Simulation tool for validating 3D scan path planning by evaluating measurement quality

The 3D inspection process based on the use of optical sensors is more widely used for industrial applications, due to their great ability to scan the entire surface in a short time. Laser-plane sensors mounted on coordinate measuring machines (CMMs) are commonly used for high-precision inspection. However, measurement quality is affected by the sensor path, defined primarily by the sensor orientation and position. Executing the scan path on the machine is time-consuming, and potential collision problems can occur. In this context, the aim of this paper is to develop a 3D scan simulation tool to evaluate a given scan path in terms of visibility and quality. Scanning quality is first investigated and evaluated experimentally depending on the configurations of the laser-plane sensor relative to the part geometry. The developed simulator is therefore based on the qualification results. The principle of the simulator is formulated by functions expressing visibility and quality conditions relative to scanning distance and angle. The path simulator is set up by visualizing the two conditions on facets of the part surface, and the quality is then estimated through the corresponding function. A case study is presented to illustrate the proposed simulation tool for scanning a test part defined by its CAD model with a given sensor path. The results are compared to real scans obtained from the sensor. This study demonstrates the effectiveness of the proposed simulation tool for predicting and estimating measurement quality. The outcome of the presented research in this paper has to be used as a predictive tool to evaluate scan paths in order to scan industrial parts with the required quality. Its integration into CMMs enables accurate anticipation of scanning results, thereby enhancing operational efficiency.