Hyper thin 3D edge measurement of honeycomb core structures based on the triangular camera-projector layout &...

Area of Science:

• Metrology
• Optical Engineering
• Materials Science

Background:

• Honeycomb core structures are widely used in aerospace and automotive industries.
• Accurate measurement of their thin edges is crucial for quality control.
• Existing 3D measurement techniques struggle with hyper-thin structures (<0.1 mm).

Purpose of the Study:

• To develop a novel hyper-thin 3D edge measurement technique.
• To accurately measure the 3D outer envelope profile of honeycomb core structures.
• To overcome limitations of current methods for measuring sub-millimeter edges.

Main Methods:

• A triangular camera-projector layout (2 cameras, 1 projector) to measure hyper-thin 3D edges.
• Phase-shifting algorithm and multi-frequency heterodyne phase-unwrapping for phase retrieval.
• A novel stereo matching method using phase mapping and epipolar constraints for accurate correspondence and outlier removal.

Main Results:

• Successfully measured the 3D profile of hyper-thin edges (<0.1 mm) of honeycomb core structures.
• The proposed triangular layout effectively eliminated data interference.
• The stereo matching method demonstrated high accuracy in edge correspondence and outlier rejection.

Conclusions:

• The proposed technique is effective for 3D edge measurement of honeycomb structures.
• It offers a viable solution for quality control of components with hyper-thin features.
• This advancement has implications for precision manufacturing and inspection.