A binocular vision system to measure width and height of deposited material in laser net-shape manufacturing

Abstract

Laser Net-Shape Manufacturing (LNSM) is an effective way for aircraft part manufacturing and repair. The process usually requires a sensor and control system to increase geometry accuracy and enhance mechanical property. This article presents a novel vision sensor, which is able to measure meltpool width and deposition height simultaneously during laser consolidation process. It works based on the theory of binocular vision. The sensor forms two separate clear images of meltpool on a CMOS camera through a group of optics, and then a processor finds an accurate shift between two images by a couple of image processing algorithms. This shift can be calibrated to axial displacement, or Z-height. Each individual image, or combination of two images, can be used to measure meltpool width, because the sensor is installed almost coaxially.Laser Net-Shape Manufacturing (LNSM) is an effective way for aircraft part manufacturing and repair. The process usually requires a sensor and control system to increase geometry accuracy and enhance mechanical property. This article presents a novel vision sensor, which is able to measure meltpool width and deposition height simultaneously during laser consolidation process. It works based on the theory of binocular vision. The sensor forms two separate clear images of meltpool on a CMOS camera through a group of optics, and then a processor finds an accurate shift between two images by a couple of image processing algorithms. This shift can be calibrated to axial displacement, or Z-height. Each individual image, or combination of two images, can be used to measure meltpool width, because the sensor is installed almost coaxially.