only needed to cover the complete object surface. The reference data set with the spatial position of the non-coded (and coded) targets can be given by photogrammetry. Then a photogrammetry system is needed. The overall accuracy heavily depends on the quality of the reference data. A concluding fine alignment is recommended to optimize all single measurements at the end. For Reference matching the orientation of the world coordinate system is defined by the orientation of the reference data.

AICON DPAPro Photogrammetry is a method to get the position or geometry of an object in three dimensional point data. Often the method is used for the measurement of large outer skin panels etc. The object to be measured is signalled at all geometry relevant points with non-coded targets. The object is surrounded by the reference cross, scale bars and coded targets. The result data are loaded into OPTOCAT and the single scans are matched by this photogrammetric measured reference points.

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7.3.1 Preparation of the measurement

Follow this advices to set up the measurement scene for a referenced matching project:

1. If necessary to use an anti reflex spray, treat the object surface before the measurement scene is set up for the photogrammetry! 2. Place the reference cross nearby the object. It defines the x and z direction of the 3D point data. 3. Place the high precision calibrated scale bar nearby the object. At least one scale bar has to be placed in the measurement scene to provide the accuracy of the photogrammetry data. Best results are given if the scale bar is diagonal in the volume to be measured. Depending on the object dimension the size and number of additional high precision calibrated scale bars have to be chosen. 4. Upgrade the measurement scene with the coded targets around the object. They are needed to identify the camera position automatically. Regard a random distribution without symmetry. Best results are given if the coded targets are positioned in different levels of the measurement volume. In case of small or medium sized objects it is not necessary to put coded targets onto the object itself. They cause very big holes in the surface data of the object when they are cut out in OPTOCAT. Only in case of very large objects the coded targets should be placed also on the object surface. It is also necessary to place some of the coded targets on the object is, if there are several subprojects needed to cover an object completely. For example if the front side of an object is measured in one project and the backside in another one. Then you get the link of both projects via the coded targets fixed on the object. To match different data sets in AICON at least 3 overlapping coded targets are necessary. The measurement scene has not to be overcrowded with coded targets. It will be sufficient if there are at least 8-10 coded targets in a random distribution in every photogrammetry image for reliable results. 5. Signal the object to be measured at all geometry relevant points with non-coded targets. For an optimization of the matching procedure in OPTOCAT every measurement view should contain approximately 5-7 index marks. Thus the number of non-coded targets should be in due proportion to the FOV of the used sensor. Also the size of the used targets depends on the FOV of the sensor. Following sizes for the non-coded targets are recommended: FOV 30 - 325 375 - 425 600 - 1050 Target [mm] 4 8 12

IMPORTANT

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7.3.2 Photogrammetry

To start the integrated photogrammetry software module from AICON you need a valid dongle. Please plug-in the dongle and press the button Photogrammetry to start a DPA measurement. Please select a path where to save the collected images and the result of the bundle adjustment. If the path DPA doesnt exist it will be created automatically.

Please refer to the AICON manual to get detailed information how to create a photogrammetry file.

7.3.3 Initialisation

Additionally to the standard settings (chapter 5) you have to define the index marks parameters with the definition of a reference file. See 5.4.7. When you have chosen Check Stability: Yes in the capture initialisation the measurement will not start until the environment is stable, that means the object or sensor are not moving and there are no big changes in the lighting conditions. For more information please scroll to section 6.1.4.1, sub point 7.

INFO

7.3.4 Scan

Within the scan procedure several steps are executed. Some of them are automatically others need the interaction of the user. Acquisition steps for the scan procedure 1. Move the sensor and/or object to the desired acquisition position within the optimal distance 2. Adjust the brightness 3. Measurement acquisition (automatic) 4. Possibly: Definition of a 2D mask 5. Index mark detection 6. Calculation of 3D data (automatic) 7. Possibly: Definition of a 3D mask 8. Matching of the data set by index marks 9. Constrained Alignment 10. Measurement result is displayed in the 3D viewer (automatic)

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Move the sensor to the desired acquisition position With the laser pointer pair set up the sensor position into the right measurement distance. With the cross in the brightness dialogue you can check if you are in the optimal distance. From patch to patch, ensure enough overlapping areas to cover the object surface completely. Every camera view should contains at least 3 measured targets. For an optimization of the matching procedure approximately 5-7 targets should be detected.

IMPORTANT

Adjust the brightness With using index marks it is maybe necessary to work with different exposures if the object and target brightness is too different. All exposures are used for the object acquisition. In addition the first intensity setting is used for the index mark detection. Refer to chapter 3.4 for details of the brightness setting possibilities. With OK the measurement is started. The scan is saved as a *.ABS file in the initialised project folder.

Brightness adjustment (GraySAT LUT): only little pink areas on the main image parts, the targets are well illuminated. Index mark detection After the measurement is done the targets are detected, the 3D data calculated and matched to the photogrammetric measured reference point data set. The result is displayed in the 3D viewer. If you would like to interact into the index mark detection and select additional index marks manually you have to set parameter Find IM interactive in the Photogrammetry initialisation 5.4.7 to YES.

INFO

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7.3.5 Align

After aligning all scans you make a fine alignment. This is a constrained alignment, which considers the index marks and the object contour.

Fine align dialog

After a fine alignment all scans should be marked green.

Standard view of the result

Graphic view of the result

Object before constrained alignment

Object after constrained alignment

7.3.6 Processing
Automatic change to the macro group processing.

7.3.7 Parameter
See chapter 5. Additionally to the standard settings you have to define the photogrammetry parameters with the definition of a reference file.

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7.3.8 Brightness

To check the scenery and brightness you can do a preview. For detailed information about brightness adjustment please see chapter 3.4.

7.3.9 Load

See chapter 7.1.9.

7.3.10

Save

See chapter 7.1.10.

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7.4 Single Scan

7.4.1

7.4.2

7.4.3

7.4.4

7.4.5

7.4.6

7.4.7

7.4.8

7.4.9

7.4.10

7.4.11

The single measurement is mainly for a check of the measurement scene and parameter before you start a measurement project.

7.4.1 Initialisation
See chapter 5.

7.4.2 Scan

A single grab will be executed. That means that several images for 3D information will be calculated automatically. The *.ABS files are shown in the ABS viewer (2D images).

7.4.3 Parameter
See chapter 5.

7.4.4 Brightness

The brightness dialog opens to set the right intensity for the measurement. For detailed information about brightness adjustment please see chapter 3.4.

Brightness adjustment (Colour8 LUT): only little white areas on the main image parts.

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7.4.5 Grab

Grab means that you only make one measurement sequence (without brightness dialog).

7.4.6 Masking

This macro masks the loaded ABS file. The parameters are set in the Initialisation dialog in chapter 5. Depending on the fringe contrast a distinction is made between reliable object parts and those, which are excluded from further evaluation.

7.4.7 Manual masking

Additional to the automatic masking you have the possibility to create a mask manually. The manual mask dialog is opened and you can select additional areas of the image, which are excluded for further data processing.

Complete image is masked Complete image is used. out. icon description Select all Select a rectangle Select an ellipse Select a freeform area Select a polygon icon

Only data from the lilac image parts are used.

description Deselect all Deselect a rectangular Deselect an ellipse Deselect a freeform area Deselect a polygon

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7.4.8 2D-Filter

The filter will smooth the *.ABS data and the noise becomes less. The parameters are set in the Initialisation dialog. See chapter 5.

7.4.9 Sort

The actual loaded *.ABS file will be calculated to the 3D mesh.

7.4.10

Load ABS

See chapter 7.1.9.

7.4.11

Save ABS

Save the scan as *.ABS file. See chapter 7.1.10.

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7.5 Collect Marks

7.5.1

7.5.2

7.5.3

7.5.4

7.5.5

7.5.6

With the measurement type collect marks it is possible to capture a point cloud of non coded marks on a object surface. This could be useful for creating a reference data set or in case you need only a few points on a surface.
-

There is no limitation regarding the object geometry and surface characteristic. Points on all surfaces can be measured. The object and/or measurement scene have to be prepared with non-coded targets. It is not necessary to know the spatial position of the non-coded targets before starting with the measurements (no photogrammetry necessary). The resulting point data set is created successively with each following measurement. The orientation of different views result automatically by the positions of the targets measured before (no pre-alignment necessary). The automatic matching process is only possible if the views overlap regarding the index marks. That means every new view must contain at least 3 index marks measured and saved before. No interactive step to define similar points like in the contour matching is necessary. The overall accuracy heavily depends on the number and positions of the index marks. A concluding optimization of all single measurements is recommended at the end. For collect marks the orientation of the world coordinate system is defined by the view of the first measurement of the project.

7.5.1 Initialisation

INFO

7.5.2 Collect

Within the collect procedure several steps are executed. Acquisition steps for the scan procedure 1. Move the sensor and/or object to the desired acquisition position within the optimal distance 2. Adjust the brightness 3. Snap acquisition (automatic) 4. Index mark detection 5. Matching of the new data set by index marks 6. Constrained Alignment 7. 3D points are displayed in the 3D viewer (automatic)

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Move the sensor and/or object to the desired acquisition position With the laser pointer pair set up the sensor position into the right measurement distance. With the cross in the brightness dialogue you can check if you are in the optimal distance. Not for the first, but for all following patches: Ensure enough overlapping index marks in each successively measured patch. Change the camera view so that the new view contains at least 3 previous measured targets.

First view

Following view

IMPORTANT

Adjust the brightness With measuring only index marks the intensity setup has only to be sufficient for well illuminated targets. The first intensity setting is always used for the index mark detection. Refer to chapter 3.4 for details of the brightness setting possibilities. With OK the measurement is started. The scan is saved as a *.ABS file in the initialised project folder.

Index mark detection After the snap is done the targets are detected and matched to the pervious measured data sets. The resulting point cloud is displayed in the 3D viewer. If you would like to interact into the index mark detection and select additional index marks manually you have to set parameter Find IM interactive in the Indexmarks initialisation 5.4.7 to YES.

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7.5.3 Optimize

Start index End index Exclude

Reference data set (default: 1)

Enter the start image number Enter the end image number If you want to exclude an image enter the image number with a semicolon between the numbers (e.g. 2-4;6..) In this example 2,3,4 and 6 are excluded. Dataset number in the pnt file

7.5.4 Parameter

See chapter 5.4.

7.5.5 Brightness

The brightness dialog opens to set the right intensity for the measurement. For detailed information about brightness adjustment please see chapter 3.4.

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7.5.6 Load Marks

Start Index (137) End Index (137) Exclude Reload sensor Delete reference

First measurement number (Example: 1). Last measurement number (Example: 37). Number to be excluded (Example: 0). Yes/ No Yes/ No

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7.6 Automatic

7.6.1

7.6.2

7.6.3

7.6.4

7.6.5

7.6.6

7.6.7

7.6.8

7.6.9

The automatic menu can be used in combination with a turntable and turn-tilt-table. Only the teach in of the axis for tilt and rotation has to be done. With the definition of the number of scans the angle steps are calculated and all positions are measured automatically. The turntable/turn-tilt-table rotates automatically in calculated angle steps and the measurements are done. A hand-operated mode can also be used. The following pictures show the different models of available turntables.

The turnTABLE , which is designed for pre-aligning scan data is able to carry objects weighing up to 20kg. The 20 turnTABLE has no tilt function.

The turn-tilt table is designed for pre-aligning scan data and is able to carry objects weighing up to 1kg.

The differences between both tables are explained in the following subsections.

7.6.1 Initialisation

See chapter 5.

7.6.2 Teach

The following sections will explain how to teach the turnTABLE and rotation table.

as well as the turn-tilt table

7.6.2.1 turnTABLE20
Before scanning an object on the computer-controlled-table it is necessary to determine the rotation axis by using the Teach button. The current turntable position will be used as reference position. If you want to change this status, press button Change Position. If not, press OK (default).

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The dialog on the right hand side will appear when Change Position is activated. Move the turntable back and forth by clicking in the desired toggle field or button. (1.0/1.0, 5.0/5.0,) and pressing The turntable will move, then press the Exit button.

To determine the rotation axis, please place a calibration object or the object to be digitized on the turntable.

Use cut planes

Automatic Mode Manual Mode

Yes/No By using cut planes all captured scan data located underneath or above the cut planes are deleted. This results in obtaining only scan data of the scan object, not of the surrounding area. See section 7.6.2.1.3. The rotation axis is calculated automatically by capturing the object from two different positions (10 angle difference between scan positions). The rotation axis is calculated manually by capturing the object from two different positions (30 angle difference between scan positions) and manually pre-aligning these scans.

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7.6.2.1.1

Automatic Teach

Please adjust the brightness for the first scan.

After pressing the OK button two scans are run automatically (in 10 step). The rotation axis is calculated by these two scans.

Press the OK button. The rotation axis will be shown as an arrow in the 3D viewer.

7.6.2.1.2

Manual Teach

Please adjust the brightness for the first scan.

