Abstract During production and manufacturing, box joint structures with bolt holes are prone to dimensional accuracy errors due to systematic failures in production devices or inadequate control of welding deformation. In order to address the limitations of low efficiency and high subjectivity associated with traditional manual inspection, a dimensional accuracy inspection technique for the box joint structure assisted by point cloud data is proposed. A section size inspection method is built that uses the normal vector relationship between structural surfaces to establish the coordinate datum for point cloud model. Then, dimensional transformation and plane geometric features are utilized to calculate feature point coordinates and section size of the joint structure. Numerical simulation is conducted to investigate the performance of the section size inspection method. The simulation results indicate that when the density of the collected point cloud for the box joint structure is maintained above 0.01/mm², the error of section size inspection can be kept below 0.5 mm. A bolt hole accuracy inspection method is developed, which establishes a multi-stage candidate point screening process for the bolt hole recognition, outlier filtering, and point cloud screening. The advance of the method lies in its ability to quickly recognize bolt holes and eliminate interference from outliers and mixed pixel points. Comparative tests demonstrate that, under the recommended parameter configuration, the recognition efficiency of the bolt hole inspection method is five times higher than that of the classical Angle Criterion method. Moreover, the filtering precision of this method exceeds 98%, and the calculation error is only 3.5% of the specified tolerance. A laboratory experiment is performed to further validate the proposed technique from a structural perspective.
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