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High Precision, Non-Line-of-Sight Point Cloud Generation

Description:

TECHNOLOGY AREA(S): Materials 

OBJECTIVE: Research and develop a technology capable of generating high precision point cloud scans of intricate parts with multiple internal services that are not accessible for traditional laser scanning or other line-of-sight techniques. 

DESCRIPTION: Many gun systems in armament require intricate castings of aluminum or steel parts with multiple internal surfaces that are very difficult to inspect with traditional means and impossible to inspect with line of sight surface scanning such as laser scanning. This makes it extremely difficult and time consuming to inspect these parts during first article testing or production lot testing which adds to lead time and risk associated with procurement. It also makes government testing of failed parts nearly impossible because of the lack of specialized tooling and fixtures to hold/check the parts. A technology is being sought that has the ability to look through the part (similar to an X-ray) and generate a very precise point cloud or surface model of the part. This point cloud or model must be accurate down to 0.0001-inch objective, 0.0005-inch threshold for the entire part. The technology must be capable of working through any steel or aluminum with a wall thickness of approximately 0.5 inches. The operation should be as automated as possible and require very little user training. The bounding box for most parts is 18 in. x 18 in. x18 in. or less, though some parts would require a larger capacity of approximately 24 in. x 24 in. x 36 in. Current scanning inspection techniques are limited to surface laser scans. There are some rudimentary X-ray inspection techniques, but these are mostly limited to visualization and flaw detection. There is currently no technology that can measure, visualize, and display non-line-of-sight dimensions, though it may be possible to marry current line-of-sight scanning with X-ray or other non-destructive inspection techniques. 

PHASE I: Demonstrate hidden surface scan feasibility and develop a complete a demonstration of concept for accurately measuring non-line-of-sight dimensions. 

PHASE II: Demonstrate a full scan of a moderately complex casting up to 18 in. x 18 in. x18 in., with internal dimensions accurately measured, tolerance, and displayed. 

PHASE III: Demonstrate a full scan of a complex casting up to 18 in. x 18 in. x18 in., with internal dimensions accurately measured, tolerance, and displayed. 

REFERENCES: 

1. J.E. Goodman, J.O'Rourke, editors \Handbook of discrete and computattional geometry," CRC Press LLC, Boca Raton, FL; Second Edition, April 2004.; 2. S. Sachs, S. Rajko, S.M. LaValle \Visibility based pursuit-evasion in an unknown planar environment," to appear in International Journal of Robotics Research, (2003).; 3. Validation of a Non-Line-of-Sight Path-Loss Model for V2V Communications at Street Intersections, Abbas, Taimoor; Thiel, Andreas; Zemen, Thomas; F. Mecklenbräuker, Christoph; Tufvesson, Fredrik

KEYWORDS: Point Cloud, Non-line-of-sight Dimensions 

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