After pressing the OK button two scans are run automatically (in 30 step). Please select the scan data of the two scans and press OK.

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The Pre-align dialog will open.

Move both views so that they point into the same direction. This will make it easier to identify distinctive corresponding reference points on the objects. Mark three corresponding points on both objects with the CTRL + LMB function. The selected points will be represented by same coloured pins. Confirm the pin settings with the OK button. With this alignment the rotation axis is calculated and will be shown as an arrow in the 3D viewer.

7.6.2.1.3

Cut Planes

When Use cut planes = YES in the Calculation of Rotation Axis dialog has been selected, after capturing the object from two different angles (using the automatic/manual mode) it is possible to move or delete the shown planes. By doing so, data which is not required is not evaluated and not loaded in 3D Viewer.

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(a) Definition, whether cut planes shall be used

(b) Positioning of cut planes

As shown on the right hand side picture, it is possible to delete or move the upper and lower plane by pressing the appropriate button. Deleting a plane results in having no scan data limitation in the selected direction. Deleting a plane cannot be undone. The selected plane can be moved. See the dialog Move Container to get further information. Press Close once the plane movement is finished.

The following pictures show the definition of the lower and upper cut plane as well as the scanning result. Please note that all data above and underneath the planes have been deleted after scanning. Concluding, the benefit of using cut planes is that it can be defined which scan data is to use and which to discard. It is for example possible to cut (and delete) the scan data of the turntable surface.

(a) Definition of cut planes position

(b) scan result by using this cut planes

Be aware that deleting a plane is irreversible. It is also impossible to reinstate a moved plane to the calculated position of the beginning. The only possibility is to teach again.

IMPORTANT

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7.6.2.2 turn-tilt table and rotation table

Before scanning an object on the computer-controlled-table it is necessary to determine the rotation axis by using the Teach button. Each time the orientation of the table and/or scanner is changed, the teach process must be repeated.

7.6.2.2.1

Using a turn-tilt table

1. Please mount the calibration object on the turn-tilt-table.

Turn the locking screw to fix the calibration object. 2. Please arrange sensor and turn-tilt-table.

To measure small objects with a small FOV it is important to observe the right working distance. For positioning the sensor in the right working distance we recommend the arrangement of scanner and turn table shown in the pictures above. It is the best to align the scanner in 45 or 90 degrees and tilt the turn table perpendicular to the scanner.

INFO

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Tilt +45 Tilt 0 Tilt 45

upside pivot position (scanner 45) horizontal pivot position (scanner 90) side pivot position (scanner reverse 45)

The 2 crosses should point onto the changeover of light and dark (half line). 3. The brightness dialog opens to set the right exposure for the measurement. For detailed information about brightness adjustment please see chapter 3.4.

4. After setting the brightness, 12 scans for defining the axes of rotation are done.

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7.6.2.2.2

Using a rotation table

Before you can scan an object on a turntable you have to define the axis of rotation by using the teach menu. 1. Place the cylinder on the turntable and press OK.

You also have the possibility to scan and fit a cone instead of a cylinder. 2. The brightness dialog opens to set the right intensity for the measurement. For detailed information about brightness adjustment please see chapter 3.4.

3. After the measurement, please select the cylinder to fit by using a selection mode with LMB and SHIFT.

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(a) select cylinder

(b) fitted cylinder

By fitting the cylinder the axis of rotation is calculated automatically.

7.6.3 Measure

In the Measure dialog please enter the number of scans that has to be taken. The rotation angle is calculated automatically. The turntable will move automatically in clockwise direction and will stop at the calculated positions where a scan is taken. After defining all parameters, press the OK button.

7.6.3.1 turnTABLE20

Automatic Scans per rotation Sensor / Object to table changed

Grab presets

Choose the number of scans to be taken; between 2 (180) and 18 (20) No: Choose No when sensor didnt move since last measurement. Sensor changed: Choose Yes when sensor did move since last measurement. One setup for all: Brightness in the Absbright dialog has to be adjusted only once before the first scan; setting is saved for all

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Wait to remove unused data Realign scans interactive

Merge together

following scans. For each grab a different setup: Adjusting a different brightness for each scan. Yes/No Decide whether OPTOCAT has to stop after scanning to remove unused data or shall go on to align and merge all data. Yes/No Decide whether scans are realigned interactive or by starting the Align function manually. Yes/No Decide whether scans ought to be merged directly after finishing the scanning or later on. STL, PLY: possible data formats Define a name for the output file No/Yes To save screen shots automatically after merge process

Merge Initialisation Save as Name 3D screen shots of final result

When the shutter time, adjusted in the Brightness dialog, is too high, a fast measurement isnt possible. Press Yes to measure in standard mode instead of fast mode.

According to the defined scans per rotations all scans are done automatically. The scanning result is shown in the 3D viewer, as well as the rotation axis defining arrow.

The turnTABLE is designed for pre-aligning scan data. After scanning is completed, the Align dialog will open for a global alignment of all scans.

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It is possible to change the position of the sensor or, instead of this, to move or turn around the object during a scan project. The following section will explain how it works.

IMPORTANT

7.6.3.1.1

Change sensor to table / object to table

After all automatically executed measurements are completed, occasionally it is necessary to add more measurements in order to capture all missing parts. To do so, the software provides two different approaches to continue the measurements without having to re-start the teach mode: Change sensor to table Change object to table.

Change the sensor position or move the object and press again the Measure button. Define all parameters such as the scans per rotation and select Sensor changed or Object changed in the second parameter line. Press OK.

In some cases more than one repetitions have to be executed. Please be aware that mixing both modes (Object changed and Sensor changed) is only possible if the Object changed-mode was executed prior to the Sensor changed-mode. If the sensor orientation has been changed once, only further steps in this mode are possible.

IMPORTANT

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Regardless of the number of scans to be done, the turntable will stop after capturing the object in the first scanning position. The pre-align dialog will open.

Mark three similar points in both windows in the same order. They will be marked with corresponding coloured pins. Confirm pin settings with the OK button. The scan will be aligned. Check the result and press OK button when they match. If not, press cancel to realign the scan.

Thereafter, all other scans are processed automatically. In a next step they have to be aligned.

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If needed, the object or sensor can be moved again. When pressing the Measure button, either the option to change the sensor or the option to change the object will be available.

If the user has done more than one scan and presses Teach button instead of Measure button after changing sensor or object position the following window will appear. Just as in the Measure dialog it is possible to specify in this dialog whether sensor or object position had changed.

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7.6.3.2 turn-tilt table and rotation table

Scans per rotation

Tilt positions

Grab presets Wait to remove unused data Interactive realign all scans Merge together

Choose the number of scans. The rotation angle is calculated automatically. 2 (180) Measure in 2 positions, the rotation angle is 180. 3 (120) Measure in 3 positions, the rotation angle is 120. 4 ( 90) Measure in 4 positions, the rotation angle is 90. 10 (36) (default) Measure in 10 positions, the rotation angle is 36. 16 (22,5) Measure in 16 positions, the rotation angle is 22,5. 17 (21) Measure in 17 positions, the rotation angle is 21. 18 (20) Measure in 18 positions, the rotation angle is 20. 0 / +45 / -45 / +45 and 0 / 0 and -45 / +45 and 45 / All Example: When you have chosen 4 scans per rotation and the tilt positions +45 and 45, then 8 scans are done. (Not possible for option rotation-table) one setup for all for each grab a different setup YES Unused data wont be removed without query. NO Unused data will be removed without query. YES The align dialog box opens. NO The align box doesnt open, aligning takes place automatically in the background. YES The scans are merged together. NO The scans arent merged together.

By using a rotation-table the choice of tilt positions are not possible and also not necessary.

When chosen Merge together = YES the merge dialog will appear (see chapter 8.2).

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The brightness dialog opens to set the right exposure for the measurement. For detailed information about brightness adjustment please see chapter 3.4.

After scanning the object on the turntable automatically, youll see the scanning result.

3. Case: Merge together = YES: The scans will be merged automatically after finishing the scanning. Before that, you have the only chance to remove unneeded data. If you dont delete anything, you will have everything youve scanned in your merged *.stl or *.ply file, scanned parts of object environment as well.

Case: Merge together = NO: You have to click the merge button by yourself after deleting data you do not need. For merging see chapter 15. Using this option also allows you to reload your scanned data in a higher resolution (standard or full resolution) before merging.

Remove data

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If the scans do not match the teach procedure must be repeated. If you do not move the scanner and the table after finishing a project, then you can start the next measurement projects without a new calculation of the axis of rotation. But if you did move anything then you have to calculate the axis of rotation again by using the teach button.

IMPORTANT

7.6.4 Single Scan

The Single Scan menu is helpful when hand-operated measurements (e.g. to complete objects) ought to be done. By pressing the button Single Scan different angles (+/-1 or +/10) can be chosen to turn the table. In the shown live pictures the scenery can be controlled.

Another possibility to change the angle in bigger steps (+/-30) can be executed with the two buttons on the remote switch.

After arrangement of the angle and confirmation with the OK-Button the measurement will be done automatically. Remote control only belongs to turnTABLE , the turn-tilt table is not delivered with this device.
20

IMPORTANT

Functions of additional buttons There are a number of additional buttons in the toolbar which can be used for hand-operated measurements.

general buttons

buttons for single scan

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The positioning laser can be switched on and off. The crosshair can be switched on and off. The bounding box can be switched on and off.

Display sensor body Display Display from up to acquisition

Yes/No Decide whether the sensor body shall be shown or not. The sensor body can be shown for the last scan (e.g. current scan 4) or for all loaded scans. Choose the first and last scan to be displayed. Then press selected scans.

Projector light can be switched on and off.

The Grid can be moved.

Pattern

Bright, Dark GC05, GC1, GC2, GC4, GC8, GC16, GC32 PHI0, PHI90, PHI180, PHI270

The camera Live image can be shown.

The last measurement can be deleted.

The turntable can be moved into the reference position (complies the Teach position).

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The turntable can be moved into a defined position by setting an angle value. The angle is counted from the zero position, not from the current position.

Turntable can be moved 10 backward.

The turntable can be moved into the zero position. For the turnTABLE , reference position and zero position are the same. The turntable can be moved forward by 10.
20

This function would tilt the turn-tilt table to +45. It cannot be used with a turnTABLE . This function would tilt a turn-tilt table to 0. It cannot be used with a turnTABLE .
20 20

This function would tilt a turn-tilt table to -45. It cannot be used with a turnTABLE . The current scanning angle can be saved. See section Additional Information to get more information about this function.

7.6.5 Parameter

See chapter 5.

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7.6.6 Align

Fine alignment dialog

Detail view after the fine alignment. All scans should be marked with OK.

Standard view of the result

Graphic view of the result

After the fine alignment the datasets intersect each other much better. That means they match well together.

7.6.7 Processing

Pressing the Processing button results in an automatic changeover to the macro group processing. One of the functions in this macro group is the merging of the scan data. To activate this function, please press the Merge button. The following dialog will appear.

Press Use this and define the file format, the name of the resulting file and whether screen shots are needed or not. Then, press OK.

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The scan data will be merged.

For further information see chapter 8 in the OPTOCAT manual.

7.6.8 Load

See chapter 7.1.9. When 3D containers of an existing project are loaded, existing cut planes are automatically loaded as well. If they are not needed, they have to be deleted manually from the 3D tree.

IMPORTANT

7.6.9 Save

See chapter 7.1.10.

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7.6.10

Additional Information

It is possible to create templates to scan an object in user defined positions, that means the turntable will be moved in user defined angle steps. This can be very helpful when many objects of a same kind are to be measured equally or in cases the user has to scan complex objects where small rotation angles are needed in difficult areas and bigger rotation steps are sufficient in areas which are easy to measure. There are two ways to define the template: a) After having scanned an object If the user has scanned an object and would like to scan the next object using the same rotation steps, a template, serving as basis for the next project, can be saved. To do this, go to File and press Save Settings as Template.

Create a name for the template.

When defining a new project, choose the created template and set the parameter Used positions to as defined in Template. Then press OK.

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After pressing the Measure button all scans are done in the rotation steps defined in the created template. b) Before scanning an object It is also possible to define a template before scanning the object. Place the scan object on the turntable and go to Single Scan in the OPTOCAT software. After initialising the sensor, turn on the projector light and take a live picture with the cameras to check whether the current position is a good position to scan. If you would like to scan the object using this position, press the floppy disk symbol.

Using the buttons on the right hand side move the turntable in user defined steps or 10 steps and check which scan position would be the most suitable for capturing the object. Press the floppy disk sign in each position youd like to scan later on. Upon completion of defining the rotation steps, they have to be saved in a template. To do this, go to File, press Save Settings as Template and define a name.

The following procedure of initialising a project with the defined template is equal to the procedure described above (paragraph a).

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7.7 Multi Sensor

7.7.1

7.7.2

7.7.3

7.7.4

7.7.5

7.7.6

7.7.7

7.7.8

7.7.9

7.7.10

7.7.11

Multiple sensor systems can only be used at the same time in Contour Matching Projects. Other measurement types like index mark matching are not possible.

