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A Calibration Method for a Laser Triangulation Scanner Mounted on a Robot Arm for Surface Mapping.

Gerardo Antonio Idrobo-Pizo1, José Maurício S T Motta2, Renato Coral Sampaio3

  • 1Faculty of Gama-FGA, Department Electronics Engineering, University of Brasilia, Brasilia-DF 72.444-240, Brazil. gerardo.idrobo@gmail.com.

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Summary

This study presents a new calibration method for a laser triangulation sensor to accurately map hydraulic turbine blade surfaces for robotic repair. The method achieves sub-millimeter accuracy for cavitation pitting and crack detection.

Keywords:
3D scanner calibrationlaser scanningrobot calibrationrobotic visionrobotic weldingsurface mappingturbine blade repairingvision triangulation

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Area of Science:

  • Robotics and Automation
  • Mechanical Engineering
  • Non-Destructive Testing

Background:

  • Hydraulic turbine blades suffer erosion from cavitation pitting and cyclic loading, necessitating repair.
  • Accurate 3D surface mapping is crucial for robotic repair of damaged turbine blades.
  • Traditional laser triangulation sensors face precision challenges over large distances due to nonlinearities.

Purpose of the Study:

  • To develop and validate a calibration method for a laser triangulation sensor for precise 3D surface scanning of hydraulic turbine blades.
  • To improve the accuracy and precision of range measurements for robotic welding repair applications.
  • To enable accurate 3D coordinate assignment for robots to repair blade damage.

Main Methods:

  • A specialized laser triangulation sensor comprising a CMOS camera and two laser diodes was developed.
  • A calibration model was proposed, incorporating camera, lens, laser, and robot arm sensor parameters.
  • The calibration involved prior camera calibration, use of calibration boards, and robot arm positioning.
  • Image processing techniques were employed to derive 3D coordinates from projected light lines.

Main Results:

  • The developed sensor achieved an accuracy below 1 mm within the operational distance range of 250 to 650 mm.
  • The proposed calibration scheme successfully improved the precision and accuracy of the range measurement sensor.
  • Experimental procedures validated the effectiveness of the calibration method for turbine blade surface mapping.

Conclusions:

  • The novel calibration method enhances the capability of laser triangulation sensors for precise 3D scanning of complex surfaces like turbine blades.
  • This technology facilitates accurate robotic repair of eroded or cracked hydraulic turbine blades.
  • The sub-millimeter accuracy achieved is critical for effective material deposition during robotic welding repairs.