Metal forming tool monitoring based on a 3D measuring endoscope using CAD assisted registration

Abstract

In order to provide timely, reliable, and comprehensive data for the maintenance of highly stressed geometries in sheet-bulk metal forming tools, this article features a possible setup by combining a 3D measuring endoscope with a two-stage kinematic. The measurement principle is based on the projection of structured light, allowing time-effective measurements of larger areas. To obtain data of proper quality, several hundred measurements are performed which then have to be registered and finally merged into one single point cloud. Factors such as heavy, unwieldy specimens affecting precise alignment. The rotational axes are therefore possibly misaligned and the kinematics and the hand-eye transformation remain uncalibrated. By the use of computer-aided design (CAD) data, registration can be improved, allowing a detailed examination of local features like gear geometries while reducing the sensitivity to detect shape deviations.