INFO

7.7.1 Initialisation

Please do not use blanks or other special characters in the save paths and project names.

IMPORTANT INFO

By clicking the options button a choice of the recent 10 projects appears. Please select the file which has to be loaded.

Select the Template that has to be used for scanning. To select and configure the multiple sensors press Edit Sensor List.

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Then, the following dialog opens. In the first window of this dialog the scan order as well as the sensor type has to be defined. The currently selected sensor type is shown here. This sensor type can be changed into other available types using Change used sensor type.

Sensor (e.g. SM1205)

Change used sensor types

1 The first scan will be done with this system. 2 The second scan will be done with this system (when 2 sensors are activated). Deactivated: The sensor in not active and will not be used. At least one sensor has to be activated! All sensor types which are available but not initialised at the moment will be shown. To change the sensor type in one of the sensor types which is named in the table, press Change Types.

In this example the smartSCAN_SE_Mono sensor type is activated. That means measurements are only possible with the left or right system camera. In Change used sensor type only the smartSCAN_SE is available. By selecting this and pressing the button Change type the sensor type will be changed from Mono to Duo. That means now only measurements using both cameras of the system are possible. One camera systems and two camera systems cant be mixed.

INFO

In the second and third window of the current dialog the sensors can be configured.

Configuration Nickname Lamp on Delay

All available FOV of the sensors will be shown. Select the FOV which has to be used for scanning. Define a user friendly name to indentify your sensor. 300ms (Default) Define a delay for turning on the sensor light of the scanner. This is important to avoid disturbance of the other sensor which is still scanning.

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Lamp of Delay

0ms (Default) Define a delay for turning off the sensor light.

After defining the configuration press OK. After pressing OK a second time, the Initialisation dialog opens. Define all parameters for scanning and go on with OK.

7.7.2 Teach

To do measurements with all sensors, which will be automatically pre-aligned, the Teach function has to be started before scanning the specific measurement object. First of all, position the sensors around the teach object (the coded semisphere which is shown below) in the right working distance by using in laser pointer. Then, check or change (when needed) the brightness of each sensor. In this example sensor SM2030 and SM2032 are in use. Press the button SM2030 and SM 2032 to check the brightness. For more details about Brightness settings see chapter 3.4.

Take texture Signal Mode

Before Scan Texture will be captured before scanning. After Scan Texture will be captured after scanning. To get an acoustic, visual or none information that a scan will be done. None Beep+Dialog Beep

(a) Teach object (coded semisphere)

After each sensor has done a measurement, the coded marks will be measured automatically. Each sensor has to detect at least 3 marks. If this is the case, an information dialog will appear that gives the user the information that the teaching was successful.

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It is not necessary, that each sensor sees and measures the same coded marks. IMPORTANT Each sensor can measure different marks independently. After teaching, please replace the coded semisphere by the scan object. Then, go on with the function Scan.

7.7.3 Scan

The scan procedure is the same as it is described in the scan sections above. The only difference is that scans will be aligned automatically by teaching (Teach), using the coded semisphere. A pre-alignment is not needed anymore for aligning the scans.

7.7.4 Align

Search Range

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max. Iterations Only Selection 3D View Update

Number of Iterations No: the whole available 3D-data is used for the alignment Yes: the alignment works only on the selected areas No: 3D-view update during alignment Yes: 3D-view update during align process (occupies capacity)

Fine alignment dialog

Detail view after the fine alignment. All scans should be marked with OK.

Standard view of the result

Graphic view of the result

Object before the fine alignment.

Object after fine alignment

After the fine alignment the datasets intersect each other much better. That means they match well together.

7.7.5 Save MAT

If the position of the sensor has changed after doing the Teach, it is possible to do an alignment to match the new measurements with the older ones. When the alignment of the scans is fine, the matrix which describes these alignment can be saved using the Save MAT function. This matrix will be saved in the MAT folder of the current project. All further scans will be aligned automatically to older scans using this matrix.

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7.7.6 Processing

Automatic change to the taskbar processing. See chapter 8 for information about processing.

7.7.7 Parameter

This function changes the parameters without initialising a project, for a quicker change of parameters. See chapter 5.

7.7.8 Brightness

To check the scenery and the brightness settings the brightness dialog can be opened. For more details see chapter 3.4.

7.7.9 Pre-Align

Select the number of the scan in your 3D tree, which you want to re-align.

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Both scans have the same colour. To see the real texture tick Texture. Then, set pins at similar points to align the scans.

To ease the finding the background can be lighted up by ticking Bright.

To check the alignment tick Preview. Then, press OK button.

INFO

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7.7.10

Load

See chapter 7.1.9.

7.7.11

Save

See chapter 7.1.10.

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7.8 Metronor

7.8.1

7.8.2

7.8.3

7.8.4

7.8.5

7.8.6

7.8.7

7.8.8

7.8.9
3D

The combination of a Metronor DUO portable CMM and a Breuckmann stereoSCAN whitelight scanning system offers high flexibility and accuracy to users of portable measurement equipment. The following chapter explains how to work with the combination of a Metronor DUO system and a Breuckmann stereoSCAN sensor, the so called naviSCAN.

naviSCAN: combination of Metronor DUO portable CMM and Breuckmann stereoSCAN3D

While the Metronor DUO system sets up a large working volume, the stereoSCAN precisely and quickly scans areas up to one square meter per shot. Stitching several shots together works seamlessly and without any user interaction through the navigation target mounted to the back of the scanner. The navigation target allows complete freedom for any movement and position of the scanner. During the scan sequence the system even monitors and notices any movement of scanner or part, thereby assuring precise measurement and scans.

Principle of operation: By tracking the navigation target mounted on the stereoSCAN3D sensor with the Metronor DUO system, several shots will be aligned automatically and seamlessly without any user interaction.

Benefits of naviSCAN Probing and Scanning works seamlessly in the same coordinate system Large working volume No need to apply (and remove) targets or stickers Quick and straightforward workflow

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Easy to use and hence quick to learn Hidden points that are not accessible through the scanner, can be measured with a touch probe Ideal combination for applications that require discrete point probing as well as high density scan data System is completely portable, with heavy duty flight cases Can be used in hostile shop floor environments System monitors vibrations and checks accuracy online

7.8.1 Initialisation

See chapter 5.

7.8.2 Combine Systems

The accuracy and performance of the combined system (naviSCAN) depends strongly on a good calibration of both, the stereoSCAN and the DUO system. Before the naviSCAN can be used make sure that both system components 3D are calibrated. For calibrating the stereoSCAN scanning system see chapter 6.1. For calibrating the Metronor DUO system see Metronor manual.

IMPORTANT

The third essential task is to exactly match the coordinate systems of both optical devices, otherwise it is not possible to align measurements automatically. How to combine the coordinate systems: 1. Calibrate the stereoSCAN scanning system as well as the Metronor DUO system. 2. Position the calibration target, consisting of at least 3 tooling balls, within the middle of the DUO system volume.
3D

calibration target

Make sure that there is enough space for the stereoSCAN system to be moved around the tooling balls with the navigation target being still within the DUO system field of view.

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The distance of the tooling balls themselves need to be adjusted to fill the field of view of the stereoSCAN system. This is about 300 mm ball distance for the 400 mm FOV and about 500 mm for the 700 mm FOV. The balls can be easily shifted on the aluminum profile to achieve this. 3. Start the function Combine Systems and scan the calibration target from at least three different angles. For this the stereoSCAN system is positioned at an angle of about 45 degrees towards the ball target.

Nr of spheres Manual Alignment Recalculate existing scans

Define number of spheres for combining both systems (Default is 3). Yes/No Decide whether scans for combining systems ought to be aligned manually or automatically. Default is no. Yes/No Decide whether scanning of 3 positions ought to be skipped, for example when measurements which were done earlier shall be loaded. Default is No.

Press OK button. The following dialog with information about the scanning procedure will appear.

According to all dialog instructions, take 3 shots of the calibration target as shown in the pictures below.

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Shot 1

Shot 2

Shot 3

Now the scan data of the tooling balls must be selected in order to calculate the center points. Follow the instructions and select the three tooling balls one after another.

(a) Selection of sphere 1

(b) Spherefitting

4. Now the balls need to be measured as precisely as possible with the Metronor lightpen touchprobe. It is recommended to use 12 points per sphere. Please make sure that the position of these balls is not altered anymore until the registration procedure is finished. The center points will be saved and transferred to the OPTOCAT software.

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Please make sure to use the same measurement order as defined in the scan procedure before. That means the ball which got #1 has to be measured first with the lightpen, then ball #2 and at least ball #3. Again, be aware that the position of the navigation target is not altered until the registration procedure is finished.

IMPORTANT

basic sketch: ball tool measurement with lightpen (in Metronor coordinate system)

5. Now, using the scan data of the ball tools (Breuckmann coordinate system) and the lightpen measurements of this tools (Metronor coordinate system) a matrix to combine both systems is determined.

6. After finishing the registration process measurements, which will be aligned automatically, can be done.

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7.8.3 Scan

The scan procedure is the same as it is described in the scan sections above. The only difference is that scans will be aligned automatically by the use of the Metronor system. A prealignment is not needed anymore.

7.8.4 Optimize Alignment

After scanning is done, it is possible to improve the alignment using the Optimize Alignment function. By defining tolerance and max deviation the movement of scans can be limited to the system accuracy. That means the overall accuracy will be kept.

Interactive Tolerance Max deviation Mode

Visualize Factor

Yes/No Scans are aligned manually or automatically Define a tolerance in mm how much scans can be moved Define a maximum deviation in mm between scans, how much scans can be moved at most (max deviation = 2x tolerance) Define the number of base points for the alignment, the points are defined automatically in the sensor volume One Point Five Points (Default) Define the Size of visualized base points 1 (Default)

(a) Optimization using 5 points per scan

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7.8.5 Processing

Automatic change to the macro group processing.

7.8.6 Parameter

This function changes the parameters without initialising a project, for a quicker change of parameters. See chapter 5.

7.8.7 Brightness

To check the scenery and the brightness settings the brightness dialog can be opened. For more details see chapter 3.4.

7.8.8 Load

See chapter 7.1.9.

7.8.9 Save

See chapter 7.1.10.

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8 Processing

8.1

8.2

8.3

8.4

8.5

8.6

8.7

8.8

8.9

8.10

After making the scans the post-processing follows. Here you can merge the single scans to one mesh and smooth the result. If you have index marks in your scans you can cut them and fill the holes. Before saving you can compress the mesh to reduce the data amount.

8.1 Re-Processing

Changes to the taskbar re-processing for an existing project.

8.1.1 Toolbar

Align: Starts mesh align for a fine alignment of the scans. If you have a Contour Matching project the contour alignment is started. If you have an Index Mark or Reference Matching project the constrained alignment is started. Re-Align: Starts n-point alignment for realigning meshes with setting pins on similar object points.

8.1.2 Load Project

Load an existing project for re-processing. For more information see chapter 5.1.

8.1.3 Parameter

Set the parameters for re-processing. For more information see chapter 5. OPTOCAT can automatically identify which kind of project (Contour, Index Mark or Reference Matching,) is selected and opens the corresponding parameter boxes automatically. With loading old projects you are requested to select the project type manually.

INFO

8.1.4 Load

See chapter 7.1.9.

181 Inspection

8.1.5 Save

See chapter 7.1.10

8.2 Parameter

For more information see chapter 5.

8.3 Merge

In the merge process the single views and single edges (when their detection has been activated) are merged together to one mesh or edge. The parameters for this process are set in the Initialisation dialog box (see chapter 5). Depending on the fact whether scan data is loaded before pressing the Merge button and the resolution of the scan data, the Merge dialog will have a different user interface. a) Pressing the Merge button without having loaded a project:

Please load a project first! b) Pressing the Merge button with having initialised a project (but no data loaded):

Use the stored 3D meshes Recalc data resolution using full

To load the 3D meshes in the resolution which has been used for capturing. To recalc and load the 3D meshes in full resolution.

182 Inspection c) Pressing the Merge button with having initialised a project and having data loaded:

Please note that the button Clear + Recalc will not appear when data is already loaded in full resolution. Choose Use this when you want to merge the currently loaded 3D data. Select Clear + Reload when you want to merge other 3D data from scans. When data which was measured in preview or standard resolution ought to be merged in full resolution, press Clear + Recalc first. Then, the scan data will be loaded higher resolution before the merge process starts. After defining which data in which quality shall be used for merging, one of the following dialogs will appear. The design of the dialog depends on the fact whether edges have been measured or not. Expert Mode Project without Edge Detection

Project with Edge Detection

In both cases the file format (Save as), the name of the resulting file (Name) as well as the fact whether a 3D screenshot of the final result is needed or not have to be defined. In Edge Detection projects it has to be defined as well whether the edges shall be merged (Merging Edges) and whether the meshes shall be extended to these edges or not (Extending meshes to edges). Merging starts directly after pressing OK button.

