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Evaluating the dimensional measurement accuracy of fringe projection profilometry for manufacturing applications: A verification study using a custom reference artifact
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School of Engineering |
Master's thesis
Electronic archive copy is available via Aalto Thesis Database.
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en
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67
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Abstract
Three-dimensional (3D) metrology is the science of measuring objects in three dimensions to enable a digitization of measurement results. It has been serving as the foundation of evolution in manufacturing. This study was motivated by the increasing industrial need for fast, contactless 3D metrology solutions capable of handling complex geometries, where fringe projection profilometry (FPP) emerges as a promising solution. It is essential to verify the performance of FPP rigorously before it could be extensively adapted to manufacturing applications. This thesis investigates the dimensional accuracy of FPP measurement in manufacturing applications from multiple perspectives.
A custom reference artifact incorporating linear distances, height variations, and spherical features was designed to verify the performance of the FPP scanner, GOM ATOS Core 200, in accordance with ISO 10360-13. Results were validated against high-precision tactile measurements obtained via a CMM and a cylindricity instrument. Two alignment approaches, cloud-to-cloud (C2C) alignment and sphere center (SC) alignment, were implemented to evaluate how alignment strategy influences measurement accuracy.
Results proved that the scanner achieves high accuracy in measuring lengths and heights but not in reconstructing spheres. The measurements revealed a length-dependent deviation pattern that error tends to scale linearly with the measured length. Limitations were also observed at the edges of the scanner's measuring volume, highlighting reduced reliability in boundary regions.
The findings in this thesis prove that FPP measurement is a promising solution for rapid, non-contact dimensional inspection in complex but non-critical geometries. The methodology and results of this verification study provide a fundamental reference for applying FPP measurement in industrial practice.