183 Inspection The following pictures show the Merge dialog in Admin Mode. Project without Edge Detection Project with Edge Detection

184 Inspection Admin Mode Merge Initialisation Define whether smart filter shall be used or not. Run smart filter on STL No, Yes Merging Edges Define whether edges shall be merged or not. No, Yes Extending meshes to Define whether meshes shall be extended to edges or not. No, Yes edges STL, PLY: possible data formats Save as Name Define a name for the output file 3D screenshots To save screenshots automatically at the end of merge process No, Yes Admin Mode Smoothgroup Define whether radius shall be calculated automatically or value Calculate Filter Radius below shall be used. Yes/No Filter Radius Insert a value for Filter Radius (in mm /inch /thou go to File Change Unit to choose required unit). Filter Angle Define critical angle that prevents points from being filtered in overlapping areas. 60 degree (Default) Iteration Number of iterations for filtering (1-10). Higher number with lower radius preserve better quality. 2 (Default) Reliability Controls how overlapping data points are handled, depending on their quality value. Higher settings keep high quality points unchanged. (Standard, Lowest, Low, High, Highest, Ignore Reliability) Smooth Color Define level of smoothing. 0: No smoothing is executed (faster) 100: medium smoothing (standard) 200: strong smoothing (to avoid visible gaps) Admin Mode Merge Calculate Min Distance

Min Distance Calculate Max Distance

Max Distance Reliability

Define whether Min Distance shall be calculated automatically or value below shall be used. Points with distances smaller than this value will be merged into one point. Yes/No Define Min Distance value (in mm /inch /thou go to File Change Unit to choose required unit). Define whether Max Distance shall be calculated automatically or value below shall be used. Points with distances greater than this value will not be connected. Yes/No Define Max Distance value (in mm /inch /thou go to File Change Unit to choose required unit). Controls which data is used for merging. Default: Lowest, all data better than this will be used. (Standard, Lowest, Low, High, Highest, Ignore Reliability)

Admin Mode Filter Smart Filter before compress

Smart Filter after compress

Maximum change Edge sharpening

Number of iterations of mesh filter smart before compress is running. 0 iterations: disable filter Larger numbers increase the filter effect. Number of iterations of mesh filter smart after compress was running. 0 iterations: disable filter Larger numbers increase the filter effect. Maximum change that is allowed to be applied on these model. Controls the performance on sharp edges. 0.1: only smoothening, keeping only sharp edges 0.9: smoothing areas with low curvature, sharpening areas with high curvature

185 Inspection

8.4 Smooth

Mesh Radius of filter [mm] Max angle Triangles

select the mesh which has to be filtered by using the 3D button select the radius of the filter select the angle limit for filtering All: the whole object will be filtered Selection: only the selected parts of the mesh will be filtered

8.5 Cut index marks

You have the possibility to cut out the targets from your 3D data automatically. You need only to specify the diameter of the cut circle and the information from the reference point data set is used to cut out the targets.

Useful only for Index Mark or Reference Matching projects!

IMPORTANT

Diameter circle

cut

To cut an index mark completely you should specify the diameter a little bit bigger than the real diameter.

186 Inspection

8.6 Fill holes

Function to close holes in the 3D data. If OPTOCAT cannot fill a hole this can be caused by a distant triangle. Use function MeshOutlierDetection (see details in section 9.4.10) to search for defect triangles and remove them. Otherwise you can also survey the edges around the hole directly, cut out faulty areas and run the fill holes process again.

Mesh/SOI Max Size [mm] Only selected areas Reliability of Filling

Select the mesh/SOI in which you want to fill the holes. Enter the maximum size of the holes. Yes: the holes are filled only on selected parts of the data. No: on the whole object the holes will be filled. used for risk analysis Highest; High; Standard; Lowest; Low

8.7 Compress

Mesh Surface error [mm] Max edge [mm] length

Select the mesh, which you want to compress. Enter the maximum surface error. This means the difference between the original surface and the processed surface. Defines the maximum edge length of the triangles. If this parameter is negative (-1), it will be ignored during the compressing.

8.8 Load
You can load data for evaluation. If you want to evaluate data from another project as the initialised one you can initialise another project first. For more information see chapter 7.1.9.

187 Inspection

8.9 Save

See chapter 7.1.10.

8.10 Scan View

By pressing this icon the scan layout which was used for scanning (Contour, Automatic,) will be reloaded.

8.11 Functions for Processing

See chapter 9.4.

188 Inspection

9 Inspection

9.1

9.2

9.1 Load

See chapter 7.1.9.

9.2 Save

See chapter 7.1.10.

9.3 Functions for Inspect 1

9.3.1 Mesh comparison

189 Inspection Distance calculation: Mesh Reference Max Distance Mode Mesh which should be visible in the 3D viewer Reference dataset, will not be shown in the 3D viewer Max distance between the two datasets in which two equal points are searched. The higher this value the longer the evaluation time. Nearest (default): the nearest distance will be visualized Along vertex normal: the next point is searched in the orientation of the vertex normal Signed (default): the differences are shown in positive and negative values depending on the orientation Absolute: the absolute value of the difference is shown only positive values

Result Type

Visualisation: Colour bar title Colour bar Min range Max range Offset Title for the colour bar Select a colour bar for visualisation of the differences Define the minimum of the colour bar Define the maximum of the colour bar Define an offset

Mode: nearest Result type: signed

Mode: along vertex normal Result type: signed

Mode: along vertex normal Result type: absolute

9.3.2 Fit plane

Before you run this function you need to select the part on which you want to fit the plane. Then open the function window with the right mouse button.

fitting mode: points

fitting mode: triangles

190 Inspection Example: calibration plate

calibration plate

fit plane

calibration plane

plate

and

fit

Container Target plane name Ignore outliers [%] Average distance [out] Standard deviation [out] Min distance [out] Max distance [out] Fitting mode

Select your object in the 3D tree (Mesh or SOI) Enter a name for the plane If there are outliers in that area you can ignore them. Enter the percentage value. Output variable name Output variable name Output variable name Output variable name Points: The algorithm uses the object points. Triangles: (standard) The algorithm uses the object triangles.

Result plane from Points and Triangles mode may differ, depending on the selected object shape.

INFO

9.3.3 Fit cone

The function FitCone achieves a cone fit on a selected area of a mesh or SOI object.

Select an area in which the cone should be fitted. Then execute the function and the cone is fitted in this area. The cone is added to the 3D tree in the desired location as a cone object.

Container Target Cone Name

Select your object in the 3D tree (Mesh or SOI) Enter a name for the cone

191 Inspection

9.3.4 Fit sphere

The function fit sphere achieves a sphere fit on a selected area of a mesh or SOI object.

This window is only shown if you select fit interactive = yes Fit interactive Fit result Fit radius Fixed radius Reliability Yes: the window sphere fitting results is shown No: the window sphere fitting results is not shown Enter a name for the fitted sphere Yes: the function will fit the radius itself No: enter a fix radius in the next line Radius of the first sphere, only if you selected fit radius: no high/ highest/ low/ lowest/ standard Quality value which includes the position in the volume, the angle, the normal, contrast, etc. Optimized/ 0.5%/ 1%/ 10%/ 20%: value of ignored outliers Standard: all data points are used No/ 1m/ 5m/ 10m/ 20m/ 50m/ fitpoints: scaling of the false colour display of the differences (data set to fitted sphere)

Fit mode Visualize

If fit interactive parameter is set to yes the result window is opened: Centre Radius rms error Fit Quality Coordinates of the centre of the sphere Radius of the sphere Root mean square value Quality of the result

192 Inspection

9.3.5 Fit dumbbell

The function FitDumbell achieves a dumbbell fit on a selected area of a mesh or SOI object.

This dialog opens only if you select fit interactive = yes

Fit interactive Sphere1 Sphere2 Fit radius Fixed radius 1 Fixed radius 2 Reliability

Fit mode Visualize Logfile

Yes: the window dialog is shown No: the window dialog is not shown Enter a name for the first sphere Enter a name for the second sphere Yes: the function will fit the radius itself No: enter a fix radius in the next two lines Radius of the first sphere, only if you selected fit radius: no Radius of the first sphere, only if you selected fit radius: no high/ highest/ low/ lowest/ standard Quality value which includes the position in the volume, the angle, the normal, contrast, etc. Optimized/ 0.3%/ 0.5%/ 1%/ 10%/ 20%: value of ignored outliers Standard: all data points are used No/ 1m/ 5m/ 10m/ 20m/ 50m/ fitpoints: scaling of the false colour display of the differences (data set to fitted dumbbell) The result can be saved in the given file.

If fit interactive parameter is set to yes the result window is opened: Centre Radius Rms error Distance centre Fit quality Coordinates of the centre Radius of each sphere Root mean square value Distance between the two centres Quality of the result

193 Inspection

9.3.6 Fit cylinder

The function FitCylinder achieves a cylinder fit on a selected area of a mesh or SOI object.

Fit interactive FitResult Object Fit Radius Fixed Radius Reliability -3D

Yes: the window dialog is shown No: the window dialog is not shown Enter a name for the fitted cylinder Yes: the function will fit the radius itself No: enter a fix radius in the next line Radius of the cylinder, only if you selected fit radius: no high/ highest/ low/ lowest/ standard Quality value which includes the position in the volume, the angle, the normal, contrast, etc. Error 1/ Error 10/ Error 100/ Error 20/ Error 5/ No: scaling of the false colour display of the differences (data set to fitted cylinder)

Visualize

Scan

Fit result

Visualisation with an Error of +- 100m

194 Inspection

9.3.7 Write PTS to ASCII

Point data (centre coordinates of a point or sphere) are saved in an ASCII file.

Container -3D Object Filename Format

Choose the point data to be saved (out of the 3D tree) Choose a file name for the point data Format of the saved number columns, standard is: %.7f %.7f %.7f means: all three numbers (x,y,z) are displayed as a float variable with 7 decimal places

9.3.8 Create

Create Points You can create a point by defining its 3D coordinates. Enter a name in the field container.

Create vector You can create a vector by defining the 3D coordinates of its start and end point. Enter a name in the field container.

195 Inspection Create plane from hesse form You can create a plane by defining the four hesse coefficients. Enter a name in the field plane name.

A*x + b*y + c*z + d = 0 in the example above the middle of the plane is point p = 0; 0; -2 Create plane from anchorpoint, u- and v-vector

With:

A = Hesse coefficient 1 B = Hesse coefficient 2 C = Hesse coefficient 3 D = Hesse coefficient 4

You can create a plane by defining one anchorpoint and the two vectors u and v.

The middle of the plane is in point p = 0; 0; -2 The dimension of the plane is set through the length of the vectors u and v.

image 1

image 2

image 3

1. Two planes made with the function plane from anchor point and u- and v-vector. The yellow one has u- and v-vector length 1 and the green plane has u- and v-vector length 3. 2. The yellow plane from point 1 and the coordinate system. There you can see the anchorpoint in p = 0;0;-2. 3. Image 2 + the plane made with hesse form. There you can see the middle point of the hesse plane in p = 0; 0;-2.

196 Inspection

Create circle from centrepoint, radius and axis You can create a circle by defining a centre point, a radius and the normal vector of the circles plane. Enter a name in the field container.

Create - sphere You can create a sphere by defining a centre point and a radius. Enter a name in the field container.

Create cone You can create a cone by defining the 3D coordinates of the bottom centre, the top centre and the radii of the bottom and top faces. Enter a name in the field container.

Create cylinder You can create a cylinder by defining the 3D coordinates of the bottom centre, the top centre and the radius. Enter a name in the field container.

197 Inspection

Create SOI You can create a SOI by defining the place in the coordinate system with the origin point and the dimension and the orientation with the u and v vectors. Enter a name in the field container and define a grid stride for the dimension of each quadrate.

9.3.9 Construct

Construct point from vector You can construct a point from a vector at several positions. Enter a name for the point in the field container and choose your vector name in field vector. Then select a position on which the point should be constructed. You have three possibilities: Start, Centre and End.

Construct point from circle You can construct a point in the centre of a circle. Enter a name for the point in the field container and choose the name of the circle in field circle.

198 Inspection

Construct point from sphere You can construct a point from a sphere. Enter a name for the point in the field container and choose the name of the sphere in field sphere.

Construct point from cone You can construct points from a cone. Enter a name for the point in the field container and select the name of the cone in field cone. Then choose a position on which the point should be constructed. You have two possibilities: CentreOfBottomFace or ConePoint.

Construct point from cylinder You can construct points from a cylinder. Enter a name for the point in the field container and select the name of the cylinder in field cylinder. Then choose a position on which the point should be constructed. You have two possibilities: CentreOfBottomFace or CentreOf TopFace.

199 Inspection Construct vector from two points You can construct a vector from two points. Enter a name for the vector in the field container and choose two points.

Construct vector from planes normal vector You can construct a normal from a plane. Enter a name for the vector in the field container and choose a plane.

Construct vector from a circle axis You can construct a vector from a circle. Enter a name for the vector in the field container and choose a circle in field circle.

Construct vector perpendicular to another vector You can construct a vector between a point and a vector. The vector will define the shortest distance between the point and the vector. Enter a name for the vector in the field container and choose a point and a vector in the appropriate field.

200 Inspection

Construct vector by combining two vectors You can construct a new vector by combining two vectors in different ways. Enter a name for the new vector in the field container and choose a combining strategy. Select the two vectors for the operation. Combining strategies: addition, start-end, connect shortest, cross product and subtraction. Examples you can see below. The red vectors are the new ones.

Construct vector from the distance between a mesh and a point You can construct a vector between a point and a mesh. Enter a name for the vector in the field container and select the targets, the point and the mesh object. The vector defines the shortest way between the point and the mesh.

Construct vector perpendicular to a plane with a certain anchor point You can construct a vector between a point and a plane. Enter a name for the vector in the field container and select the targets, the point and the plane. The vector defines the shortest way between the point and the plane.

201 Inspection

Construct plane from three points You can construct a plane from three points. Enter a name for the plane in the field container and select the three points from your 3D tree.

Construct plane from point and vector You can construct a plane from a point and a vector. Enter a name for the plane in the field container. Then choose the point and the vector from the 3D tree.

202 Inspection Construct plane from point and plane You can construct a plane from a point and a plane. Enter a name for the plane in the field container. Then choose the point and the plane from the 3D tree.

Construct circle from three points You can construct a circle from three points. Enter a name for the circle in the field container and select the three points from the 3D tree.

Construct sphere from centre and radius You can construct a sphere from a centre point and a point which distance to the other point defines the radius of the sphere. Enter a name for the sphere in the field container and select the two points.

203 Inspection Construct sphere from four points You can construct a sphere from four points. Enter a name for the sphere in the field container. Select four points from the 3D tree.

Construct cone from centre and axis You can construct a cone from a vector and a point. Enter a name for the cone in the field container. The vector defines the height and the orientation of the cone.

Construct cylinder from point and axis You can construct a cylinder from a vector and a point. Enter a name for the cylinder in the field container. The vector defines the height and the orientation of the cylinder and the point defines the radius.

204 Inspection Construct mesh from vector group You can construct a mesh from a vector group (at least three vectors). They have to define a closed area. Enter a name for the mesh in the field container. Select the container with the vector group.

If you do not have the vectors in a container for their own, make a new 3D group (container) with function New3DGroup and put the vectors inside (by drag and drop).

INFO

9.3.10

Intersect

Intersect two vectors If you have two vectors this function shows the intersection between them. Enter a name for the intersection in the field container. Select the two target vectors from the 3D tree.

205 Inspection Intersect three planes If you have three planes this function shows the intersection between them. Enter a name for the intersection in the field container. Select the three target planes from the 3D tree.

Intersect vector and plane If you have a vector and a plane this function shows the intersection between them. Enter a name for the intersection in the field container. Select the target vector and plane from the 3D tree.

Intersect sphere and vector If you have a vector and a sphere this function shows the intersection between them. Enter a name for the intersection in the field container. Select the target vector and sphere from the 3D tree.

206 Inspection Intersect cone and vector If you have a vector and a cone this function shows the intersection between them. Enter a name for the intersection in the field container. Select the two targets, vector and cone, from the 3D tree.

Intersect cylinder and vector If you have a vector and a cylinder this function shows the intersection between them. Enter a name for the intersection in the field container. Select the two targets, vector and cylinder, from the 3D tree.

Intersect mesh and vector If you have a vector and a mesh this function shows the intersection between them. Enter a name for the intersection in the field container. Select the two targets, vector and mesh, from the 3D tree.

207 Inspection Intersect two planes If you have a two planes this function shows the intersection between them. Enter a name for the intersection vector in the field container. Select the two plane targets from the 3D tree.

9.3.11

Measure

Measure distance between two points

Measure distance between point and vector

208 Inspection Measure distance between plane and point

Measure distance between two vectors

Measure angle between three points

209 Inspection Measure angel between two vectors

Measure angle between plane and vector

Measure angle between two planes

210 Inspection

9.3.12

Inspect surface point

Function to sample data points on a Mesh. Thereby either points or vectors can be generated. Define a container for the resulting points or vectors. If no container is defined points or vectors can only be sampled and not generated!

With clicking on the Mesh in the 3D viewer with CTRL + left mouse button a point or vector is generated. The coordinates and normal are displayed in the dialog box. With Inspect vertices the area around the click position is taken into account. Not the click position itself is used to generate the point, instead the next real Mesh point is used.

Resulting points and vectors on the Mesh and in the 3D tree.

9.3.13

Make sections

This function creates parallel sections on a 3D object. These sections can be created parallel to the coordinate planes (X-Y, X-Z or Y-Z plane) or parallel to a free defined plane. Thereby the user defined plane has to be created before executing the section function. To use the coordinate planes for the sections it is useful to orientate the data set in a suitable direction before (for example with function CoordSystem321 in section 9.3.16). The Make Sections provide two different modi. Step: The section distance is specified by the Step [mm] parameter. The parameter Number of Sections is not used. Number: The number of sections is specified by the Number Of Sections parameter. The parameter Step [mm] is not used. All calculations of the sections are based on the dimension of the object bounding box.

211 Inspection

9.3.14

LUT attrib

This function compares 3D elements by means a 3D LUT table and stores this in a CTR file.

212 Inspection

9.3.15

Compare PNT file

With this function two arbitrary datasets of a PNT file are compared with each other. The deviation between the points by each other is displayed as a sphere. With LUTattrib function you can visualize the difference spheres in a false colour scaling.

9.3.16

Coord system 321

This function creates a new coordinate system according to the 321 method. The points are selected with CTRL + left mouse button clicking on desired points on the mesh. The first 3 points are for the definition of a plane, then 2 points to define a vector line and finally a point for the origin of the new coordinate system. With the Flip possibility you can invert the orientation of the plane or line respectively.

original coordinate system

changed coordinate system

213 Inspection

9.3.17

Coord system from planes

With this function you have the possibility to define a new coordinate system by 3 different planes. First you should define the planes. Afterwards you can choose a new name for the coordinate system and select the planes out of the 3D tree. With the Flip possibility you can invert the orientation of the planes.

9.3.18

Move container

With the MoveContainer function you can move single objects or groups in the coordinate system relatively.

214 Inspection

9.3.19

Container clear

The content of a container will be emptied but the container itself will not be erased.

9.3.20

Container erase

The complete container with its content will be erased.

9.3.21

Select intersection

This function selects or deselects inner or outer intersections of an element (sphere, plane, group) with all active 3D objects in the 3D view.

215 Inspection

9.3.22

Select Shell

This function selects all triangles of the mesh, which are connected to a selected area. With inverting the selection after the Select Shell functionality, all single triangle areas are selected automatically and could be removed.

9.3.23

Change selection

The function ChangeSelection selects or deselects points in the 3D views of all active SOI. Selected points are displayed red.

9.3.24

Snapshot 3D

You can save the content of the 3D viewer as an image (supported formats are *.bmp, *.jpg, *.gif and *.png).

216 Inspection

9.3.25

SOI compensation

This function executes a compensation of a 3D element. A new 3D raster is calculated by means of polynomial areas.

Original SOI

Compensation with SOI + compensation polynomial degree 3

Compensation with polynomial degree 12

Function only works on a SOI (raster) object, not on a Mesh (triangulated).

IMPORTANT

9.3.26

SOI compare

This function compares 3D element with each other.

Function only works on a SOI (raster) object, not on a Mesh (triangulated).

IMPORTANT

217 Inspection

9.4 Functions for Inspect 2

9.4.1 N-Point Align

Function to align a container by defining similar object points.

3D Object / Group modus

Select the object or object group for alignment. Three axis rotation: 3 similar object points in both windows have to be defined. The object can be rotated in x,y and z dimension. One axis rotation: Only 2 similar object points have to be defined. The object can be rotated only around one dimension. Translation: Only 1 similar object point has to be defined. The object can be only translated. The background colour of the N Point Align dialog can be changed by loading a user defined image.

background image

To use the translation mode, the orientation of the object in both window views should be similar.

INFO

218 Inspection

9.4.2 Mesh Align

Function to align data sets via their contour.

Subsampling Maximum distance Convergence Iterations Interactive

Grouping

Mesh group Only selection

3D-view update Reliability Adaptive Distance New Convergence Condition

Amount of points for alignment; the lower the value, the faster the alignment Distance for the search of a equivalent point in the different datasets Convergence value, if all single scans achieved this value, the iteration process is stopped. Number of iteration steps. Yes: dialog box will be shown (see the images below) No: alignment is done without showing the dialog. The progress of the alignment can be tracked in the OPTOCAT status line (no user interaction is possible). No: aligns all single scans Yes: aligns groups to each other but does not change the orientation of the single scans in a group Select the container for alignment No: all object points (regarding the subsampling) are used for alignment Yes: only the selected part of the object is used for alignment Yes: the changes after each iteration are shown in the 3D viewer No: only the result is shown after running the function (faster) Ignore Reliability / Highest / High / Standard / Low / Lowest Yes No Yes No

219 Inspection

9.4.3 Mesh Align Extended

Function for constrained alignment. The data sets are aligned via their contour with regarding available information from index marks. This function only can be used for Index Mark and Referenced Projects when index marks are loaded in the 3D viewer.

IMPORTANT

Only additional parameter: (for all other refer to section Mesh Align before) Point group Constrain weight Point group for alignment Weight of matching with point data and contour. Small value: more contour matching High value: more photogrammetry/index mark matching

220 Inspection Index-mark tolerance (mm) Range in which variations stay unconsidered, is the distance between point and reference inside the tolerance, the constrain weight will be set to the value zero, that means the distance will be ignored by aligning the data sets lengths-scale, within the weight of a point with the distance from the reference outside the tolerance grows from zero to a maximum value

Index-mark transition (mm)

9.4.4 Sensor Volume and Position

Function for visualising the sensor volume. Using the function can help to get an idea whether the device under test is positioned correctly.

Display Display from up to acquisition

Current scan shows sensor volume for the last scan Loaded scan only shows sensor volume for all loaded scans 1. Scan shows sensor volume e.g. for the first scan 3. Scan up to the last scan (range can be changed manually!) Selected scans Press these button after defining the range to see the visualisation.

9.4.5 Smooth Group

SmoothGroup is a function to smooth the single meshes before the merge process.

3D group Radius of filter [mm] Max angle

Select the container from the 3D tree for smoothing Automatic, or you can enter a radius manually Angle criteria within the data are optimized

221 Inspection # iterations Reliability Number of process iterations High/ Highest/ Low/ Lowest/ Standard Quality value which includes the position in the volume, the angle, the normal, contrast, etc. To regulate the intensity.

Smooth Color Intensity (%)

9.4.6 Merge
With this function, a common net made up of triangles is calculated from as many connected 3D objects as desired. To achieve the best results, the objects should previously have been averaged with the function SmoothGroup (see 9.4.5).

3D group Mesh Max distance [mm] Reliability

Min distance [mm] | Automatic

Select the container from the 3D tree for merging Enter a name for the result mesh Automatic: average edge length of all triangles Manual: High/ Highest/ Low/ Lowest/ Standard Quality value which includes the position in the volume, the angle, the normal, contrast, etc. Defines the minimum distance automatically

9.4.7 Mesh Optimization

This function optimizes the arrangement of the 3D elements triangles network.

222 Inspection Mesh Sensitivity Min number of triangles per vertex Max number of triangles per vertex Min inner angle Max inner angle Select the container from the 3D tree for optimization. Angular difference between a pair of triangles and the surrounding area. Below no optimization is started. Minimum number of triangles, one vertex will be reduced to. Maximum number of triangles, one vertex will be split into. Minimum value of a triangle angle. Edge detection angle

9.4.8 Flip Mesh Normal

With this function, the normal vector of a 3D object can be turned.

Mesh Only Selected Area

Select the container from the 3D tree Yes: only mesh normal vector from selected triangles are flipped No: the normal vector from the complete mesh is flipped

9.4.9 Clean Mesh

With this function, abnormal or non manifold faces in a given 3D object can be identified. After the function is executed all defect faces are shown in the both result container and can be deleted.

Mesh Heal Mesh Abnormal faces Non manifold faces

Select the container from the 3D tree to be cleaned ON: the function tries to reorganize the defect faces area OFF: the function only identifies the defect faces Result container to visualize abnormal faces Result container for non manifold faces

223 Inspection

9.4.10

Mesh Outlier Detection

All outlier triangles are selected.

Mesh Max angle Only selected areas New Algorithm

Select the container from the 3D tree to be analyzed 0: All boundary faces are selected. Suitable values are 10 45 depending on the 3D object. No / Yes

9.4.11

Visualize Mesh Reliability

Function to visualize the data quality value which includes the position in the volume, the angle, the normal and contrast information.

Mesh / Mesh Group

Select the container from the 3D tree to be analyzed

9.4.12

Find Holes In Mesh

Function to analyze holes in a Mesh.

Mesh Destination Container Group

Select a mesh data set to find the holes inside Result container to visualize the detected holes

224 Inspection

9.4.13

Fill Holes

Function to close holes in the 3D data. See 8.6.

9.4.14

Cut Mesh

Function to cut a Mesh. Before starting a cutting plane has to be defined.

Mesh Target Plane Name Mesh above Plane

Select a mesh to be cut Select a plane which cut the mesh Resulting mesh part above the plane

225 Inspection

9.4.15

Filter Mesh

The FilterMesh function removes the noise from the surface of a Mesh object. This function should be executed before compressing a Mesh with the CompressMesh function.

Mesh Radius of filter [mm] Max angle Triangles

Select the container from the 3D tree for filtering Select the radius of the filter in mm Maximum angle for filtering Selection: only the selected parts of the mesh will be filtered All: all triangles will be filtered

9.4.16

MultiVis Dialog

Enable and disable the Multivisdialog to show the quality different of data and the different data types (stereo, mono 20, mono10).

9.4.17

Snapshot 3D

You can save the content of the 3D viewer as an image (supported formats are *.bmp, *.jpg, *.gif and *.png). See 9.3.24.

226 Inspection

9.4.18

Edge Merge

A group of netlines will be merged together depending on the quality and overlapping factor. When calculation standard edges the quality depends from the viewing angle, with tapelines the quality is taken from the vertex quality of the mesh.

Input Container for edge lines Output Container for edge lines Reliability

minimum overlap factor

Name of NetLline Container (group is also possible) Name of Container with the fitting result Reliability of taken edges Lowest: lowest quality (grade 5) Low: grade 4 Standard: grade 3 High: grade 2 Highest: best quality (grade 1) Overlap as percentage of the amount of incoming and outcoming points in a section

Example: edges before and after merging

227 Inspection

9.4.19

Edge Fit

EdgeFit searches in the defined Container for basic geometries as circles, rectangle, slot, etc., which can be fitted into the netlines. The choice the geometries can be made automaticly or manual.

Input container for edge lines Output container for edge lines Output point data Number of match data set Old dataset Fit object Radius Tolerance Line topology

Select the name of the NetLine-Container (a group is also possible) output from fitting; container for the result data saves the centre points and radii in the primitive.pnt file number of data set in primitive.pnt file Overwrite, Append or ask if file primitive.pnt exist Select the geometry that has to be fitted Automatic / Circle / Rectangle / Slot radius of fit objects tolerance of fit objects arbitrary or closed

After fitting there is a new directory with the fitted geometries. The primitives will be saved automatically in Primitive.CTR in the directory Edges in your project.

228 Inspection

Example: Result after fitting

9.4.20

Edge Filter

OPTOCAT offers the possibility to filter detected edges.

Input container for edges lines Smoothing

Chose the container, which has to be filtered Define Filter type: Average: filters stronger than Curvature filer Curvature: Filters less than the Average filter, with the benefit that edges are retained in a better way (uses B-Splines calculation) Smart: Filter which sustains edges

Example: Smoothing of detected edges

229 Inspection

9.4.21

Compress NetLine

Function to thin out a netline object. Compress Netline compresses netlines by deleting node points. The amount of deleted nodes depends on the two parameters for the error and the edge length.

NetLine Container Line Error [mm] Max Edge Length [mm]

Select the Netline Container. Allowed distance between original points and new edges. Maximum allowed edge length.

Example for NetLine Compress.

9.4.22

Edge Average

Edge Average calculates the average netline of all NetLines and moves the original data towards the average depending on a quality weight factor.

Input Container Output Container Reliability

Select the Netline Container. Select the Netline Container for the result. Select the reliabilty of the edges. Lowest / Low / Standard / High / Highest

230 Inspection

Example for Edge Average.

231 Inspection

9.4.23

Edge Connect

Function to connect edges of netlines.

Input Container Max distance [mm] | Automatic

Max Angle Detection Mode

Only selected areas

Select the Netline Container. Maximum length of generated connections. In Automatic mode this length will be calculated automatically and will be in the range of the typical edge length of the netline. Maximum allowed angle in degree (values between 0 and 180). Type of line which has to be connected. TapelineCenter TapelineBorder All Yes: Only selected parts will be connected. No: Selection will be ignored.

Example for Edge Connect.

232 Inspection

9.4.24

Mesh Extend to Edge

Function to extend meshes up to edge lines. After a scan, in most cases meshes have more or less jagged borders, because there is no surface information near edges. But if you have extracted edges with the EdgeFind function, the meshes can be extended up to these edge lines.

Mesh Container for edge lines Merged edges Max distance (mm) | Automatic

Select the Mesh Container. Select the NetLine Container. Define the Name for the resulting Container. Radius of Search in mm.

Example for Mesh Extend to Edge.

233 Inspection

9.4.25

Clean Mesh (all)

Function to clean all meshes. With this function, abnormal or non manifold faces in a given 3D object can be identified and deleted.

Start Index End Index Exclude Remove small shells Minimum connected

Select the number of the first mesh. Select the number of the last mesh. Select the number of the mesh which hasnt to be cleaned. Yes No Insert the minimum number of points that have to be connected.

9.4.26

Mesh Outlier Detection (all)

Function to select all outlier triangles.

Start Number End Number Exclude Detection angle

Select the number of the first mesh. Select the number of the last mesh. Scans which do not have to be loaded. Select angle for detection.

234 Inspection

9.4.27

Compress Mesh (all)

Function to compress all meshes.

Start Number End Number Surface error [mm] Max edge [mm] length

Select the number of the first mesh. Select the number of the last mesh. Enter the maximum surface error. This means the difference between the original surface and the processed surface. Defines the maximum edge length of the triangles. If this parameter is negative (-1), it will be ignored during the compressing.

9.4.28

Filter Mesh (all)

Function to remove the noise from the surface of a Mesh object.

Start Number End Number

Select the number of the first mesh. Select the number of the last mesh.

235 Inspection Exclude Triangles 1.Filter Scans which do not have to be filtered. All - all triangles are filtered Selection only selected triangles are filtered Standard Smart Edge No Standard Smart Edge No Standard Smart Edge

2.Filter

3.Filter

9.4.29

Save All Meshes (all)

Function to save all meshes in a specific format.

Start Index End Index Exclude Format

Select the number of the first mesh. Select the number of the last mesh. Select the number of the mesh which hasnt to be saved. Choose the file format: STL, PLY or CTR.

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10 Tools
10.1 10.2 10.3 10.4 10.7

10.5

10.6

10.1 Check system

10.1.1 Check calibration

To use this functions the sensor is needed in the online mode (system has to be connected). When pressing the button Check Calibration you first of all have to check whether the right sensor is initialised or not. If not, choose the right Scanner Serial Number, then press OK button.

Set the calibration plate in front of the Scanner and define whether you want to select a pnt file or whether it has to be chosen automatically.

Extended parameters

Yes: you can select a pnt file No: the pnt file from the sensorfiles is taken automatically

When Extended Parameters = YES was chosen, please select the right calibration plate pnt file.

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237

PNT file name of plate Only stereo: Type of marks

Select the right *.PNT file of your calibration plate All: all marks are used for the process Only encoded: only the encoded marks are used in the process

Check whether the right calibration plate is positioned in front of the sensor.

Then, a measurement is done and the result is visualised in the 3D viewer. If the visualisation looks good, that means almost all index marks are green and yellow, the calibration is still useable. If not, a recalibration is necessary.

10.1.2

VDI 2634

Sensor Serial Number New calibration VDI type

Select the connected sensor Yes: make a new calibration before starting the accuracy check No: direct start with the accuracy check VDI 2634-2 single scans VDI 2634-2 flatness Evaluation 2634-2 single Evaluation 2634-2 flatness Change artefact

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Tools

For detailed information about the accuracy check please look at the IntroductionForAccuracyCheck.pdf document. You find this in the OPTOCAT subfolder DOC.

10.1.3

Log View

All OPTOCAT events like the execution of functions are listed in a log file with the execution time, name of the function and the duration.

10.2 Calibration
10.2.1 Sensor calibration

Input point data Input sensor data Input scale bars Output point data Output calibration planes Output sensor data

Enter the path and the file name of the valid pnt file from the calibration plate (*.pnt) Enter the path and the file name of the sensorfile (*.cam) Used scale bars and non referenced calibration plate for calibration. Enter the path and the file name of the point dataset (*_out.pnt) which will be created by OPTOCAT. Enter the path and filename of the *_planes.pnt Enter the path and the file name of the output sensorfile (*_out.cam) which will be created by OPTOCAT.

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239

Output polynomial coefficients Log file Minimize additionally the deviations of the object points Extended Calibration Mode Max. cycle (default: -3) Outlier threshold (default: 4)

Enter the path and the file name for a log file (*.txt). Yes/ No

Yes/ No Number of process iterations -n: with a minus in front a result dialog is shown after the process

10.2.2

Check calibration

Input point data Input sensor data Input polynomial coefficients Output point data Output planes Log file calibration

Enter the path and the file name of the valid pnt file from the calibration plate (*.pnt) Enter the path and the file name of the sensorfile (*.cam)

Enter the path and the file name of the point dataset (*_out.pnt) which will be created by OPTOCAT. Enter the path and filename of the *_planes.pnt Enter the path and the file name for a log file (*.txt).

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10.2.3

Projector calibration

Input sensor data Output sensor data Output sensor data for left optotope Output sensor data for right optotope Output point data for left optotope Output point data for right optotope Log file Fit external orientations Fit internal orientations Delete old image data Add new image data Perform calibration Calibration level

Enter the path and the file name of the sensorfile (*.cam) Enter the path and the file name of the output sensorfile (*.cam), which will be created by OPTOCAT. Enter the path and the file name of the output sensorfile (*.cam) for the left camera, which will be created by OPTOCAT. Enter the path and the file name of the output sensorfile (*.cam) for the right camera, which will be created by OPTOCAT. Enter the path and the file name of the point dataset (*.pnt) for the left camera, which will be created by OPTOCAT. Enter the path and the file name of the point dataset (*.pnt) for the right camera, which will be created by OPTOCAT. Enter the path and the file name for a log file (*.txt). External orientations are for example: camera, projector and position No/Yes Internal camera parameter e.g. distortion No/Yes Deletes existing data from the output files No/Yes Adds new image data in the output files No/Yes Calculates the calibration result No/Yes Standard value is 1

Tools

241

10.2.4

Scale calibration

Input point data Input sensor data Input Scale bars Output point data Output calibration planes Output sensor data Output polynomial coefficients Log file Minimize additionally the deviations of the object points

PNT-data with reference- and measurement data of marks as input CAM-data with sensor data as input PNT-data with reference- and measurement data of marks as output PNT-data with combined reference- and measurement data of marks as output CAM-data with sensor data as output PLM-data with coefficients of the polynom correction as output Enter the path and the file name for a log file (*.txt). For No (default) the minimization of the bundle compensation is executed only for 2d Points in the images. This case of bundle compensation shall be used normally Yes: for this case of bundle compensation also 3D object points are used. This is more stable but needs more time for calculation Define whether a polynomial correction shall be executed. The bundle compensation is executed with an iterations process. After a cycle of 10 iterations the process stops and asks if the process shall go on or aborted. This parameter sets the number of cycles without asking. Barrier in units of the standard deviation. All marks, which are out of this barrier will be abolished. The default value is 4.0 and should only be changed from experts.

Polynomial correction (default: no) Max cycles (default: 0)

Outlier threshold

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10.2.5

Set scale

This function is setting a scaling factor into the sensor file (in x,y and z dimension).

Input sensor data Output sensor data Scale factor

Enter the path and the file name of the sensor file (*.cam) Enter the path and the file name of the output sensor file (*.cam), which will be created by OPTOCAT. Enter the scale factor, which OPTOCAT has measured in Kalibscale.

10.3 Photogrammetry
10.3.1 Evaluation

To evaluate a photogrammetry project you need a dongle for the photogrammetry software. The evaluated photogrammetry data are saved directly in your project folder so that you can directly go on with measuring.

10.3.2

Save Reference

With save reference you can select a save directory for your evaluated photogrammetry data.

10.3.3

Load Reference

The reference points of the initialised project are loaded automatically.

Tools

243

10.4 Feature lines

10.4.1 Load

See chapter 7.1.9.

10.4.2

Feature Lines

With this option you can detect features based on curvatures and certain parameters.

Input: mesh Curvature model Range for averaging curvature (mean lattice spacing) [mm] Polynomial degree of B splines Output: feature lines

Choose a mesh to detect feature lines Realistic: more accurate, but slowly Simplified: faster calculation

Fitting degree of the resulting feature lines. 1 means the original calculated B-Splines. Define a result container for the feature lines

To visualise the coloured feature lines the 3D viewer material visualisation mode has to be set Enabled.

IMPORTANT

244

Tools

To extract the desired feature lines, adjust the lower and upper curvature radius sliders in the dialog box. It is also possible to search only for convex or only for concave features (select or deselect the corresponding check boxes). Finalize the extraction with Get Features. The founded features are displayed yellow. (With Erase Features you can reject founded features.) To get the B-Splines confirm the yellow displayed features with Calc Lines. The calculated BSplines are now available in the previous defined output container in the 3D tree.

Get Features

Calc Lines

10.4.3

Save

See chapter 7.1.10.

10.5 BRE Export

The .ABS files are loaded and exported as a .BRE file.

Tools

245

Start Index End Index Exclude

Export in world coordinates Reload sensor

Select the number of your start *.ABS file Select the number of the last *.ABS file which you want to export If you want to exclude an image enter the image numbers with a semicolon between the numbers or a range of numbers (e.g. 2-4;6 2,3,4,6 will be excluded). Yes / No Select whether the world coordinate system has to be loaded. If not, choose No. No: to use sensor information from the acquisition Yes: to reload sensor information

This function exports current loaded project data with the current set parameters. Ensure that the right project with suitable parameters is initialised before starting.

INFO

10.6 Temperature

If your scanner has a temperature sensor you can read out the temperature with this function.

10.7 2D Window

10.7.1

Abssensor

Re-initialises the sensor projector and cameras.

Sensor Offline

Select an available sensor with the right FOV. No: for measurement Yes: only processing Only Projector: to reinitialise only the projector and not the cameras

10.7.2

Abs Init

Initialising parameters for coordinate transformations of the raw data.

246

Tools

Transformation Trafofile Handling

Reference

No: (default) Yes: to activate a coordinate transformation Only if Handling is set to NO: Filename of transformation matrix. Only if Transformation is set to YES: No: no handling system is used Yes: coordinate values are read from a handling system Select the file name of the reference data.

10.7.3

Abslimits

With setting the limits to Yes the scan volume is limited in x, y and z dimension (calibrated sensor volume). With setting the limits to No the calibrated sensor volume is ignored (only for experts).

Tools

247

10.7.4

Abslight

With this function the projector light can be turned on/off.

Time Off [s] Mode

After a period of TIME OFF seconds the light source of the projector will be switched off or on automatically. On: Projector light is switched on. Off: Projector light is switched off. Toggle: Projector light changes between on and off.

10.7.5

Abslaser

Positioning laser can be switched on and off.

Mode

On: laser pointers are switched on Off: laser pointers are switched off Toggle: laser pointers changes between on and off

10.7.6

Abslive

Function to display a camera live image.

Source Autoexposure

Select an AOI (for example A1 for black and white and A7 for colour image). No: Live image brightness can be set manually. Yes: Live image brightness is set automatically.

248

Tools

10.7.7

Autoexposure

Function to set the image brightness automatically. Thereby limits for shutter, gain and brightness can be defined, within the function optimizes the setup.

Minshutter Maxshutter Mingain Maxgain Minbrightness Maxbrightness Correction Tolerance [%] Flickerless Use Projector Mask

Set a value for a minimum shutter time Set a value for a maximum shutter time Set a value for a minimum gain Set a value for a maximum gain time Set a value for a minimum brightness Set a value for a maximum brightness Correction value for the automatic value (between 0,5 and 4) Percent of the pixel which are allowed to be overexposed None/ 50Hz/ 60Hz Yes /No

Tools

249

10.7.8

Absbright

Function which displays the camera live images to setup the brightness of cameras and projector. In addition you have the possibilities to switch tools for finding the optimal working distance with the lasers and the cross.

Outlut Pattern Flickerless Fast Link presets Autoexposure Correction Tolerance [%] Modus

Colour16/ Colour8/ Grey/ Greyred/ Greysat/ Mixed/ Sinus/ SinusMixed Bright/ Dark/ GC05/ GC1, None/ 50Hz/ 60Hz Only shutter times possible which enable a fast acquisition The brightness difference between the different presets is set automatically with a factor 2 No: live image brightness can be set manually Yes: live image brightness is set automatically Correction value for the autoexposure function Percent of data which are allowed to be overexposed Display modus for systems with one or two cameras. (Automatic / Optotop one camera / Stereo- two cameras)

10.7.9

Absload

This function loads the entire data set of a 3D measurement including the sensor description file *.CAM of that measurement.

Filename Interactive

Select the path and file name Yes: the Windows dialog to browse opens

250

Tools

No: the path from the line filename is used

10.7.10

Abssave

Function to save raw data format ABS.

Filename Fileformat

Interactive

Select the path and file name Select file format ABS: format from OPTOCAT 2009 ABS V4: format compatible with older OPTOCAT versions Yes: the Windows dialog to browse opens No: the path from the line filename is used

10.7.11

Absgrab

Function to execute a measurement acquisition sequence.

Grabmode

Average Phase

Continuous: fast acquisition mode Continuous high security Demo: very slow for demonstration Standard: step by step mode Standard high security: Standard multi-intens: multiple measurements in standard speed with different shutter values Trigger 2, 3, 4,, 16, 32, 64, 128, 256, NO

Tools

251

Average Graycode Intensities/Exposures

Mode Simultaneous Check Stability Stability Tolerance (%)

2, 3, 4,, 16, 32, 64, 128, 256, NO 1 (default): intensity for bright matt objects 1 of 2: average of 2 images with 2 different exposures for objects with coloured surfaces 1 of 3: average of 3 images with 3 different exposures for objects with dark areas/corners. 1 of 4: average of 4 images with 4 different exposures for reflective object surfaces On-Line, Off-Line No/ Yes No/ Yes Factor how many vibrations, are allowed

10.7.12

Absmask extended

Function for the 3D data preprocessing. The raw data are analyzed regarding their phase, graycode, contrast and quality.

Mode

Reliability

erosion

Standard: recommended OPTOCAT V4.x: not recommended, old mask process Fast: not recommended, only for objects with flat surface Check zeta Standard: recommended More data: additional filter of the phase image Maximum data: additional filter of phase and graycode images More quality: Maximum quality: User defined: Calibration/ FacescannerII / Bodyscanner / FacescannerI / Roadmeas Number of iterations

All other parameters of the ABSMaskExt function are only relevant if reliability mode User Defined is chosen. This should not be done!

INFO

252

Tools

10.7.13

Phase enhance

This function detects phase systematic phase errors due to faulty calibration or a movement of the object during measurement. This function can enhance the result with respect to these effects. The quality of the result depends on the quality of the input data. Please note that the algorithm is not able to distinguish systematic from random errors or phase discontinuities due to the object under test.

IMPORTANT

Source Table-File Scaling Degree XStart YStart XEnd YEnd Interactive

Choose an AOI of phase image that has to be enhanced. Name of the file that contains the calculated LookUp-Table. Value of the systematic phase error from the scaling graph. Pixel coordinates of the user-defined starting point. Pixel coordinates of the user-defined starting point. Pixel coordinates of the user-defined end point. Pixel coordinates of the user-defined end point. YES: a dialog box for visualisation of the systematic error is opened NO: the correction of systematic error is done without user interaction

Tools

253

10.7.14

Local Phase Correction

The function LocalPhaseCorrection removes phase errors in the 3D measurement. Before this function can be used the ABS image has to be loaded and masked (function ABSMASK). After the phase correction the masking is done with the preset values.

Error threshold [Deg] Average factor Maximum hole size [Pixel]

Angle limit, below the correction will be executed, maximum value is 10 value to define the grade of the correction (suitable values 310) maximum number of pixels, which could be interpolated (suitable values 010)

10.7.15

Absfilt

This function performs a two-dimensional filter operation on the unwrapped phase image (combination of gray-code and phase).

Filtertype

Filter area

Maskout

No Filter, Average, Gauss, Median, Fourier, Polynomial, Modified Average, Modified Median Select a filter Horizontal 3,5,7; Vertical 3,5,7; Kernel 3x3,5x5,7x7,9x9,11x11,13x13,15x15 Select a filter size Yes, No Select if the data should be masked out or not

The AbsFilt function should not be used with stereo data, because the filter operation can produce defect 3D data.

INFO

254

Tools

10.7.16

ABS Export

This function saves the 3D-data of a rectangular shaped area to a file. The density of the sampling grid is user-defined. Executing this function results in opening a dialogue box for defining the area if the parameter INTERACTIVE is set to YES.

Source Interactive

XStart, YStart XEnd, YEnd StepX, StepY

Filename Transformation

Select AOI to export Yes: the area to export is defined by mouse drag No: the export area is defined by Xsrat, Ystart, Xend and Yend Pipe: data are written in a named pipe to be read by another processing software coordinates of upper left corner of the area to be exported coordinates of lower right corner of the area to be exported step width of the sampling grid in X- and Y-direction 1 means evaluation of every pixel 2 means evaluation of every second pixel and so on File name and path for saving Only for BRE export: Execute: data are transformed by the matrix specified in function AbsInit For Visualisation Only: data are not transformed

Tools

255

10.7.17

AbsSequence

All images from the gray code and phase shift sequence are acquired synchronically, depending on the sequence version.

Cameras Simultaneous Trigger Grabmode

Average Phase Average Graycode Intensities/Exposures

Sequence Prefix

1 for optoTOP 3D 1,2 for stereoSCAN , smartSCAN 3D No: for optoTOP and stereoSCAN Yes: cameras make a simultaneous snap Off: do not change this parameter Continuous: measurement in continuous speed Standard: measurement in standard speed (multi exposures mode with choosing only different shutter values) Trigger: triggered standard measurement No, 2, 4, 8, 16, 32, 64, 128, 256 each Phase image is averaged over the given number times No, 2, 4, 8, 16, 32, 64, 128, 256 each gray code image is averaged over the given number times 1: (default) measurement with one intensity 1 of 2: average of 2 images with 2 different exposure settings (brightness and/or shutter value) 1 of 3: average of 3 images with 3 different exposure settings (brightness and/or shutter value) 1 of 4: average of 4 images with 4 different exposure settings (brightness and/or shutter value) For using two cameras, for each a different prefix can be chosen. For example LC or RC for left or right camera.

256

Tools

10.7.18

AbsCalculate

A with AbsSequence acquired series of gray code and phase images can be processed to get the result AOIs: Camera, Phase, Contrast, GrayCode and LowPhase (can be saved in ABS format).

Cameras Average phase Intensities/Exposure

1 for optoTOP 3D 1,2 for stereoSCAN No, 2, 4, 8, 16, 32, 64, 128, 256 each Phase image is averaged over the given number times 1: (default) measurement with one intensity 1 of 2: average of 2 images with 2 different intensity settings (brightness and/or shutter value) 1 of 3: average of 3 images with 3 different intensity settings (brightness and/or shutter value) 1 of 4: average of 4 images with 4 different intensity settings (brightness and/or shutter value)

All parameters of AbsCalculate have to be set corresponding to the parameter setting in function AbsSequence.

INFO

10.7.19

Set Cam Settings

Select a camera from the list and define the acquisition parameters (shutter, gain, offset) for the camera.

Camera Shutter Gain Offset

Identification of active cameras Camera shutter time [ms] Camera gain value Camera offset value

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257

10.7.20

Cam Synchronisation

The function CamSynchronisation synchronises two cameras to each other. It is possible to synchronise several cameras on a reference camera.

Reference Camera Synchronise Camera

Identification for reference camera Identification for synchronise camera

10.7.21

Show Cam Synchronisation

The function ShowCamSynchronisation displays the result of the camera synchronisation (see also function CamSynchronisation 10.7.20).

10.7.22

Synchronsnap

A camera snap is done with each defined camera.

Cameras AOI List Trigger Flash

Identification for cameras: 1,2 for stereoSCAN Name of the AOIs in which the result images should be displayed Yes: the snap is started with a trigger signal No: the snap is not triggered Yes: external flash is used No: no flash

258

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10.7.23

Synchronsnap Average

An averaged camera snap is done with each defined camera.

Cameras AOI List Count

Identification for cameras 3D 1,2 for stereoSCAN Name of the AOIs in which the result images should be displayed Number of images to be averaged

10.7.24

Load Cam

Sensor initialisation file (SensorName.CAM file) is opened.

camera set

Name of the *.CAM file

10.7.25

Init Coord Machine

Initialisation of a coordinate machine.

Type

None, Input, Zmess, Elisa, Format 100 Continuous, Format MZ1030 Continuous, Format Userdefined, CNC machine, Tracker

Tools

259

10.7.26

Init Joystick

Initialisation of a joystick (normally used with a linear axis).

Interactive

On: a joystick is used Off: no joystick is used

10.7.27

Abs Position

This function is used to shift and turn a coordinate machine.

Interactive

Stepper Position1

Velocity1

On: a dialog box for interactive machine controlling is opened Off: the below defined parameters for Stepper, Position1 and Velocity1 are used Absolute: moves absolute to a reference position Relative: moves relative to the current position Depending on the settings in CNC.INI: Either a distance value in millimeters for a translation or an angle value in degrees to rotate around an axis Speed of the translation or rotation movement

260

Support

11 Support

11.1

11.2

11.3

11.4

11.5

11.6

11.7

11.8

11.1 Reload layout

If the layout is damaged you can reload the layout without closing OPTOCAT.

11.2 Start OPTOCAT Help

Opens the OPTOCAT help menu.

Support

261

11.3 Open the OPTOCAT brief manual

A selection window opens with several manual from the DOC subfolder of OPTOCAT. For opening the documents you need the Acrobat Reader.

OPTOCAT manuals Support manuals

IntroductionForAccuracyCheck Laser-Adjustment-Tool Optocat2009-QuickUserQuide AvoidingOfElectronicalDamages ChangeOfComport DeinstallationOfTheBCamDriver Remote SystemCheckBasler Vermeidung-elektronischer-Defekte WindowsPrivileges

11.4 Save Service

All AOIs are saved to %DIROFW%\service\test\test.bmp.

11.5 Load Service

AOIs saved with the macro service can be loaded with this function.

11.6 Zip Service

The files, which are made with Save Service, are packed in a zip archive to send us for support (%DIROFW%\Service\zipservice.zip).

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Support

11.7 Start the OLWizard

Starts the OLWizard program: %DIROFW%\Tool\OLWizard.exe. More about the OLWizard see in chapter 2.4.1.

11.8 Remote help

Starts the Breuckmann Remote help tool for remote maintenance. More about the Remote help program you find in chapter 2.4.4.

Customer

263

12 Customer

The Customer task bar offers the possibility to make customer macros. Also you can open demo data from the Breuckmann CD.

264

New Colour Coding

Appendix A

New Colour Coding

Since OPTOCAT Version 2009 the colour coding has changed. This is important to know for the Find Index Mark function (e.g. used in calibration) as well as the new function IM Live.

A1 Find Index Marks (e.g. Calibration)

Previous versions of OPTOCAT (e.g. OPTOCAT 2007): 2 camera system red coloured marks mean yellow coloured marks mean Example for stereo case: ... detected in both camera pictures detected in one picture, but not in the second one 1 camera system detected in one camera picture - does not happen -

Since OPTOCAT 2009: 2 camera system green coloured marks mean purple coloured marks mean red coloured marks mean ... detected in both camera pictures detected in one picture, but not in the second one that they are out of the limits (only red when limits are activated) 1 camera system detected in one camera picture - does not happen -

that they are out of the limits (only red when limits are activated)

Example for stereo case:

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New Colour Coding

A2 IM Live
IM Live is a new function in Optocat 2009.

2 camera system green coloured marks mean ...detected in both camera pictures and found in the reference detected in both camera pictures but not found in the reference (or no reference available) detected in both camera pictures and found in the reference, but beyond the limits

1 camera system detected in one camera picture and found in the reference

yellow coloured marks mean

detected in one camera pictures but not found in the reference (or no reference available) detected in one camera pictures and found in the reference, but beyond the limits

red coloured marks mean

Example for Detection of Index Marks using a 2 camera system:

In the stereo case IM Live only shows related points.

NOTE

266

Extended Measuring Fields

Appendix B

Extended Measuring Fields

B1 Sensor Calibration of special (extended) FOV with 15 calibration positions

This description is valid for stereoSCAN , triTOS and optoTOP-HE.
3D

NOTE

The FOV 950 (up to 1025) is a special (extended) measuring field for different kind of scanner types because extreme wide angle lenses are used. For extended FOV the calibration strategy is a little bit different to the standard FOV. Instead of nine positions (7 parallel and 2 tilted positions) in the standard mode 15 positions for extended FOV have to be calibrated. Why are this additional snaps necessary? The cameras see more and the marks on the calibration plate look smaller than in standard FOV.

IMPORTANT

This appendix is an additional description to chapter 6.1.4 Sensor calibration which describes the standard calibration procedure. Please read chapter 6 and follow all descriptions of building up of the sensor and adjustment for calibration of chapter 6.1.1.1 until 6.1.3. Start the calibration procedure in chapter 6.1.4 and only in point number 10 switch in this appendix and follow after that step the normal procedure further with step 11. Calibration positions: Overview Diagonal: -1 -2/3 -1/3 working distance +1/3 +2/3 +1 2. position 3. position 4. position 1. position 5. position 6. position 7. position 10. position 11. position Back in almost farthest position 3 see details below 12. 13. 14. 15. position position position position Additional positions for (extended) measuring field this special 8. position 9. position

Back in working distance of position 1 see details below

267

Extended Measuring Fields

Standard calibration positions in illustrated description (positions #1-9) 3D (exemplary illustrated in case of stereoSCAN HE-950 but also valid for triTOS and optoTOP-HE) 1. Seven parallel positions (analogue to standard calibration)

Position 1: working distance

Position 2: farthest position (e.g.~ -240 mm)

Position 3: -2/3 of the value for the farthest position (e.g.~ -160 mm)

Position 4: -1/3 of the value for the farthest position (e.g. ~ -80 mm)

Position 5: +1/3 of the value for the nearest position (e.g.~ +80 mm)

Position 6: +2/3 of the value for the nearest position (e.g.~ +160 mm)

Position 7: nearest position (e.g.~ +240 mm)

268

Extended Measuring Fields

2. two tilted positions

Position 8 : tilted left Additional positions (#10-15)

Position 9 : tilted right

Position 10 and 11 : set the calibration plate back in the working distance (position 1) and move the calibration plate: on the left side of the camera picture (position 10) on the right side of the camera picture (position 11) Position 10 : first picture in the working distance plate (position 1) on the left side of the camera picture

left camera

right camera

Position 11 : second picture in the working distance plate (position 1) on the right side of the camera picture

left camera

right camera

Position 12-15: set the calibration plate in position 3 (of the nine standard positions; close to farthest 3D position but inside the calibration volume: e.g. stereoSCAN HE-L-950: ~-160mm; optoTOP-HEL600-950: ~-165mm) and let the calibration plate fix. Only the sensor will be moved in the next calibration positions. In comparison to the calibration positions before not the calibration plate will be moved. Only the sensor positioning will be changed.

IMPORTANT

269

Extended Measuring Fields

Turn the sensor with the tripod head using pan/tilt operation so that the calibration plate can be seen in the camera picture: Position Sensor positioned # 12 13 14 15 Calibration plate is to be seen in the camera picture: in the left upper on the right lower side side in the left lower on the right upper side side in the right on the left upper side lower side in the right on the left lower upper side side is

Rules: In x-direction left / right means turn the tripod head around the y-axes anticlockwise / clockwise. In y-direction down / up means turn the tripod head around the x-axes anticlockwise / clockwise.

IMPORTANT

in x-direction: left in y-direction: up y x

Position 12 : Sensor has to be turned with the tripod head in the left upper side. Calibration plate has to be seen in the camera picture on the right lower side.

left camera

right camera

in y-direction: down y

Position 13 : Sensor has to be turned with the tripod head down around the x-axes. Calibration plate has to be seen in the camera picture on the right upper side.
x

left camera

right camera

270

Extended Measuring Fields

in x-direction: right y

Position 14 : Sensor has to be turned with the tripod head right around the y-axes. Calibration plate has to be seen in the camera picture on the left upper side.
x

left camera

right camera

in y-direction: up

Position 15 : Sensor has to be turned with the tripod head up around the x-axes. Calibration plate has to be seen in the camera picture on the left lower side.

left camera

right camera

271

Extended Measuring Fields

B2 Sensor Calibration of special (extended) FOV with 28 calibration positions (e.g. optoTOP based triTOS-HE L600-1700)
The FOV 1700 is a special (extended) measuring field because extreme wide angle lenses are used. Additionally the calibration strategy is a little bit different to the standard FOV. Instead of nine positions (7 parallel and 2 tilted positions) in the standard mode 28 calibration positions have to be used in this special mode. Why are this additional snaps necessary? The cameras see more and the marks on the calibration plate look smaller than in standard FOV.

IMPORTANT

Calibration positions: Overview Additional positions for (extended) measuring field this special

-1 -2/3 -1/3 working distance +1/3 +2/3 +1

2. position 3. position 4. position 1. position 5. position 6. position 7. position

6 additional positions (10-15) in working distance of position 1.) see details below: 10. position 11. position 12. position 13. position 14. position 15. position 9 additional positions (16-24) back in position 3.) (-2/3 of the value for the farthest position) see details below: 16. position 17. position 18. position 19. position 20. position 21. position 22. position 23. position 24. position 4 additional positions (25-28) back in position 6.) (+2/3 of the value for the nearest position) see details below: 25. position 26. position 27. position 28. position

Diagonal: 8. position 9. position

272

Extended Measuring Fields

Standard calibration positions in illustrated description (positions #1-9) 1. Seven parallel positions (analogue to standard calibration) 2. two tilted positions

Additional positions (#10-15) Position 10-15: set the calibration plate in this case back in working distance to position 1 (of the nine standard positions = Zero-position) and let the calibration plate fix. Only the sensor will be moved in the next calibration positions. In comparison to the calibration positions before not the calibration plate will be moved. Only the sensor position will be changed.

IMPORTANT

Turn the sensor with the tripod head using pan/tilt operation so that the calibration plate can be seen in the camera picture:

Position 10: Calibration plate has to be seen in the camera picture on the left upper side.

Position 11: Calibration plate has to be seen in the camera picture on the middle upper side.

Position 12: Calibration plate has to be seen in the camera picture on the right upper side.

Position 13: Calibration plate has to be seen in the camera picture on the right lower side.

Position 14: Calibration plate has to be seen in the camera picture on the middle lower side.

Position 15: Calibration plate has to be seen in the camera picture on the left lower side.

273

Extended Measuring Fields

Additional positions (#16-24) Position 16-24: set the calibration plate in this case in position 3 (of the nine standard positions; close to farthest position but inside of the calibration volume) and let the calibration plate fix. Only the sensor will be moved in the next calibration positions.

Turn the sensor with the tripod head using pan/tilt operation so that the calibration plate can be seen in the camera picture:

Position 16: Calibration plate has to be seen in the camera picture on the left upper side.

Position 17: Calibration plate has to be seen in the camera picture on the middle upper side.

Position 18: Calibration plate has to be seen in the camera picture on the right upper side.

Position 19: Calibration plate has to be seen in the camera picture on the right middle side.

Position 20: Calibration plate has to be seen in the camera picture on the centre of the image.

Position 21: Calibration plate has to be seen in the camera picture on the left middle side.

Position 22: Calibration plate has to be seen in the camera picture on the left lower side.

Position 23: Calibration plate has to be seen in the camera picture on the middle lower side.

Position 24: Calibration plate has to be seen in the camera picture on the right upper side.

274

Extended Measuring Fields

Additional positions (#25-28)

Position 25-28: set the calibration plate in this case in position 6 (of the nine standard positions; close to nearest position but inside of the calibration volume) and let the calibration plate fix. Only the sensor will be moved in the next calibration positions.

Turn the sensor with the tripod head using pan/tilt operation so that the calibration plate can to be seen in the camera picture:

Position 25: Calibration plate has to be seen in the camera picture on the left upper side.

Position 26: Calibration plate has to be seen in the camera picture on the right upper side.

Position 27: Calibration plate has to be seen in the camera picture on the right lower side.

Position 28: Calibration plate has to be seen in the camera picture on the left lower side.

275

Edges

Appendix C

Edges

Edges can be detected directly during the measurement (Contour Matching-, Indexmark Matching-, Reference Matching-Projects) or later in the reprocessing.

C1 General Information
Sensor position: The quality of an edge is determined in standard mode by the angle of the sensor to the edge (the optimal angle is about 80) and the contrast of the bright image. That means the reliability is made up of 50% of the angle criteria and 50% of contrast information.

Optimal angle between sensor and edge (left), quality class depending on angle (right)

The following table shows the quality classes depending on angle. from 180 89 88 86,5 84 74 60 42 24 to 89 89 88 86,5 84 74 60 42 0 quality class 5 4 3 2 1 2 3 4 5

In the tape mode the quality of the mesh triangles which is calculated at the part of the tape edge is adopted. There are different kind of edges which can be evaluated (see 5.4.10 Edge Detection). In addition to the standard edges which achieve the angle criteria and due to a border of a masked area tapelines (all, border of tapelines, center of tapelines) can be detected.

276

Edges

The following picture shows whether an edge is a standard edge or not.

Furthermore it is possible to extract all edges automatically or to chose the edges which has to be extracted manually (interactive way). The following picture shows interactive choice of edges.

C2 Initialisation dialogue

In the Project Initialisation the parameters for Edge Detection can be chosen. Please refer to 5.4.10 Edge Detection to see the parameters which are available.

277

Notes

Breuckmann GmbH Torenstrae 14 88709 Meersburg Germany phone: ++49 (0)7532 4346 0 fax: ++49 (0)7532 4346 50 mailto:support@breuckmann.com http://www.breuckmann.com ftp://ftp.breuckmann.com/incoming

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